Main shaft bearing temperature measurement early warning system and method

Abstract

The invention relates to the technical field of wind power equipment monitoring and control. The invention provides a main shaft bearing temperature measurement early warning system and method, and the method comprises the steps: forming a sensor installation hole in a main shaft bearing seat, and installing a main shaft temperature measurement sensor in the sensor installation hole; a signal cable of the main shaft temperature measuring sensor is protected, and the signal cable, a main shaft lubricating system oil pipe and a cable are wired to a cabin control cabinet together; connecting the signal cable to a specified terminal strip in the cabin control cabinet, and shielding and grounding the signal cable; a temperature monitoring program is arranged in the main control module, when the spindle bearing temperature is larger than the first preset threshold value, alarm is triggered, shutdown operation is executed, and the problems that a traditional wind power generation system is large in spindle bearing temperature monitoring mode error, the actual temperature condition of a bearing cannot be accurately reflected, and the bearing temperature is not accurately monitored are solved. Therefore, the problems of low temperature measurement precision, unstable signal transmission and insensitive alarm and shutdown mechanism are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of wind power equipment monitoring and control, and in particular to a main shaft bearing temperature measurement and early warning system and method. Background Art

[0002] In the wind power generation system, the main shaft bearing, as one of the key components, undertakes the important task of supporting and transmitting the rotational force of the wind rotor. Its operating status directly affects the safety and reliability of the wind turbine. During long-term operation, the main shaft bearing will cause the temperature to rise due to factors such as friction, poor lubrication, and overload, which may cause bearing damage, unit shutdown, or even more serious safety accidents. Therefore, real-time monitoring and effective management of the temperature of the main shaft bearing is an important measure to ensure the stable operation of the wind turbine.

[0003] Traditional wind power generation systems have many deficiencies in monitoring the main shaft bearing temperature. For example, some systems use indirect temperature measurement methods to infer the bearing temperature by measuring the temperature of other components related to the main shaft bearing. This method often has large errors and cannot accurately reflect the actual temperature of the bearing. Although other systems use direct temperature measurement methods, they have deficiencies in the installation of temperature sensors, protection of signal cables, transmission and processing of temperature signals, etc., resulting in low temperature measurement accuracy, unstable signal transmission, and insensitive alarm and shutdown mechanisms. Summary of the invention

[0004] The purpose of the present invention is to provide a main shaft bearing temperature measurement and early warning system and method, aiming to solve the problem that the traditional wind power generation system has large errors in the monitoring method of the main shaft bearing temperature, and cannot accurately reflect the actual temperature of the bearing, resulting in low temperature measurement accuracy, unstable signal transmission, and insensitive alarm and shutdown mechanisms.

[0005] The present invention is achieved through the following technical solutions:

[0006] A spindle bearing temperature measurement and early warning method, comprising the steps of:

[0007] A sensor mounting hole is provided on the spindle bearing seat, and the spindle temperature sensor is installed in the sensor mounting hole;

[0008] Protect the signal cable of the spindle temperature sensor, and route the signal cable together with the oil pipe and cable of the spindle lubrication system to the cabin control cabinet;

[0009] Connect the signal cable to the designated terminal block in the cabin control cabinet and ground the signal cable shield;

[0010] A temperature monitoring program is set in the main control module. When the spindle bearing temperature is greater than a first preset threshold, an alarm is triggered and a shutdown operation is performed.

[0011] Optionally, a second preset threshold is set through the main control module, and the second preset threshold is smaller than the first preset threshold; when the spindle bearing temperature is greater than the first preset threshold, an alarm is triggered and a shutdown operation is performed. If the spindle bearing temperature is greater than the second preset threshold, restarting the unit is prohibited. If the spindle bearing temperature is less than or equal to the second preset threshold, the unit is restarted according to actual needs.

[0012] Optionally, the first preset threshold is 65°C, and the second preset threshold is 60°C.

[0013] Optionally, before installing the main shaft temperature sensor, lock the wind wheel lock; after the installation is completed, clean the construction area and unlock the wind wheel lock after confirming safety.

[0014] Optionally, before installing the spindle temperature sensor into the sensor mounting hole, apply thermal grease on the spindle temperature sensor.

[0015] Optionally, the sensor mounting hole is formed by drilling a blind hole and tapping a thread.

[0016] Optionally, after the spindle temperature sensor is installed, use a marker pen to mark the sensor.

[0017] Optionally, during the installation and wiring of the spindle temperature sensor, the oil pipes, cables and sensor signal cables of the spindle lubrication system are arranged and fixed.

[0018] Optionally, a human-machine interaction interface is provided on the cabin control cabinet, and the historical data of the spindle bearing temperature is recorded through the temperature monitoring program. The real-time temperature, alarm information and shutdown status of the spindle bearing are displayed through the human-machine exchange interface. The operator views the historical data, sets corresponding parameters and performs fault diagnosis through the human-machine exchange interface.

[0019] The present invention also provides a spindle bearing temperature measurement and early warning system, which is used to implement the spindle bearing temperature measurement and early warning method as described above, comprising:

[0020] The sensor module includes a spindle temperature sensor for detecting the temperature of the spindle bearing in real time;

[0021] The cable protection module is used to protect the signal cable of the spindle temperature sensor, so that the signal cable can be routed to the cabin control cabinet together with the oil pipe and cable of the spindle lubrication system;

[0022] A signal transmission module is used to transmit the temperature signal collected by the spindle temperature sensor to a designated terminal block in the cabin control cabinet through a signal cable;

[0023] The cabin control cabinet has a built-in main control module, which is equipped with a temperature monitoring program for receiving and processing temperature signals from the sensor module;

[0024] The wind wheel lock module is used to lock and unlock the wind wheel.

[0025] The technical solution of the present invention has at least the following advantages and beneficial effects:

[0026] Improve the accuracy and real-time performance of temperature monitoring: By adopting high-precision and high-reliability spindle temperature sensors, the temperature changes of the spindle bearings can be monitored in real time and accurately, potential fault hazards can be discovered in time, and the safety and reliability of wind turbines can be improved.

[0027] Optimize the installation and wiring process: The sensor mounting hole is formed by blind drilling and tapping, which not only ensures the stability of the installation but also simplifies the installation steps; the signal cable is routed together with the oil pipe and cable of the spindle lubrication system and is protected by a high-temperature and corrosion-resistant corrugated pipe, which is not only beautiful and tidy, but also reduces the risk of cable damage and improves the overall durability of the system.

[0028] Enhanced system stability and reliability: The signal cable adopts a shielding design, which effectively reduces the impact of electromagnetic interference on the temperature signal and ensures the stability and reliability of signal transmission. At the same time, fixing clips and brackets are set at key positions to avoid shaking and falling off of cables and oil pipes, further improving the stability of the system.

[0029] Intelligent temperature monitoring and early warning: By setting up a temperature monitoring program in the main control module and setting dual preset thresholds, it can trigger an alarm and execute a shutdown operation in time when the spindle bearing temperature is abnormal, effectively preventing equipment damage and safety accidents caused by excessive temperature; at the same time, the setting of the human-computer interaction interface enables operators to easily view real-time temperature, historical data, alarm information and shutdown status, improving operational efficiency and troubleshooting speed.

[0030] Easy maintenance and repair: During the installation and wiring process, use a marker pen to mark the cables and corrugated tubes, and record key information such as the routing path, materials used and fixing positions, etc., which provides detailed reference and guidance for future maintenance and repair work; in addition, the integration of fault diagnosis functions also helps operators quickly locate problems, reducing downtime and repair costs.

[0031] Improve the operating efficiency of wind turbines: Through intelligent temperature monitoring and early warning systems, it is possible to ensure that wind turbines operate in the best condition, reduce downtime caused by faults, and thus improve the operating efficiency and power generation of wind turbines. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 It is a flow chart of the spindle bearing temperature measurement and early warning method in Embodiment 1 of the present invention;

[0033] Figure 2 It is a structural schematic diagram of the spindle bearing temperature measurement and early warning system in Example 2 of the present invention;

[0034] Figure 3 Schematic diagram of the wiring of the spindle temperature sensor in the embodiment of the present invention;

[0035] Figure 4 Schematic diagram of the installation position structure of the spindle temperature sensor in an embodiment of the present invention;

[0036] Icon: 1-spindle bearing seat, 101-sensor mounting hole. DETAILED DESCRIPTION

[0037] 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.

[0038] Example 1

[0039] Reference Figure 1 , a spindle bearing temperature measurement and early warning method, comprising the steps of:

[0040] Step 1: a sensor mounting hole 101 is provided on the spindle bearing seat 1, and a spindle temperature sensor is installed in the sensor mounting hole 101;

[0041] In this embodiment, before installing the spindle temperature sensor, confirm that all required tools are available, including but not limited to electric drills, taps, wrenches, screwdrivers, thermal grease, markers, cleaning cloths, etc.; check the surface of the spindle bearing seat 1 to ensure that it is flat, free of rust and damage.

[0042] In this embodiment, the sensor mounting hole 101 is formed by drilling a blind hole and tapping a thread. According to the design drawing, an electric drill is used to drill a hole at a designated position on the spindle bearing seat 1. mm, and a blind hole with a depth of 70 mm to 75 mm. Pay attention to maintaining the verticality and position accuracy of the hole; use an M12×1.5 tap to tap the blind hole, and control the tapping depth between 15 mm and 20 mm. During the tapping process, ensure that the tap is stable to avoid damaging the thread. Use a cleaning cloth or vacuum cleaner to clean up iron filings, paint residues and other debris generated during the drilling and tapping process to ensure that the working area is clean and free of impurities; check whether there is any residual metal filings in the hole to ensure that the hole is smooth and unobstructed.

[0043] In this embodiment, before installing the main shaft temperature sensor, the wind wheel lock is locked to ensure that the main shaft is in a stationary state to prevent accidental rotation during the installation process.

[0044] In this embodiment, before installing the spindle temperature sensor into the sensor installation hole 101, apply a proper amount of thermal grease on the contact surface between the spindle temperature sensor and the spindle. The thermal grease can be Kraft K5025 to improve the temperature conduction efficiency. Carefully insert the sensor into the tapped blind hole to ensure that the bottom of the sensor is in close contact with the bearing seat and the threaded part matches the thread in the hole well. Use a wrench or screwdriver to rotate the sensor until it is firmly fixed on the bearing seat. Be careful not to overtighten to avoid damaging the sensor or the bearing seat. Figure 4 As shown, multiple sensor mounting holes 101 can be set according to actual conditions. The temperature measuring mechanism has several temperature measuring ends. Each sensor mounting hole 101 is connected to a corresponding temperature measuring end. A marker pen is used to mark each temperature measuring end for future maintenance and repair. The angle θ between the sensor mounting hole 101 and the horizontal vertical line can be 30°±5°; an electric drill can be used to drill a designated position on the spindle bearing seat 1. Use a blind hole with a diameter of 1.5 mm and a depth of 70 mm to 75 mm as the sensor installation hole 101, and pay attention to maintaining the verticality and position accuracy of the hole; use an M12×1.5 tap to tap the blind hole, and control the tapping depth between 15 mm and 20 mm. During the tapping process, ensure that the tap is stable to avoid damaging the thread. Use a cleaning cloth or vacuum cleaner to clean up iron filings, paint residues and other debris generated during the drilling and tapping process to ensure that the working area is clean and free of impurities; check whether there are any residual metal filings in the sensor installation hole 101, and ensure that the sensor installation hole 101 is smooth and unobstructed.

[0045] In this embodiment, after the spindle temperature sensor is installed, a marking pen is used to draw a line on the sensor or on the bearing seat near the sensor to facilitate future inspection of whether the sensor is loose or shifted; the sensor is gently shaken to check whether it is firmly installed or loose.

[0046] In this embodiment, after the installation is completed, the construction area is cleaned to ensure that there are no tools or debris left behind, and all operations are confirmed to comply with safety regulations and have no safety hazards. After confirming safety, the wind wheel lock is unlocked to prepare for subsequent work.

[0047] Step 2: Protect the signal cable of the spindle temperature sensor, and route the signal cable together with the oil pipe and cable of the spindle lubrication system to the cabin control cabinet;

[0048] In this embodiment, ensure that all necessary tools and materials are ready, including bellows, cable ties, insulating tape, markers and other tools and materials; check the existing layout of the oil pipes and cables of the spindle lubrication system, and plan the best routing path to minimize interference and potential risks. Take out a bellows of appropriate length, ensure that its length is sufficient to cover the entire routing path from the sensor to the cabin control cabinet, and leave a certain margin for future maintenance and replacement; insert the signal cable of the spindle temperature sensor into the bellows, and ensure that the cable is not kinked or excessively bent in the bellows to avoid affecting signal transmission; use insulating tape or cable ties to fix the bellows at both ends and the appropriate position in the middle to prevent the bellows from falling off or damaging the cable during movement. According to the planned routing path, the bellows containing the signal cable shall be arranged along the direction of the oil pipe and cable of the spindle lubrication system; where it is necessary to turn or pass through obstacles, special tools or techniques shall be used to ensure a smooth transition of the bellows to avoid damage to the cable due to sharp bends; use a marker pen to mark the bellows and cables for quick identification during future maintenance and repair.

[0049] In this embodiment, during the installation and wiring of the spindle temperature sensor, the oil pipes, cables and sensor signal cables of the spindle lubrication system are arranged and fixed. At key positions of the entire wiring path, use brackets, buckles or cable ties to fix the bellows and cables to appropriate support structures to ensure that they do not shake or fall off during the operation of the unit; check and organize all cables and oil pipes to ensure that they are neatly arranged, without cross interference, and comply with safety regulations. After completing the wiring layout, perform a final check to ensure that all cables and oil pipes are properly fixed and have no damage or exposed parts; verify the connectivity of the signal cable to ensure that the temperature signal can be smoothly transmitted to the cabin control cabinet. Record key information such as the wiring path, materials used and fixing positions, and update the unit maintenance manual or related documents to provide detailed reference and guidance for possible future maintenance and overhaul work.

[0050] Step 3: Connect the signal cable to the designated terminal block in the cabin control cabinet and ground the signal cable shield;

[0051] In this embodiment, Figure 3 As shown in the figure, confirm the specific location of pins 23 and 24 of the X7 terminal block in the cabin control cabinet according to the drawing; use insulation strippers to carefully strip the insulation layer of the spindle temperature sensor signal cable to expose a sufficient length of metal core and shielding layer, and be careful not to damage the core and shielding layer; Figure 3According to the wiring requirements, connect the 23rd and 24th pins of the X7 terminal block respectively, and use a crimping pliers to press the wire core onto the terminal block to ensure that the connection is firm and reliable; peel off the shielding layer of the signal cable to expose a metal shielding mesh of sufficient length; use a shielded grounding clamp to connect the shielding layer to the grounding terminal of the cabin control cabinet, such as the 70 terminal corresponding to the Mita unit, to ensure that the shielding layer is effectively grounded. The grounding clamp should be tightened and reliable to prevent loosening. Use a marker to mark the connected cables for future maintenance and repair; organize the cables to ensure that the wiring is neat and beautiful, and avoid interference with other equipment or components. Carefully check all connection points to ensure that there is no looseness, short circuit, or open circuit; perform a power-on test to check whether the spindle temperature sensor can work normally and whether the signal can be accurately transmitted to the main control module. Archive the detailed process, wiring diagram, test results and other records for future reference.

[0052] Step 4: Set a temperature monitoring program in the main control module. When the spindle bearing temperature is greater than a first preset threshold, an alarm is triggered and a shutdown operation is performed.

[0053] In this embodiment, a second preset threshold is set through the main control module, and the second preset threshold is smaller than the first preset threshold; when the spindle bearing temperature is greater than the first preset threshold, an alarm is triggered and a shutdown operation is performed. If the spindle bearing temperature is greater than the second preset threshold, restarting the unit is prohibited. If the spindle bearing temperature is less than or equal to the second preset threshold, the unit is restarted according to actual needs.

[0054] In this embodiment, a human-machine interaction interface is set on the cabin control cabinet, and the historical data of the spindle bearing temperature is recorded through the temperature monitoring program. The real-time temperature, alarm information and shutdown status of the spindle bearing are displayed through the human-machine exchange interface. The operator can view the historical data, set corresponding parameters and perform fault diagnosis through the human-machine exchange interface.

[0055] In this embodiment, a programming environment suitable for the development of wind power control systems is selected, such as C / C++, PLC programming software, etc.; the interface protocol between the main control module and the sensor module, such as Modbus, CAN, Profibus, etc., is confirmed, and the corresponding driver or library file is prepared. When the program starts, all variables and modules related to temperature monitoring are initialized, including setting the temperature threshold, setting the first preset threshold to 65°C, and setting the second preset threshold to 60°C; writing a loop or a timed task to read the real-time temperature data of the main shaft bearing from the sensor module. The read temperature data is compared with the preset threshold; if the temperature is greater than the first preset threshold, the alarm logic is triggered; if the temperature is greater than the second preset threshold and the unit is in a shutdown state, it is forbidden to restart the unit; if the main shaft bearing temperature is less than or equal to the second preset threshold, the unit is restarted according to actual needs. When the temperature exceeds the first preset threshold, the alarm system is controlled by the main control module to send out an audible and visual alarm, and the alarm information is displayed on the human-computer interaction interface. At the same time, the alarm information is recorded in the system log for subsequent analysis; after the alarm is triggered, the shutdown command is immediately executed, the wind wheel lock module is closed (if it has not been locked), and the unit is stopped; after shutdown, the main control module monitors the temperature of the spindle bearing until the temperature drops below the second preset threshold, and the unit is allowed to restart. The temperature, alarm status and shutdown status of the spindle bearing are displayed in real time on the human-computer interaction interface; a historical data query function is provided, allowing operators to view the historical change trend of the spindle bearing temperature; operators are allowed to set parameters such as temperature thresholds and alarm methods through the interface; integrated fault diagnosis function, based on temperature data and other system parameters, provides possible fault causes and solutions.

[0056] In this embodiment, unit tests are performed on each module of the temperature monitoring program to ensure that it functions correctly; the temperature monitoring program is integrated with the main control module, sensor module, etc. for testing to verify the collaborative working ability of the entire system; and field tests are performed on the Yunda WD82-1500T unit to verify the actual effect and reliability of the temperature monitoring system.

[0057] Example 2

[0058] Based on Example 1, refer to Figure 2 This embodiment provides a spindle bearing temperature measurement and early warning system, which is used to implement the spindle bearing temperature measurement and early warning method as described above, including:

[0059] The sensor module includes a spindle temperature sensor for real-time detection of the temperature of the spindle bearing. In this embodiment, a high-precision, high-reliability temperature sensor is selected, such as a temperature sensor of model KZWK / P-200, for real-time detection of the temperature of the spindle bearing. The sensor needs to have fast response and long-term stability to ensure the accuracy of the measurement data.

[0060] The cable protection module is used to protect the signal cable of the spindle temperature sensor so that the signal cable is routed to the cabin control cabinet together with the oil pipe and cable of the spindle lubrication system. In this embodiment, a high-temperature resistant and corrosion-resistant bellows is selected to provide full protection for the signal cable of the spindle temperature sensor to prevent the cable from being damaged in a complex environment. A fixing clamp is provided on the routing path to fix the bellows, oil pipe, cable, etc. together to avoid mutual interference and wear.

[0061] The signal transmission module is used to transmit the temperature signal collected by the spindle temperature sensor to the designated terminal block in the cabin control cabinet through the signal cable; in this embodiment, a shielded signal cable is selected to reduce the impact of electromagnetic interference on the temperature signal, and the cable length is customized according to the actual situation of the unit to ensure the stability and reliability of signal transmission; a special terminal block, such as the X7 terminal block, is set in the cabin control cabinet to receive the signal cable of the spindle temperature sensor, and ensure that the wiring is firm and the contact is good.

[0062] The cabin control cabinet has a built-in main control module, and the main control module is provided with a temperature monitoring program for receiving and processing temperature signals from the sensor module; in this embodiment, the main control module has a built-in high-performance microprocessor or PLC, which runs the temperature monitoring program to receive, process and display the temperature data of the spindle bearing in real time; a human-machine interaction interface is provided on the cabin control cabinet, and the human-machine interaction interface provides a friendly operation interface for displaying the real-time temperature, historical data, alarm information and shutdown status of the spindle bearing. At the same time, it supports operators to set temperature thresholds, view fault diagnosis information, etc.

[0063] The wind wheel locking module is used to lock and unlock the wind wheel; in this embodiment, a mechanical or electric locking device is used to ensure that the main shaft cannot rotate when installing a main shaft temperature sensor or performing other maintenance work, thereby ensuring the safety of the operator; the wind wheel locking module is provided with a control unit, which is connected to the main control module and receives instructions from the main control module to realize the locking and unlocking operations of the wind wheel.

[0064] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A spindle bearing temperature measurement and early warning method, characterized in that: Includes steps: A sensor mounting hole is provided on the spindle bearing seat, and the spindle temperature sensor is installed in the sensor mounting hole; Protect the signal cable of the spindle temperature sensor, and route the signal cable together with the oil pipe and cable of the spindle lubrication system to the cabin control cabinet; Connect the signal cable to the designated terminal block in the cabin control cabinet and ground the signal cable shield; A temperature monitoring program is set in the main control module. When the spindle bearing temperature is greater than a first preset threshold, an alarm is triggered and a shutdown operation is performed.

2. The spindle bearing temperature measurement and early warning method according to claim 1, characterized in that: A second preset threshold is set through the main control module, and the second preset threshold is less than the first preset threshold; when the spindle bearing temperature is greater than the first preset threshold, an alarm is triggered and a shutdown operation is performed. If the spindle bearing temperature is greater than the second preset threshold, restarting the unit is prohibited. If the spindle bearing temperature is less than or equal to the second preset threshold, the unit is restarted according to actual needs.

3. The spindle bearing temperature measurement and early warning method according to claim 2, characterized in that: The first preset threshold is 65°C, and the second preset threshold is 60°C.

4. The spindle bearing temperature measurement and early warning method according to claim 1, characterized in that: Before installing the spindle temperature sensor, lock the wind wheel lock; after installation, clean the construction area and unlock the wind wheel lock after confirming safety.

5. The spindle bearing temperature measurement and early warning method according to claim 1, characterized in that: Before installing the spindle temperature sensor into the sensor mounting hole, apply thermal grease on the spindle temperature sensor.

6. The spindle bearing temperature measurement and early warning method according to claim 1, characterized in that: The sensor mounting hole is formed by drilling a blind hole and tapping a thread.

7. The spindle bearing temperature measurement and early warning method according to claim 1, characterized in that: After the spindle temperature sensor is installed, use a marker to mark the sensor.

8. The spindle bearing temperature measurement and early warning method according to claim 1, characterized in that: During the installation and wiring of the spindle temperature sensor, the spindle lubrication system oil pipes, cables and sensor signal cables are sorted and fixed.

9. The spindle bearing temperature measurement and early warning method according to claim 1, characterized in that: A human-machine interaction interface is set up on the cabin control cabinet. The historical data of the spindle bearing temperature is recorded through the temperature monitoring program. The real-time temperature, alarm information and shutdown status of the spindle bearing are displayed through the human-machine exchange interface. The operator can view the historical data, set corresponding parameters and perform fault diagnosis through the human-machine exchange interface.

10. A spindle bearing temperature measurement and early warning system, used to implement the spindle bearing temperature measurement and early warning method according to claims 1-9, characterized in that: include: The sensor module includes a spindle temperature sensor for detecting the temperature of the spindle bearing in real time; The cable protection module is used to protect the signal cable of the spindle temperature sensor, so that the signal cable can be routed to the cabin control cabinet together with the oil pipe and cable of the spindle lubrication system; A signal transmission module is used to transmit the temperature signal collected by the spindle temperature sensor to a designated terminal block in the cabin control cabinet through a signal cable; The cabin control cabinet has a built-in main control module, which is equipped with a temperature monitoring program for receiving and processing temperature signals from the sensor module; The wind wheel lock module is used to lock and unlock the wind wheel.

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