Rotating wheel defect reason analysis method and system based on physical and chemical analysis technology

Abstract

The invention relates to the technical field of physicochemical analysis, and discloses a runner defect reason analysis method and system based on the physicochemical analysis technology, and the runner defect reason analysis method based on the physicochemical analysis technology comprises the steps: selecting a defect region from a to-be-detected runner, then carrying out the test analysis of the defect region, and obtaining a test analysis result, a defect area diagnosis report is generated according to a test analysis result, finally, a runner defect maintenance strategy and prevention measures are formulated based on the defect area diagnosis report, material science, mechanics and chemical analysis means are comprehensively utilized, multi-dimensional and deep test analysis is conducted on runner defects, defect types, forms and distribution characteristics can be accurately recognized, and the accuracy of runner defect maintenance is improved. According to the method, the defects of the water turbine are overcome, the root cause of the defects is deeply traced, a scientific basis is provided for subsequent maintenance and prevention measures, equipment faults and accident risks caused by the defects are effectively reduced, safe operation of the water turbine is guaranteed, and the long-term reliability and the service life of the equipment are further enhanced.

Description

Technical Field

[0001] The present invention belongs to the technical field of physical and chemical analysis, and in particular relates to a method and system for analyzing the causes of runner defects based on physical and chemical analysis technology. Background Art

[0002] As the core component of a hydropower station, the running state of a water turbine runner directly affects the performance and safety of the entire hydropower generator set. However, during long-term operation, the runner is subjected to complex water flow loads and wear and corrosion. The runner may have defects such as cracks, wear, corrosion, deformation, and block loss due to various factors such as material fatigue, corrosion, and wear. If these defects are not discovered and handled in time, they may lead to serious equipment failures or even safety accidents.

[0003] Traditional wheel defect detection methods mostly rely on manual visual inspection and empirical judgment, or simple non-destructive testing technology, which is difficult to deeply reveal the physical and chemical mechanism of defect generation. There are problems such as strong subjectivity and low precision, which limits the accuracy and effectiveness of fault diagnosis. Summary of the invention

[0004] The purpose of the present invention is to overcome the above-mentioned problems and to provide a method and system for analyzing the causes of runner defects based on physical and chemical analysis technology. The method achieves accurate identification and cause tracing of runner defects by comprehensively using materials science, mechanics and chemical analysis methods.

[0005] In order to achieve the above object, the present invention adopts the following technical solution: In a first aspect, the present invention provides a method for analyzing the cause of a runner defect based on physical and chemical analysis technology, comprising the following steps: Selecting a defective area from the rotating wheel to be inspected; Conduct test analysis on the defective area and obtain test analysis results; Generate defect area diagnosis report based on test analysis results; Formulate runner defect repair strategies and preventive measures based on defect area diagnosis reports.

[0006] A further improvement of the present invention is that the step of selecting a defective area from the rotating wheel to be inspected also includes preprocessing the selected defective area, using non-destructive or minimally destructive sampling technology to perform necessary cleaning, cutting and grinding on the defective area, so that the surface of the defective area is flat, clean and the defects are clearly exposed.

[0007] A further improvement of the present invention is that the step of testing and analyzing the defective area of ​​the runner specifically includes physical and chemical property analysis, mechanical property evaluation, and environmental factor investigation and simulation testing.

[0008] A further improvement of the present invention is that the step of testing and analyzing the defective area also includes macroscopic analysis and measurement, using photography and three-dimensional scanning to record the surface morphology, size and defect distribution characteristics of the defective area.

[0009] A further improvement of the present invention is that the step of generating a defect area diagnosis report based on the test analysis results also includes establishing a database, integrating the physical and chemical properties analysis results, mechanical properties evaluation results, environmental factor investigation and simulation test results and macro analysis and measurement results into the database to form complete wheel defect information.

[0010] A further improvement of the present invention is that the step of generating a defect area diagnosis report according to the test analysis results specifically includes identifying the runner defect information in the database to obtain defect features, and then establishing a corresponding relationship between the defect type and the cause of the defect according to the defect features and the runner defect information; The defect characteristics include the shape, size, location and distribution pattern of the defect.

[0011] A further improvement of the present invention is that the step of formulating a wheel defect repair strategy and preventive measures based on the defect area diagnosis report specifically includes formulating a wheel defect repair strategy and preventive measures according to the defect area diagnosis report, targeting different defect types, severities and causes.

[0012] In a second aspect, the present invention further provides a runner defect cause analysis system based on physical and chemical analysis technology, comprising the following modules: A data acquisition module, used for selecting defective areas from the wheel to be inspected; Data analysis module, used to test and analyze defect areas and obtain test analysis results; A report generation module is used to generate a defect area diagnosis report based on the test analysis results; The strategy formulation module is used to formulate rotor defect repair strategies and preventive measures based on the defect area diagnosis report.

[0013] In a third aspect, the present invention also provides an electronic device, comprising a memory and a processor, wherein the memory stores a computer program, and the processor implements the steps of the above-mentioned method for analyzing the cause of a wheel defect based on physical and chemical analysis technology when executing the computer program.

[0014] In a fourth aspect, the present invention also provides a storage medium having a computer program stored thereon, wherein when the computer program is executed by a processor, the steps of the above-mentioned method for analyzing the cause of a wheel defect based on physical and chemical analysis technology are implemented.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The present invention first selects a defective area from the impeller to be tested, then tests and analyzes the defective area to obtain the test and analysis results, generates a defective area diagnosis report according to the test and analysis results, and finally formulates a impeller defect maintenance strategy and preventive measures based on the defective area diagnosis report. The present invention comprehensively uses material science, mechanics and chemical analysis methods to perform multi-dimensional and in-depth test and analysis on impeller defects, which can accurately identify the defect type, morphology and distribution characteristics, and deeply trace the root cause of the defect formation, providing a scientific basis for subsequent maintenance and preventive measures. The present invention can accurately judge the type, severity and cause of impeller defects, improve the scientificity and accuracy of impeller defect detection, provide a basis for timely taking effective maintenance measures, effectively extend the service life of the turbine, reduce operation and maintenance costs, and promote efficient and safe operation of the hydropower station. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings described herein are only for explanation purposes and are not intended to limit the scope of the present invention in any way. In addition, the shapes and proportional dimensions of the various components in the drawings are only schematic, used to help understand the present invention, and are not intended to specifically limit the shapes and proportional dimensions of the various components of the present invention.

[0017] Figure 1 It is a schematic flow chart of the method for analyzing the cause of runner defects based on physical and chemical analysis technology of the present invention; Figure 2 It is a schematic diagram of the process of the runner defect cause analysis system based on physical and chemical analysis technology of the present invention; Figure 3 The present invention is a flowchart of a method for analyzing the cause of a runner defect based on physical and chemical analysis technology according to an embodiment of the present invention. DETAILED DESCRIPTION

[0018] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0019] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0021] In the description of the embodiments of the present invention, it should be noted that if the terms "upper", "lower", "horizontal", "inner", etc. indicate an orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the product of the invention is usually placed when in use, it is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention. In addition, the terms "first", "second", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0022] In addition, if the term "horizontal" appears, it does not mean that the component must be absolutely horizontal, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", which does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0023] In the description of the embodiments of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal connection of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0024] The present invention is further described in detail below in conjunction with the accompanying drawings: like Figure 1 As shown, the present invention provides a method for analyzing the cause of a runner defect based on physical and chemical analysis technology, comprising the following steps: S1, selecting a defective area from the runner to be inspected, specifically, selecting a representative defective area of ​​the runner from the runner to be inspected without affecting the normal operation of the turbine, and using non-destructive or micro-destructive sampling technology to perform necessary cleaning, cutting and grinding on the defective area, so that the surface of the defective area is flat, clean and the defect is clearly exposed; S2, test and analyze the defective area to obtain the test and analysis results; The step of testing and analyzing the defective area of ​​the runner specifically includes macroscopic analysis and measurement, physical and chemical performance analysis, mechanical performance evaluation, and environmental factor investigation and simulation test; Among them, macroscopic analysis and measurement use high-resolution photography and 3D scanning to record the surface morphology, size and defect distribution characteristics of the defect area; The physical and chemical performance analysis specifically includes chemical composition analysis and microstructure analysis; The chemical composition analysis uses a spectrometer and an energy spectrometer to determine the element composition and content of the defective sample, and to perform quantitative analysis on element segregation and foreign matter intrusion; The microstructure analysis uses a scanning electron microscope and a transmission electron microscope to observe the microscopic morphology and organizational structure of the defective sample and analyze the relationship between the microstructure change and the defect formation; The mechanical properties analysis specifically includes hardness test, fatigue test and stress analysis; The stress analysis uses finite element simulation technology to reconstruct the working stress state of the defect area and analyze the defect formation mechanism; The environmental factor investigation mainly investigates the operating environment of the turbine, including water quality and operating conditions, and evaluates the impact of environmental factors on the performance of the runner material; The simulation test simulates the temperature, pressure and medium of the runner under laboratory conditions, observes the development and change of defects, and reveals the mechanism of environmental factors on the formation of defects; S3, generating a defect area diagnosis report based on the test analysis results; It also includes establishing a database, integrating the results of physical and chemical performance analysis, mechanical performance evaluation, environmental factor investigation and simulation test results, and macro analysis and measurement results into the database to form complete runner defect information, and then identifying the runner defect information in the database to obtain defect characteristics, and then establishing a corresponding relationship between defect type and defect cause based on the defect characteristics and runner defect information; The defect characteristics include shape, size, location and distribution pattern of the defect; S4, formulate runner defect repair strategy and preventive measures based on defect area diagnosis report; Based on the defect area diagnosis report, targeted maintenance strategies and preventive measures are formulated according to different defect types, severity and causes to ensure safe and reliable operation of the runner.

[0025] like Figure 2 As shown, the present invention also provides a wheel defect cause analysis system based on physical and chemical analysis technology, comprising the following modules: A data acquisition module, used for selecting defective areas from the wheel to be inspected; Data analysis module, used to test and analyze defect areas and obtain test analysis results; A report generation module is used to generate a defect area diagnosis report based on the test analysis results; The strategy formulation module is used to formulate rotor defect repair strategies and preventive measures based on the defect area diagnosis report.

[0026] It also includes a database construction and management module, which is used to store and manage macro-analysis and measurement results, physical and chemical properties analysis results, mechanical properties analysis results, and environmental factors investigation and simulation test results, and supports data query, update and backup functions.

[0027] Embodiment 1: like Figure 3 As shown, this embodiment provides a method for analyzing the cause of a runner defect based on physical and chemical analysis technology, comprising the following steps: S1, sample collection, under the premise of not affecting the normal operation of the turbine, select representative runner defect areas from the runner to be tested; S2, pretreatment, using non-destructive or minimally destructive sampling techniques to obtain samples of representative defective areas of the rotor, and performing necessary cleaning, cutting and grinding to ensure that the samples can be used for subsequent analysis; S3, macroscopic analysis, analyzes the chemical composition, microstructure, hardness test, fatigue test and stress of the samples. The chemical composition of the samples in the defective area of ​​the runner is analyzed by a spectrometer and an energy spectrometer to determine the element composition and content, reveal the influence of material composition on defect formation, and confirm whether there is element segregation or foreign matter intrusion; Through cutting, inlaying, rough grinding, lapping, polishing and etching, the microscopic morphology, organizational structure, grain structure and phase composition of the samples in the defective area of ​​the runner are observed using scanning electron microscopy and transmission electron microscopy, the relationship between microstructural changes and defect formation is analyzed, and whether there are problems such as coarse grains, inclusions and second phase precipitation is evaluated; Determine the hardness of the sample defect area and its surroundings and analyze the degradation of material properties; Select samples from defective areas for fatigue life testing to evaluate the fatigue resistance of defective areas; Finite element simulation technology is used to reconstruct the working stress state of the defect area and analyze the defect formation mechanism; S4, investigation and simulation, investigate the operating environment of the turbine, including water quality and operating conditions, evaluate the impact of environmental factors on the performance of the runner material, simulate the temperature, pressure and medium of the runner under laboratory conditions, observe the development and changes of defects, and reveal the mechanism of environmental factors on defect formation; S5, comprehensive analysis and cause judgment, based on the above macro analysis, investigation and simulation, the macro analysis results, physical and chemical properties analysis results, mechanical properties test results, environmental factors investigation and simulation results are integrated into the database to form a complete runner defect information database; Use data mining and machine learning analysis algorithms to deeply mine the information in the rotor defect database, identify defect characteristics, and establish the corresponding relationship between defect types and causes; Combined with the above test data, statistical and machine learning algorithms are used to establish a correlation model between defects and various influencing factors. Based on the data analysis results, a runner defect diagnosis report is automatically generated to accurately determine the specific cause of the runner defect, including defect type, severity, cause and recommended repair measures; The automated data collection, processing and analysis process greatly shortens the defect diagnosis cycle and improves work efficiency; S6, repair suggestions, based on the impeller defect diagnosis report, formulate targeted maintenance strategies and preventive measures for different defect types, severity and causes. According to the suggestions in the diagnosis report, a targeted repair plan can be formulated, and the design, manufacturing and operation of the impeller can be optimized to improve the reliability and service life of the equipment.

[0028] Embodiment 2: The present invention also provides an electronic device for analyzing the causes of wheel defects based on physical and chemical analysis technology; the electronic device includes a memory, at least one processor, a computer program stored in the memory and executable on the at least one processor, and at least one communication bus.

[0029] The memory can be used to store the computer program, and the processor implements the steps of the method for analyzing the cause of the wheel defect based on the physical and chemical analysis technology described in the embodiment by running or executing the computer program stored in the memory and calling the data stored in the memory. The memory can mainly include a program storage area and a data storage area, wherein the program storage area can store an operating system, an application required for at least one function (such as a sound playback function, an image playback function, etc.), etc.; the data storage area can store data created according to the use of the electronic device (such as audio data), etc. In addition, the memory can include a non-volatile memory, such as a hard disk, a memory, a plug-in hard disk, a smart memory card (SmartMedia Card, SMC), a secure digital (Secure Digital, SD) card, a flash card (Flash Card), at least one disk storage device, a flash memory device, or other non-volatile solid-state storage devices.

[0030] The at least one processor may be a central processing unit (CPU), or other general-purpose processors, digital signal processors (DSP), application-specific integrated circuits (ASIC), field-programmable gate arrays (FPGA) or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The processor may be a microprocessor or any conventional processor, etc. The processor is the control center of the electronic device, and various interfaces and lines are used to connect various parts of the entire electronic device.

[0031] The memory in the electronic device stores a plurality of instructions to implement a method for analyzing the cause of a wheel defect based on physical and chemical analysis technology, and the processor can execute the plurality of instructions to implement: Selecting a defective area from the rotating wheel to be inspected; Conduct test analysis on the defective area and obtain test analysis results; Generate defect area diagnosis report based on test analysis results; Formulate runner defect repair strategies and preventive measures based on defect area diagnosis reports.

[0032] Embodiment 3: If the module / unit integrated in the electronic device is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the present invention implements all or part of the process in the above-mentioned embodiment method, and can also be completed by instructing the relevant hardware through a computer program. The computer program can be stored in a computer-readable storage medium, and the computer program can implement the steps of the above-mentioned method embodiments when executed by the processor. Among them, the computer program includes computer program code, and the computer program code can be in source code form, object code form, executable file or some intermediate form. The computer-readable medium may include: any entity or device that can carry the computer program code, recording medium, U disk, mobile hard disk, disk, optical disk, computer memory and read-only memory (ROM, Read-Only Memory).

[0033] It will be appreciated by those skilled in the art that embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Furthermore, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0034] The present invention is described with reference to flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to embodiments of the present invention. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0035] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0036] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process in the computer or other programmable device. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0037] Many embodiments and many applications beyond the examples provided will be apparent to those skilled in the art upon reading the above description. Therefore, the scope of the present teachings should not be determined with reference to the above description, but rather with reference to the preceding claims and the full scope of equivalents to which such claims are entitled. For the purpose of comprehensiveness, all articles and references, including disclosures of patent applications and publications, are incorporated herein by reference. The omission of any aspect of the subject matter disclosed herein in the preceding claims is not intended to be a disclaimer of such subject matter, nor should it be considered that the applicants did not consider such subject matter to be part of the disclosed inventive subject matter.

[0038] The above content is a further detailed description of the present invention. It cannot be determined that the specific implementation methods of the present invention are limited to these. For ordinary technicians in the technical field to which the present invention belongs, without departing from the concept of the present invention, they can also make several simple deductions or substitutions, which should be regarded as belonging to the protection scope of the present invention determined by the submitted claims.

Claims

1. A method for analyzing the causes of runner defects based on physical and chemical analysis technology, characterized in that: The following steps are involved: Selecting a defective area from the rotating wheel to be inspected; Conduct test analysis on the defective area and obtain test analysis results; Generate defect area diagnosis report based on test analysis results; Formulate runner defect repair strategies and preventive measures based on defect area diagnosis reports.

2. The method for analyzing the cause of runner defects based on physical and chemical analysis technology according to claim 1, characterized in that: The step of selecting a defective area from the rotating wheel to be inspected also includes pre-processing the selected defective area, using non-destructive or micro-destructive sampling technology to clean, cut and grind the defective area so that the surface of the defective area is flat, clean and the defects are clearly exposed.

3. The method for analyzing the cause of runner defects based on physical and chemical analysis technology according to claim 1, characterized in that: The steps of testing and analyzing the defective area of ​​the runner specifically include physical and chemical property analysis, mechanical property evaluation, environmental factor investigation and simulation test.

4. The method for analyzing the cause of runner defects based on physical and chemical analysis technology according to claim 1, characterized in that: The step of testing and analyzing the defective area also includes macroscopic analysis and measurement, using photography and three-dimensional scanning to record the surface morphology, size and defect distribution characteristics of the defective area.

5. The runner defect cause analysis system based on physical and chemical analysis technology according to claim 1 is characterized in that: The step of generating a defect area diagnosis report based on the test analysis results also includes establishing a database, integrating the physical and chemical properties analysis results, mechanical properties evaluation results, environmental factor investigation and simulation test results, and macro analysis and measurement results into the database to form complete wheel defect information.

6. The method for analyzing the cause of runner defects based on physical and chemical analysis technology according to claim 5, characterized in that: The step of generating a defect area diagnosis report according to the test analysis results specifically includes identifying the wheel defect information in the database to obtain defect characteristics, and then establishing a corresponding relationship between the defect type and the defect cause according to the defect characteristics and the wheel defect information; The defect characteristics include the shape, size, location and distribution pattern of the defect.

7. The method for analyzing the cause of runner defects based on physical and chemical analysis technology according to claim 1, characterized in that: The step of formulating a rotor defect repair strategy and preventive measures based on the defect area diagnosis report specifically includes formulating a rotor defect repair strategy and preventive measures according to the defect area diagnosis report and targeting different defect types, severity levels and causes.

8. A runner defect cause analysis system based on physical and chemical analysis technology, characterized in that: Includes the following modules: A data acquisition module, used for selecting defective areas from the wheel to be inspected; Data analysis module, used to test and analyze defect areas and obtain test analysis results; A report generation module is used to generate a defect area diagnosis report based on the test analysis results; The strategy formulation module is used to formulate rotor defect repair strategies and preventive measures based on the defect area diagnosis report.

9. An electronic device comprising a memory and a processor, wherein the memory stores a computer program, wherein: When the processor executes the computer program, the steps of the method for analyzing the cause of a wheel defect based on physical and chemical analysis technology according to any one of claims 1 to 7 are implemented.

10. A storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the method for analyzing the cause of a defect of a rotor based on physical and chemical analysis technology according to any one of claims 1 to 7 are implemented.

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