Digital turning and dynamic test analysis integrated device for vertical water-turbine generator set

Abstract

The invention provides a digital turning and dynamic test analysis integrated device for a vertical water-turbine generator set, and relates to the technical field of water-turbine generator maintenance and fault analysis, and the device comprises a key phase sensor which is used for taking a key phase signal as a triggering point of data collection when the set rotates; the large shaft positioning unit is used for synchronously acquiring data of each measurement section and automatically marking angles during manual moving point turning; the throw sensor is used for measuring throw data of each guide bearing in the operation process of the turning gear or the unit; the acquisition extension set is used for receiving data from the key phase sensor, the large shaft positioning unit and the throw sensor, carrying out primary processing on the data and then sending the data to the analysis host through a wireless network; and the analysis host is used for calculating and displaying the data sent by the acquisition extensions and providing technical support for unit state evaluation and fault diagnosis.

Description

Technical Field

[0001] The present application relates to the technical field of maintenance and fault analysis of hydraulic generators, and in particular to an integrated device for digital turning and dynamic testing and analysis of vertical hydraulic generator sets. Background Art

[0002] The axis of the unit is an important basis for measuring the manufacturing and installation quality of the hydro-turbine generator set. If the axis of a unit is of poor quality, the main shaft will swing greatly during rotation, and the external unbalanced force on the rotating parts during operation will also increase, resulting in increased vibration of the unit and deterioration of the bearing operating conditions, which seriously affects the safe and stable operation of the unit. The axis of the unit can be divided into static axis and dynamic axis. For the static axis, the manual turning method is currently mainly used for measurement. The state of the shaft system when the unit is running is called the dynamic axis. For the dynamic axis, the dynamic axis condition of the unit is currently mainly analyzed through the swing data of each guide bearing in the unit online monitoring system.

[0003] When measuring the static axis of the unit by turning, a dial indicator is set on the fixed part, and the rotating part of the unit is slowly rotated by external force. The swing data of the turning point of the shaft is manually measured and recorded to analyze the inclination and deflection of the axis. Manual measurement and analysis of turning data have the following shortcomings:

[0004] 1) The dial indicator is a contact measurement, and surface friction will cause measurement errors;

[0005] 2) Turning requires multiple measurement sections, and each measurement section requires a dedicated person to record and organize data, which is time-consuming and labor-intensive, and prone to human errors;

[0006] 3) Manual calculation of data is labor-intensive and prone to calculation errors;

[0007] 4) Each measurement section is usually manually marked with 8 turning points at equal distances, and there are errors in marking the turning points;

[0008] 5) The number of turning points is insufficient, and the profile shape of the cross section cannot be accurately measured. If the turning points are increased, the workload of manual recording and data sorting will increase greatly;

[0009] 6) During the operation of the unit, the dynamic axis is greatly different from the static axis due to the influence of hydraulic imbalance, electromagnetic imbalance and mechanical imbalance, and manual turning cannot be used to measure the dynamic axis. Summary of the invention

[0010] The present application aims to solve one of the technical problems in the related art at least to some extent.

[0011] To this end, the purpose of this application is to propose an integrated device for digital turning and dynamic testing and analysis of a vertical hydro-turbine generator set.

[0012] To achieve the above-mentioned purpose, the embodiment of the present application proposes a vertical hydro-turbine generator set digital turning gear and dynamic test and analysis integrated device, comprising:

[0013] Key phase sensor, used to use key phase signal as trigger point for data collection when the unit is rotating;

[0014] The main axis positioning unit is used to realize the synchronous data collection of each measuring section and automatically mark the angle when the manual turning point is performed;

[0015] The swing sensor is used to measure the swing data of each guide bearing during the turning or unit operation;

[0016] The acquisition extension is used to receive data from the key phase sensor, the main shaft positioning unit, and the swing sensor, and after preliminary processing, send the data to the analysis host through the wireless network;

[0017] The analysis host is used to calculate and display the data sent by the acquisition extension, and provide technical support for unit status evaluation and fault diagnosis.

[0018] Optionally, there are multiple swing sensors, which are arranged at five locations: upper guide, lower guide, water guide, thrust head, and coupling flange. A preset sleeve is deployed at each location and installed at a 90-degree angle.

[0019] Optionally, there are multiple collection extensions, which are arranged at five locations: upper guide, lower guide, water guide, thrust head, and connecting shaft flange.

[0020] Optionally, also include:

[0021] Eddy current sensor and laser displacement sensor are used to measure the vibration or displacement data of the rotor during the turning or unit operation;

[0022] Encoded sensors are used to provide high-precision angle encoding.

[0023] Optionally, the data collection extension is also used to:

[0024] The data from the eddy current sensor, the laser displacement sensor and the encoding sensor are received, and after preliminary processing, the data are sent to the analysis host via a wireless network.

[0025] Optionally, based on the data sent by the acquisition extension, the analysis host is specifically used to:

[0026] Analyze the shaft profile to determine whether the shaft roundness exceeds the standard;

[0027] Analyze the static axis status of the unit by combining different algorithms of rigid or elastic turning gears used by different types of units;

[0028] Conduct simulated cranking at low speed and conduct comparative analysis of the unit's dynamic axis under different operating conditions;

[0029] By calculating and comparing the dynamic axis and static axis of the unit, the cause of the unbalanced force is analyzed.

[0030] The present application provides an integrated device for digital turning and dynamic testing and analysis of a vertical hydro-turbine generator set. By adopting a variety of sensors such as key phase sensors, large shaft positioning units and swing sensors, accurate analysis of the contour shape of the shaft is achieved, thereby determining whether the roundness of the shaft exceeds the standard, avoiding equipment failures caused by shaft roundness problems, and improving the accuracy and reliability of shaft detection; by introducing a dynamic turning method and automatic angle marking function, there is no need to manually mark the turning points during manual turning, avoiding errors and operational complexity in the manual marking process, and improving the efficiency and consistency of data collection; by combining different types of units with different algorithms for rigid or elastic turning, the turning of the unit is digitalized and intelligent, avoiding the traditional turning. The measurement error caused by algorithm mismatch in the method improves the accuracy and work efficiency of cranking measurement, and provides a reliable data basis and technical solution for maintenance; by simultaneously collecting manual cranking data and unit dynamic data, it realizes simulated cranking at low speed, and conducts comparative analysis of the unit dynamic axis under different working conditions, avoiding insufficient information caused by relying on a single data source, and improving the comprehensiveness and accuracy of the unit dynamic performance evaluation; by calculating and comparing the unit dynamic axis and static axis, it realizes accurate identification of the cause of unbalanced force, avoids equipment failure and unstable operation caused by unbalanced force, improves the technical support capabilities of unit status evaluation and fault diagnosis, and ensures the safe operation and maintenance efficiency of the equipment. .

[0031] Additional aspects and advantages of the present application will be given in part in the description below, and in part will become apparent from the description below, or will be learned through the practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The above and / or additional aspects and advantages of the present application will become apparent and easily understood from the following description of the embodiments in conjunction with the accompanying drawings, in which:

[0033] Figure 1 A schematic diagram of the structure of a digital turning gear and dynamic test and analysis integrated device for a vertical hydro-turbine generator set provided in an embodiment of the present application;

[0034] Figure 2A schematic structural diagram of a digital turning gear and dynamic test and analysis integrated device for a vertical hydro-turbine generator set provided in an embodiment of the present application. DETAILED DESCRIPTION

[0035] Embodiments of the present application are described in detail below, and examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present application, and should not be construed as limiting the present application.

[0036] The axis of the unit is an important basis for measuring the manufacturing and installation quality of the hydro-turbine generator set. If the axis of a unit is of poor quality, the main shaft will swing greatly during rotation, and the external unbalanced force on the rotating parts during operation will also increase, resulting in increased vibration of the unit and deterioration of the bearing operating conditions, which seriously affects the safe and stable operation of the unit. The axis of the unit can be divided into static axis and dynamic axis. For the static axis, the manual turning method is currently mainly used for measurement. The state of the shaft system when the unit is running is called the dynamic axis. For the dynamic axis, the dynamic axis condition of the unit is currently mainly analyzed through the swing data of each guide bearing in the unit online monitoring system.

[0037] When measuring the static axis of the unit by turning, a dial indicator is set on the fixed part, and the rotating part of the unit is slowly rotated by external force. The swing data of the turning point of the shaft is manually measured and recorded to analyze the inclination and deflection of the axis. Manual measurement and analysis of turning data have the following shortcomings:

[0038] 1) The dial indicator is a contact measurement, and surface friction will cause measurement errors;

[0039] 2) Turning requires multiple measurement sections, and each measurement section requires a dedicated person to record and organize data, which is time-consuming and labor-intensive, and prone to human errors;

[0040] 3) Manual calculation of data is labor-intensive and prone to calculation errors;

[0041] 4) Each measurement section is usually manually marked with 8 turning points at equal distances, and there are errors in marking the turning points;

[0042] 5) The number of turning points is insufficient, and the profile shape of the cross section cannot be accurately measured. If the turning points are increased, the workload of manual recording and data sorting will increase greatly;

[0043] 6) During the operation of the unit, the dynamic axis is greatly different from the static axis due to the influence of hydraulic imbalance, electromagnetic imbalance and mechanical imbalance, and manual turning cannot be used to measure the dynamic axis.

[0044] To address this problem, the present application provides a digital turning gear and dynamic test and analysis integrated device for a vertical hydro-turbine generator set. Figure 1 The structure diagram of a vertical hydro-generator set digital turning gear and dynamic test and analysis integrated device 10 provided in the embodiment of the present application. Figure 1 As shown, the device comprises:

[0045] The key phase sensor 100 is used to use the key phase signal as a trigger point for data collection when the unit is rotating.

[0046] In the embodiment of the present application, the key phase signal collected by the key phase sensor is used to synchronize data collection of other sensors to ensure the accuracy and synchronization of the data.

[0047] The main shaft positioning unit 200 is used to realize the synchronous data collection of each measuring section and automatically mark the angle when the manual moving point turning is performed.

[0048] In the embodiment of the present application, during manual turning, the main shaft positioning unit can realize synchronous data collection of each measurement section and automatically mark the angle, and collect data of no less than 32 points in one rotation.

[0049] The swing sensor 300 is used to measure the swing data of each guide bearing during the operation of the turning gear or the unit.

[0050] In the embodiment of the present application, during the operation of the turning gear or the unit, 3) swing sensors are arranged at five locations, namely the upper guide, lower guide, water guide, thrust head, and coupling flange, to measure the swing data, with 2 sets deployed at each location, installed at a 90-degree angle.

[0051] The acquisition extension 400 is used to receive data from the key phase sensor, the main shaft positioning unit, and the swing sensor, and after preliminary processing, send the data to the analysis host through the wireless network.

[0052] In the embodiment of the present application, the integrated device for digital turning and dynamic testing and analysis of the vertical hydro-turbine generator set is equipped with 5 sets of acquisition extensions with wireless transmission function, which are used to collect data from five parts: upper guide, lower guide, water guide, thrust head, and coupling flange. Manual turning is not less than 32 points / revolution, and dynamic sampling is not less than 64 points / revolution.

[0053] The analysis host 500 is used to calculate and display the data sent by the collection extension, and provide technical support for unit status evaluation and fault diagnosis.

[0054] In addition, if Figure 2 As shown, the device also includes:

[0055] The eddy current sensor 600 and the laser displacement sensor 700 are used to measure the vibration or displacement data of the rotor during the operation of the cranking gear or the unit.

[0056] The encoding sensor 800 is used to provide high-precision angle encoding, and the angle information it provides is used by the large-axis positioning device to mark and synchronize data.

[0057] Specifically, the collection extension is also used for:

[0058] It receives data from eddy current sensors, laser displacement sensors, and encoding sensors, processes them preliminarily, and then sends them to the analysis host via a wireless network.

[0059] In summary, through the data of the above-mentioned components, the analysis host can achieve the following functions:

[0060] 1. Analyze the profile of the shaft to determine whether the shaft roundness exceeds the standard.

[0061] It can be understood that by arranging multiple sensors around the shaft, such as laser displacement sensors or eddy current sensors, its contour shape data can be collected in real time, and then the collection extension receives the data from each sensor and records and preliminarily processes the data in real time when the shaft rotates.

[0062] In the embodiment of the present application, the analysis host first integrates the data obtained from different positions into a unified coordinate system to form a complete shaft profile map, and then uses a roundness detection algorithm (such as least squares fitting) to calculate the actual roundness of the shaft and compare it with the standard roundness.

[0063] In a possible embodiment, a specific value of the roundness exceeding the standard can be set according to international standards or industry standards, which is not specifically limited in this application. If the actual roundness exceeds the set value, it is determined to be exceeding the standard.

[0064] Example description:

[0065] Assuming that the displacement data collected by the sensor during the rotation of the shaft can be used to draw the contour of the shaft, the analysis host uses the least squares method to fit the average radius of the shaft to 100 mm and the standard radius to 99.5 mm, so the roundness error is calculated to be 0.5 mm, which will be marked as exceeding the standard, prompting technicians to repair or adjust.

[0066] 2. Analyze the static axis status of the unit by using different algorithms of rigid or elastic turning gears for different types of units.

[0067] In the embodiment of the present application, the analysis host first receives data from the acquisition extension, and these data include angle, displacement and vibration data obtained in static measurement.

[0068] The analysis host then selects the corresponding algorithm according to the type of unit (rigid or elastic turning gear). For example, if it is a rigid turning gear, a linear algebra method based on static equilibrium conditions can be used to solve it; if it is an elastic turning gear, the deformation theory of elastic body can be used for analysis, which is not specifically limited in this application.

[0069] Finally, the dynamic data obtained under different working conditions (such as different loads, different speeds, etc.) are compared and analyzed to identify the changes and trends of the dynamic axis.

[0070] Example description:

[0071] For example, in a low-speed simulated cranking test, the main engine was analyzed and found that the maximum dynamic displacement of the rotor was 0.5mm at a speed of 100RPM, while the dynamic displacement increased to 1.2mm at 150RPM. By comparing these data, the stability and performance changes of the unit under different working conditions can be judged.

[0072] 3. Carry out simulated cranking at low speed and conduct comparative analysis of the dynamic axis of the unit under different working conditions.

[0073] In the embodiment of the present application, the analysis host sets corresponding simulated cranking parameters, such as speed, time, etc., according to the low speed conditions, and simulates the cranking process through the control system. During the simulated cranking process, data from various sensors (such as eddy current sensors and laser displacement sensors) are continuously received to record dynamic displacement and vibration conditions. Finally, the dynamic data obtained under different working conditions (such as different loads, different speeds, etc.) are compared and analyzed to identify the changes and trends of the dynamic axis.

[0074] Example:

[0075] For example, in a low-speed simulated cranking test, the main engine was analyzed and found that the maximum dynamic displacement of the rotor was 0.5mm at a speed of 100RPM, while the dynamic displacement increased to 1.2mm at 150RPM. By comparing these data, the stability and performance changes of the unit under different working conditions can be judged.

[0076] 4. Analyze the causes of unbalanced force by calculating and comparing the dynamic axis and static axis of the unit.

[0077] In an embodiment of the present application, the analysis host integrates the measurement data of the dynamic axis and the static axis into a unified database, and then calculates the source of the unbalanced force by analyzing the difference between the static and dynamic states; finally, combined with the working conditions and historical data of the unit, the possible causes of the unbalanced force are analyzed, such as component wear, improper installation or material defects.

[0078] As a possible implementation method, a physical model can be used to consider factors such as mass distribution and rotation speed to deduce the size and direction of the unbalanced force, which is not specifically limited in this application.

[0079] Example:

[0080] Assume that in the comparative analysis, it is found that the displacement of the dynamic axis is significantly greater than that of the static axis, and the analysis of the main engine derives that the unbalanced force is about 5 N. Further investigation found that a part of the rotor has uneven mass distribution due to long-term wear, which in turn causes the unbalanced force.

[0081] In addition, the device proposed in this application can also achieve: there is no need to mark the turning points during manual turning, and a dynamic turning method is used. After the rotating part rotates one circle, each measuring section synchronously collects data and automatically marks the angle.

[0082] Specifically, in the embodiment of the present application, a servo motor or a stepper motor is used to control the turning device. When the turning device is manually operated, the rotation angle is recorded by an automated system, and key data collection points are automatically identified during rotation through a key phase sensor installed on each measuring section.

[0083] Then, the host analyzes the data sent by the collection extension, monitors the rotation angle of the shaft in real time, and records the data collection time and angle of each section during one rotation. The automatic marking mechanism can be set through a preset program. When one rotation is completed, the angle of each section will be automatically recorded and associated with the corresponding data, avoiding the tedious manual marking.

[0084] Example:

[0085] For example, when the operator manually turns the shaft and rotates it one circle, the device proposed in this application automatically records each angle of rotation (such as 0°, 45°, 90°, etc.) and automatically triggers data collection at each point. After completing one circle of rotation, the analysis host associates the data of each cross section of the shaft with the corresponding angle to form a complete set of dynamic data sets without manual intervention and marking.

[0086] Example 1

[0087] The present invention is further described in detail below in conjunction with the embodiments. In a vertical hydro-turbine generator set, the generator shaft system is composed of an upper end shaft, a rotor center body, and a main shaft, and is connected to the turbine shaft by a flange. The device provided by the present invention is used to deal with the problem of excessive electromagnetic vibration of the generator stator, and the following specific steps are adopted:

[0088] 1. Main technical parameters

[0089] 1) Eddy current sensor: range 4mm resolution 4um power supply -24V frequency response 1KHz;

[0090] 2) Laser displacement sensor: range 104mm resolution 10um power supply +24V frequency response 40Hz;

[0091] 3) Key phase sensor: inductive, range 4mm, power supply +24V, frequency response 100Hz;

[0092] 4) Encoding sensor: built-in infrared type, encoding wheel 100 grids, circumference 30cm;

[0093] 5) Collection extension: 10 collection channels, 1 key phase channel, 1 interval channel, collection accuracy 2um;

[0094] 6) Analysis host: industrial control PC, customized software, 3 extensions, 36 channels;

[0095] 7) Wireless network: 433M-510M Lora power 2W distance straight line of sight 8000M.

[0096] 2. Operation process

[0097] 1) Check the equipment, including three extension units, one main unit, several eddy current sensors, one key phase sensor, one encoder guide wheel, and brackets for each measuring point.

[0098] 2) Lay out the wires to the extension location according to the workspace, connect the wires of each sensor, check that everything is correct, and then turn on the power of the extension.

[0099] 3) The host sends a communication test command to check the communication success rate. If the communication success rate is poor, change the antenna position or direction, keep away from metal objects, and reduce external wireless interference.

[0100] 4) Debug the eddy current sensor, use the pad to adjust the appropriate gap, install it firmly, stick the key phase mark, adjust the distance of the key phase sensor to distinguish the key phase mark, and make sure the encoding guide wheel is close and not slipping.

[0101] 5) Perform a preliminary test, rotate three times in a row, and observe whether the data at the same point is consistent or within the allowable clearance range. If not, re-adjust the sensor.

[0102] 6) Formal test: rotate one circle continuously, analyze the data and generate a report, then measure again after adjustment.

[0103] 7) After the inspection is completed, turn off the extension power, remove the sensor, remove the bracket, and evacuate the equipment.

[0104] The above shows and describes the basic principles, main features and advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

[0105] Furthermore, in the descriptions of the aforementioned embodiments, the descriptions with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

Claims

1. A vertical hydro-generator set digital turning and dynamic test and analysis integrated device, characterized in that: include: Key phase sensor, used to use key phase signal as trigger point for data collection when the unit is rotating; The main axis positioning unit is used to realize the synchronous data collection of each measuring section and automatically mark the angle when the manual turning point is performed; The swing sensor is used to measure the swing data of each guide bearing during the turning or unit operation; The acquisition extension is used to receive data from the key phase sensor, the main shaft positioning unit, and the swing sensor, and after preliminary processing, send the data to the analysis host through the wireless network; The analysis host is used to calculate and display the data sent by the acquisition extension, and provide technical support for unit status evaluation and fault diagnosis.

2. The device according to claim 1, characterized in that There are multiple swing sensors, which are arranged at five locations: upper guide, lower guide, water guide, thrust head, and coupling flange. A preset sleeve is deployed at each location and installed at an angle of 90 degrees.

3. The device according to claim 1, characterized in that There are multiple collection extensions, which are respectively arranged at five locations: upper guide, lower guide, water guide, thrust head, and connecting shaft flange.

4. The device according to claim 1, characterized in that Also includes: Eddy current sensor and laser displacement sensor are used to measure the vibration or displacement data of the rotor during the turning or unit operation; Encoded sensors are used to provide high-precision angle encoding.

5. The device according to claim 4, characterized in that The collection extension is also used for: The data from the eddy current sensor, the laser displacement sensor and the encoding sensor are received, and after preliminary processing, the data are sent to the analysis host via a wireless network.

6. The device according to claim 1, characterized in that Based on the data sent by the acquisition extension, the analysis host is specifically used to: Analyze the shaft profile to determine whether the shaft roundness exceeds the standard; Analyze the static axis status of the unit by combining different algorithms of rigid or elastic turning gears used by different types of units; Conduct simulated cranking at low speed and conduct comparative analysis of the unit's dynamic axis under different operating conditions; By calculating and comparing the dynamic axis and static axis of the unit, the cause of the unbalanced force is analyzed.

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