Blade bolt flaw detection system for wind driven generator

Abstract

The invention provides a blade bolt flaw detection system for a wind driven generator, which belongs to the technical field of flaw detection and comprises a three-dimensional scanning module for scanning a bolt based on a preset scanning device to generate a three-dimensional model of the bolt; the probe matching module is used for extracting geometric parameters of the bolt based on the three-dimensional model of the bolt, determining a form coefficient of the bolt and matching a corresponding ultrasonic probe based on the form coefficient of the bolt; the coefficient determination module is used for analyzing the matched ultrasonic probe to obtain ultrasonic probe parameters and determining the contact coefficient of the ultrasonic probe based on the ultrasonic probe parameters; the flaw detection operation module is used for determining contact parameters based on the contact coefficients of the ultrasonic probes and carrying out ultrasonic flaw detection based on the ultrasonic probes corresponding to the bolts and the contact parameters; the flaw detection analysis module is used for acquiring flaw detection data, analyzing the flaw detection data and generating a three-dimensional flaw detection model and a flaw detection report, so that the detection reliability of the wind driven generator bolt is improved, and the safe operation of equipment is guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of flaw detection, and in particular to a blade bolt flaw detection system for a wind turbine. Background Art

[0002] With the development of wind power generation technology, the reliability of bolts has become an important factor affecting the safe operation of wind turbines.

[0003] At present, traditional flaw detection methods mostly rely on manual detection or simple ultrasonic detection, which is inefficient and inaccurate. Existing technical solutions usually use fixed probes for flaw detection, which is difficult to adapt to bolts of different shapes and sizes, resulting in frequent missed detection or false detection.

[0004] Therefore, the present invention provides a blade bolt flaw detection system for a wind turbine. Summary of the invention

[0005] The present invention provides a blade bolt flaw detection system for a wind turbine, which is used to accurately generate a three-dimensional model of the bolt through three-dimensional scanning and shape coefficient matching, thereby ensuring that the flaw detection process is highly targeted, matching ultrasonic probes and optimizing contact coefficients to improve the accuracy and efficiency of flaw detection, overcoming the limitations of traditional methods, providing detailed three-dimensional flaw detection models and reports, facilitating rapid identification of potential defects, significantly improving the detection reliability of wind turbine bolts, and ensuring the safe operation of the equipment.

[0006] The present invention provides a blade bolt flaw detection system for a wind turbine, comprising:

[0007] 3D scanning module: scans the bolt based on a preset scanning device to generate a 3D model of the bolt;

[0008] Probe matching module: Extract the geometric parameters of the bolt based on the three-dimensional model of the bolt, and then determine the shape coefficient of the bolt, and match the corresponding ultrasonic probe based on the shape coefficient of the bolt;

[0009] Coefficient determination module: analyzing the matched ultrasonic probe to obtain ultrasonic probe parameters, and determining the contact coefficient of the ultrasonic probe based on the ultrasonic probe parameters;

[0010] Flaw detection operation module: Determine the contact parameters based on the contact coefficient of the ultrasonic probe, and perform ultrasonic flaw detection based on the ultrasonic probe and contact parameters corresponding to the bolt;

[0011] Flaw detection analysis module: obtains and analyzes flaw detection data, and then generates a three-dimensional flaw detection model and a flaw detection report.

[0012] The present invention provides a blade bolt flaw detection system for a wind turbine, a three-dimensional scanning module, comprising:

[0013] Bolt processing unit: clean the bolt surface, remove dirt and oil, and spray matte powder;

[0014] Bolt scanning unit: Based on the preset high-resolution 3D scanner, aim the scanner at the bolt, start the scanning program, use the preset laser and camera technology and scan the bolt at multiple angles according to the geometric features of the bolt, record the scanning data, and generate point cloud data of the bolt;

[0015] Model generation unit: import the point cloud data into the computer, use the preset data processing software to perform point cloud registration, denoising and filtering, and then generate a three-dimensional model of the bolt.

[0016] The present invention provides a blade bolt flaw detection system for a wind turbine generator, a probe matching module, comprising:

[0017] Parameter extraction unit: extracts the geometric parameters of the bolt from the generated 3D model based on a preset extraction method;

[0018] Coefficient determination unit: based on the extracted geometric parameters, determine the shape coefficient of the bolt;

[0019] Probe matching unit: Based on the determined shape coefficient, an ultrasonic probe suitable for the bolt is selected from the preset ultrasonic probe database.

[0020] The present invention provides a blade bolt flaw detection system for a wind turbine, a coefficient determination unit, comprising:

[0021] Based on the extracted geometric parameters, determine the shape coefficient of the bolt:

[0022]

[0023] Among them, K is the shape factor of the bolt, R 1 is the average roughness of the bolt surface, T thread depth, D t is the diameter of the thread, D m is the preset maximum diameter of the thread, E is the elastic coefficient of the bolt material, θ is the temperature coefficient of the environment, L is the effective length of the bolt, D is the average diameter of the bolt, V is the volume of the bolt, ρ is the density of the bolt material, α is the influence coefficient of temperature on the bolt, T 1 is the ambient temperature, T 0 is the preset reference temperature.

[0024] The present invention provides a blade bolt flaw detection system for a wind turbine, a coefficient determination module, comprising:

[0025] Parameter acquisition unit: acquires probe parameters of a matching ultrasonic probe based on a preset ultrasonic probe database;

[0026] Coefficient determination unit: According to the geometric parameters of the bolt and the selected ultrasonic probe parameters, the contact conditions are analyzed to determine the contact coefficient:

[0027]

[0028] Among them, K c is the contact coefficient, A is the effective contact area of ​​the ultrasonic probe, P is the contact pressure applied by the probe, c f is the surface lubrication coefficient of the ultrasonic probe, R a is the roughness coefficient of the bolt surface, D is the average diameter of the bolt, μ is the friction coefficient of the bolt material, L 1 is the preset target contact length.

[0029] The present invention provides a blade bolt flaw detection system for a wind turbine generator, and a flaw detection operation module, comprising:

[0030] Parameter acquisition unit: determines the basic contact parameters of the ultrasonic probe based on the preset equipment manual;

[0031] A parameter adjustment unit: adjusting a basic contact parameter of the ultrasonic probe based on the determined contact coefficient;

[0032] Flaw detection preparation unit: Apply an appropriate amount of ultrasonic coupling agent on the bolt surface, install a matching ultrasonic probe, start the ultrasonic flaw detector, and perform flaw detection based on the preset scanning path.

[0033] The present invention provides a blade bolt flaw detection system for a wind turbine, and a parameter adjustment unit, comprising:

[0034] The first adjustment subunit: when the contact coefficient is less than the first preset contact coefficient, the pressure applied by the probe to the bolt surface is gradually adjusted based on the preset frequency;

[0035] Angle acquisition subunit: determines the corresponding contact angle coefficient based on the contact coefficient and the preset coefficient-angle coefficient database, and obtains the optimal contact angle range based on the preset contact angle coefficient-angle range data table;

[0036] The second adjustment subunit is used for gradually adjusting the contact angle between the probe and the bolt surface based on a preset single adjustment angle within the optimal contact angle range, and stops adjusting when the contact coefficient is greater than a second preset contact coefficient;

[0037] The third adjustment subunit: according to the shape characteristics of the bolt, gradually adjust the position of the probe along the axial direction of the bolt, and stop adjusting when the contact coefficient is greater than the third preset contact coefficient.

[0038] The present invention provides a blade bolt flaw detection system for a wind turbine, and a flaw detection report, including: basic information of the flaw detection event, description of the detection object, ultrasonic probe parameters, detection process and parameters, flaw detection data, flaw detection data analysis and evaluation results, flaw detection conclusions and suggestions, and appendix.

[0039] On the other hand, the present invention further provides a non-transitory computer-readable storage medium having a computer program stored thereon, which implements any of the above-mentioned XXXX methods when executed by a processor.

[0040] On the other hand, the present invention further provides a computer program product, comprising a computer program, wherein when the computer program is executed by a processor, the computer program implements any one of the above-mentioned XXXX methods.

[0041] Compared with the prior art, the present invention has the following beneficial effects:

[0042] Through 3D scanning and shape coefficient matching, the 3D model of the bolt is accurately generated to ensure that the flaw detection process is highly targeted. Matching the ultrasonic probe and optimizing the contact coefficient improve the accuracy and efficiency of flaw detection, overcome the limitations of traditional methods, and provide detailed 3D flaw detection models and reports, which help to quickly identify potential defects, significantly improve the detection reliability of wind turbine bolts, and ensure the safe operation of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0044] Figure 1 The present invention is a schematic structural diagram of a blade bolt flaw detection system for a wind turbine provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0045] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be clearly and completely described below in conjunction with the drawings of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. 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.

[0046] Example 1

[0047] The embodiment of the present invention provides a blade bolt flaw detection system for a wind turbine, such as Figure 1As shown, including:

[0048] 3D scanning module: Scans the bolts based on the preset scanning system to generate a 3D model of the bolts;

[0049] Probe matching module: Extract the geometric parameters of the bolt based on the three-dimensional model of the bolt, and then determine the shape coefficient of the bolt, and match the corresponding ultrasonic probe based on the shape coefficient of the bolt;

[0050] Coefficient determination module: analyzing the matched ultrasonic probe to obtain ultrasonic probe parameters, and determining the contact coefficient of the ultrasonic probe based on the ultrasonic probe parameters;

[0051] Flaw detection operation module: Determine the contact parameters based on the contact coefficient of the ultrasonic probe, and perform ultrasonic flaw detection based on the ultrasonic probe and contact parameters corresponding to the bolt;

[0052] Flaw detection analysis module: obtains and analyzes flaw detection data, and then generates a three-dimensional flaw detection model and a flaw detection report.

[0053] In this embodiment, the three-dimensional model of the bolt is a digital representation obtained by three-dimensional scanning technology, which contains all geometric information of the bolt, including shape, size and position. For example, the bolt is scanned using a 3D scanner to generate a virtual model containing information such as bolt diameter, length, thread shape, etc.;

[0054] In this embodiment, the geometric parameters of the bolt are values ​​describing the shape and size of the bolt, such as diameter, length, pitch and thread angle, etc. For example, for a standard M10 bolt, its geometric parameters include an outer diameter of 10 mm and a thread with 1.5 threads per millimeter;

[0055] In this embodiment, the shape coefficient is a parameter that characterizes the shape characteristics of the bolt, and is used to evaluate the adaptability of the bolt when matching the ultrasonic probe. For example, if the shape of a bolt is special (such as a hexagonal head bolt), its shape coefficient may be different from that of a standard cylindrical bolt, thereby affecting the probe selection;

[0056] In this embodiment, the ultrasonic probe is a device used for flaw detection, and its selection is based on the geometric parameters and form coefficients of the bolts to ensure the best detection effect. For example, for bolts with complex shapes, a curved ultrasonic probe that can adapt to their geometric characteristics is selected.

[0057] In this embodiment, the probe parameters include operating frequency, beam angle, sensitivity, etc., which are used to determine the performance of the probe during the flaw detection process. For example, the operating frequency of a probe is 5 MHz, and the beam angle is 30 degrees. These parameters will affect its ability to detect small cracks.

[0058] In this embodiment, the contact coefficient is a parameter for evaluating the contact between the ultrasonic probe and the bolt, which affects the propagation efficiency and quality of the sound wave. For example, if the probe is in good contact with the bolt surface, the contact coefficient may be close to 1, indicating that the sound wave transmission efficiency is high.

[0059] In this embodiment, the contact parameters include contact pressure, contact area, etc., which affect the effect of ultrasonic flaw detection. For example, during the flaw detection process, the contact pressure applied by the probe is 2N and the contact area is 5mm. 2 .

[0060] In this embodiment, ultrasonic flaw detection is a non-destructive testing technology that detects internal defects of materials by emitting ultrasonic waves and analyzing their echoes. For example, ultrasonic flaw detection is performed on bolts, and tiny cracks are found inside them, which are confirmed by echo signal analysis.

[0061] In this embodiment, the three-dimensional flaw detection model is a visualization model generated based on the flaw detection data, which shows the spatial distribution and characteristics of internal defects of the bolt. For example, the generated three-dimensional flaw detection model shows the specific location and shape of the crack in the bolt, which is convenient for subsequent analysis and processing.

[0062] The beneficial effects of the above technical solution are: through three-dimensional scanning and morphological coefficient matching, the three-dimensional model of the bolt is accurately generated to ensure that the flaw detection process is highly targeted, matching ultrasonic probes and optimizing contact coefficients improve the accuracy and efficiency of flaw detection, overcome the limitations of traditional methods, and provide detailed three-dimensional flaw detection models and reports, which helps to quickly identify potential defects, significantly improve the detection reliability of wind turbine bolts, and ensure the safe operation of the equipment.

[0063] Example 2

[0064] The embodiment of the present invention provides a blade bolt flaw detection system for a wind turbine, a three-dimensional scanning module, including:

[0065] Bolt processing unit: clean the bolt surface, remove dirt and oil, and spray matte powder;

[0066] Bolt scanning unit: Based on the preset high-resolution 3D scanner, aim the scanner at the bolt, start the scanning program, use the preset laser and camera technology and scan the bolt at multiple angles according to the geometric features of the bolt, record the scanning data, and generate point cloud data of the bolt;

[0067] Model generation unit: import the point cloud data into the computer, use the preset data processing software to perform point cloud registration, denoising and filtering, and then generate a three-dimensional model of the bolt.

[0068] In this embodiment, the preset high-resolution 3D scanner has a high-resolution function and can capture 3D data with rich details. It is usually equipped with laser scanning and camera technology to ensure high accuracy. For example, using a high-resolution 3D laser scanner such as FARO Focus3D can obtain accurate 3D data of the bolt in a short time, including tiny defects and textures on the surface;

[0069] In this embodiment, point cloud data is a set of discrete points representing the surface of an object acquired by a scanner, and is usually used to construct a three-dimensional model. Each point contains position coordinates and possible color information. For example, after scanning, the generated point cloud data may include millions of points, which reflect the shape and features of the bolt surface, forming a dense three-dimensional representation.

[0070] In this embodiment, the preset data processing software is software for processing and analyzing point cloud data, and has functions such as point cloud registration, denoising, and filtering to generate a final three-dimensional model. For example, software such as Geomagic or CloudCompare is used to process the scanned point cloud data, remove background noise, and align point cloud data at different angles to generate a high-quality bolt three-dimensional model.

[0071] The beneficial effects of the above technical solution are: high-precision detection of bolts is achieved through the 3D scanning module. The bolt processing unit first cleans the bolt surface to ensure the accuracy of the scanning data. The bolt scanning unit uses a high-resolution 3D scanner to capture the geometric features of the bolts from multiple angles and generate detailed point cloud data. The model generation unit uses advanced data processing software to align, denoise and filter the point cloud, and finally generates an accurate 3D model. This technical process greatly improves the accuracy and efficiency of flaw detection and provides a strong guarantee for the safe operation of wind turbines.

[0072] Example 3

[0073] The embodiment of the present invention provides a blade bolt flaw detection system for a wind turbine, a probe matching module, including:

[0074] Parameter extraction unit: extracts the geometric parameters of the bolt from the generated 3D model based on a preset extraction method;

[0075] Coefficient determination unit: based on the extracted geometric parameters, determine the shape coefficient of the bolt;

[0076] Probe matching unit: Based on the determined shape coefficient, an ultrasonic probe suitable for the bolt is selected from the preset ultrasonic probe database.

[0077] In this embodiment, the preset extraction method refers to a specific algorithm or technology used in the data processing process to extract the required geometric parameters from the three-dimensional model. The method can be optimized according to different application requirements to improve the accuracy and efficiency of the extraction. For example, an edge detection-based extraction method is used to automatically identify the diameter, length and thread features of the bolt by analyzing the edge information in the point cloud data. This method can effectively extract key geometric parameters from complex three-dimensional data, which is convenient for subsequent probe matching and analysis.

[0078] The beneficial effects of the above technical solution are: through the probe matching module, the matching process between the probe and the bolt is optimized, the geometric parameters of the bolt are accurately extracted from the three-dimensional model, the accuracy of the data is ensured, the shape coefficient is calculated, and the bolt characteristics are further quantified. The probe matching unit selects the best probe from the ultrasonic probe database according to the shape coefficient, which enhances the adaptability and effectiveness of flaw detection. This process improves the efficiency of flaw detection, reduces the risk of potential failures, and improves the safety of wind turbines.

[0079] Example 4

[0080] The embodiment of the present invention provides a blade bolt flaw detection system for a wind turbine, and a coefficient determination unit, comprising:

[0081] Based on the extracted geometric parameters, determine the shape coefficient of the bolt:

[0082]

[0083] Among them, K is the shape factor of the bolt, R 1 is the average roughness of the bolt surface, T thread depth, D t is the diameter of the thread, D m is the preset maximum diameter of the thread, E is the elastic coefficient of the bolt material, θ is the temperature coefficient of the environment, L is the effective length of the bolt, D is the average diameter of the bolt, V is the volume of the bolt, ρ is the density of the bolt material, α is the influence coefficient of temperature on the bolt, T 1 is the ambient temperature, T 0 is the preset reference temperature.

[0084] In this embodiment, the preset maximum diameter of the thread refers to the maximum diameter value of the threaded portion specified in the design, which is usually used to ensure that the bolt has sufficient strength and stability when connected. This value may be set based on material properties and application requirements. For example, for an M16 bolt used in a wind turbine, the preset maximum diameter may be 16mm to ensure that the thread can still maintain good connection performance under high load conditions;

[0085] In this embodiment, the elastic modulus (or Young's modulus) is a parameter that measures the relationship between stress and strain of a material during the elastic deformation stage, and indicates the material's ability to resist deformation. The higher the elastic modulus, the smaller the deformation of the material when subjected to stress. For example, the elastic modulus of steel is usually around 200 GPa, while the elastic modulus of aluminum is about 70 GPa. This means that under the same stress, the deformation degree of steel is much lower than that of aluminum;

[0086] In this embodiment, the effective length refers to the length of the bolt that actually participates in the force in the connection, usually excluding the bolt head and the part that is not fully engaged. It affects the tensile and shear resistance of the bolt. If the total length of a bolt is 100mm and the head occupies 10mm, the effective length is 90mm. This part of the length determines the load-bearing capacity of the bolt;

[0087] In this embodiment, the temperature influence coefficient on the bolt is a parameter used to quantify the effect of temperature change on the bolt performance (such as strength, stiffness, etc.), which is usually related to the material properties. This coefficient is used to adjust the design and use of the bolt under different temperature conditions. For example, the temperature influence coefficient of steel may be 0.000012 / ℃, which means that when the temperature rises, the size of the bolt will increase accordingly, affecting its tightening effect;

[0088] In this embodiment, the preset reference temperature is a standard temperature used when analyzing bolt performance, and is usually used to calculate and compare bolt behaviors under different temperature conditions. The temperature can be set according to specific application fields or industry standards. For example, in many engineering applications, the preset reference temperature may be set to 20°C, which is the standard under normal temperature conditions, so as to facilitate comparison with performance under high or low temperature conditions.

[0089] The beneficial effects of the above technical solution are: through the coefficient determination unit, the shape coefficient of the bolt is accurately calculated, the reliability and accuracy of the flaw detection are improved, the geometric parameters of the bolt, such as surface roughness, thread depth and diameter, are comprehensively considered, and the material elastic coefficient and ambient temperature factors are introduced to achieve a comprehensive evaluation of the bolt performance. By quantifying these variables, the flaw detection effect under different environmental conditions is ensured, the potential risks are reduced, and the overall safety and stability of the wind turbine are improved.

[0090] Example 5

[0091] The embodiment of the present invention provides a blade bolt flaw detection system for a wind turbine, a coefficient determination module, including:

[0092] Parameter acquisition unit: acquires probe parameters of a matching ultrasonic probe based on a preset ultrasonic probe database;

[0093] Coefficient determination unit: According to the geometric parameters of the bolt and the selected ultrasonic probe parameters, the contact conditions are analyzed to determine the contact coefficient:

[0094]

[0095] Among them, K c is the contact coefficient, A is the effective contact area of ​​the ultrasonic probe, P is the contact pressure applied by the probe, C f is the surface lubrication coefficient of the ultrasonic probe, R a is the roughness coefficient of the bolt surface, D is the average diameter of the bolt, μ is the friction coefficient of the bolt material, L 1 is the preset target contact length.

[0096] In this embodiment, the contact condition refers to the interaction state between the ultrasonic probe and the bolt surface, involving factors such as contact pressure, surface state (such as smoothness) and contact area. Reasonable contact conditions are crucial to the effectiveness of ultrasonic flaw detection because they affect the propagation and reflection characteristics of waves. For example, when the ultrasonic probe is in close contact with the bolt surface and appropriate pressure is applied, the contact condition is good and the sound wave can be effectively transmitted, thereby improving the sensitivity of flaw detection. If there is dirt or roughness between the probe and the bolt surface, the contact condition is poor, which may lead to inaccurate flaw detection results;

[0097] In this embodiment, the effective contact area refers to the surface area that actually participates in the propagation of sound waves when the ultrasonic probe contacts the bolt. This area directly affects the transmission efficiency of sound waves and the accuracy of flaw detection. If the diameter of a circular ultrasonic probe is 10 mm, its theoretical contact area is π×(52)=78.5 mm2π×(52)=78.5 mm2. However, if the surface is rough or uneven, the actual effective contact area may be reduced to 60 mm 2 , which will affect the reflection intensity of the sound wave and the flaw detection results;

[0098] In this embodiment, the preset target contact length refers to the contact length that is designed to be achieved when the ultrasonic probe contacts the bolt. This length is usually set based on the flaw detection requirements and the geometric characteristics of the bolt to ensure effective propagation of the sound wave. For example, in the design, if the target length of the ultrasonic probe contacting the bolt surface is expected to be 20 mm, this can ensure that the sound wave can cover the key area of ​​the bolt to detect possible cracks or defects.

[0099] The beneficial effects of the above technical solution are: through the coefficient determination module, accurate analysis and optimization of contact conditions are achieved, matching parameters are extracted from the ultrasonic probe database to ensure efficient cooperation between the probe and the bolt, and the contact coefficient is scientifically calculated by combining the bolt geometric parameters and probe characteristics, and the influencing factors such as contact area, pressure and surface roughness are quantified, which improves the accuracy and reliability of flaw detection. This method effectively reduces the uncertainty in the flaw detection process and enhances the safety of wind turbines.

[0100] Example 6

[0101] The embodiment of the present invention provides a blade bolt flaw detection system for a wind turbine, and a flaw detection operation module, including:

[0102] Parameter acquisition unit: determines the basic contact parameters of the ultrasonic probe based on the preset equipment manual;

[0103] A parameter adjustment unit: adjusting a basic contact parameter of the ultrasonic probe based on the determined contact coefficient;

[0104] Flaw detection preparation unit: Apply an appropriate amount of ultrasonic coupling agent on the bolt surface, install a matching ultrasonic probe, start the ultrasonic flaw detector, and perform flaw detection based on the preset scanning path.

[0105] In this embodiment, the basic contact parameters refer to the basic settings required when the ultrasonic probe contacts the object to be detected (such as a bolt) during the ultrasonic flaw detection process, including contact pressure, contact area, applied force, etc., which are used to ensure that the ultrasonic wave can be effectively transmitted and reflected, thereby improving the accuracy of flaw detection. For example, the basic contact parameters specified in the manual of ultrasonic flaw detection equipment may include: the contact pressure applied by the probe is 5N, the contact area is 78.5mm 2 , these parameters ensure that the probe can effectively contact the bolt surface.

[0106] In this embodiment, the basic contact parameters of the ultrasonic probe are adjusted based on the determined contact coefficient. This process involves optimizing the basic contact parameters of the ultrasonic probe according to the calculated contact coefficient to adapt to specific flaw detection requirements. The contact coefficient reflects the difference between the actual contact conditions and the ideal conditions. After adjustment, the flaw detection effect can be improved. If the contact coefficient is calculated to be 0.85, it means that the actual contact conditions are slightly insufficient relative to the ideal state. In order to compensate for this, the contact pressure may need to be adjusted to 6N to ensure better sound wave transmission effect.

[0107] In this embodiment, the preset scanning path refers to a scheme in which the ultrasonic probe scans the object to be inspected according to a certain track or pattern when performing ultrasonic flaw detection. The design of this path is intended to ensure that the flaw detection covers all important areas to maximize the detection of possible defects. For example, for the flaw detection of bolts, a spiral scanning path can be designed to ensure that the probe scans evenly along the axial and radial directions of the bolts. The path length may be set to 40 mm to cover the entire surface of the bolt.

[0108] The beneficial effects of the above technical solution are: through modular flaw detection operations, the flaw detection efficiency and accuracy are improved, the scientific nature of the ultrasonic probe contact parameters is ensured, the basic parameters are optimized according to the contact coefficient, the detection effect is enhanced, and the stability of signal transmission is ensured by accurately applying coupling agent and correctly installing the probe, which reduces human intervention and greatly improves the flaw detection quality and safety of wind turbines.

[0109] Example 7

[0110] The embodiment of the present invention provides a blade bolt flaw detection system for a wind turbine, and a parameter adjustment unit, comprising:

[0111] The first adjustment subunit: when the contact coefficient is less than the first preset contact coefficient, the pressure applied by the probe to the bolt surface is gradually adjusted based on the preset frequency;

[0112] Angle acquisition subunit: determines the corresponding contact angle coefficient based on the contact coefficient and the preset coefficient-angle coefficient database, and obtains the optimal contact angle range based on the preset contact angle coefficient-angle range data table;

[0113] The second adjustment subunit is used for gradually adjusting the contact angle between the probe and the bolt surface based on a preset single adjustment angle within the optimal contact angle range, and stops adjusting when the contact coefficient is greater than a second preset contact coefficient;

[0114] The third adjustment subunit: according to the shape characteristics of the bolt, gradually adjust the position of the probe along the axial direction of the bolt, and stop adjusting when the contact coefficient is greater than the third preset contact coefficient.

[0115] In this embodiment, the first preset contact coefficient is a threshold value set during design, which is used to judge the effectiveness of the contact between the ultrasonic probe and the bolt. When the contact coefficient is less than this value, pressure adjustment is required to improve the contact state. For example, the first preset contact coefficient may be set to 0.75. If the actual measured contact coefficient is 0.65, the system will start the first adjustment subunit to gradually increase the pressure applied to the bolt surface;

[0116] In this embodiment, the preset frequency refers to the frequency of the applied pressure change used during the adjustment process. This frequency is preset to ensure a smooth and effective adjustment process. Assuming the preset frequency is 0.5 Hz, it means that the system will gradually increase the pressure applied to the bolt surface once every 2 seconds until the ideal contact state is reached.

[0117] In this embodiment, the contact angle coefficient is used to describe the angle characteristics when the probe contacts the bolt, which affects the transmission effect of the ultrasonic wave. This coefficient is obtained by comparing with the preset coefficient-angle coefficient database. If the contact angle coefficient is 0.9, it means that the contact angle between the probe and the bolt is effective and can transmit the ultrasonic wave well.

[0118] In this embodiment, the optimal contact angle range is an angle interval determined based on the contact angle coefficient. Within this range, the contact effect between the probe and the bolt is optimal, which is beneficial to improving the quality of flaw detection. If the optimal contact angle range is 15° to 25°, the contact angle of the probe should be adjusted within this range to obtain the best flaw detection effect.

[0119] In this embodiment, the preset single adjustment angle refers to the specific angle value of each adjustment when adjusting the contact angle between the probe and the bolt. This value is also preset to ensure the accuracy of the adjustment process. Assuming that the preset single adjustment angle is 2°, the contact angle of the probe will increase or decrease by 2° each time it is adjusted until the optimal contact angle range is reached;

[0120] In this embodiment, the second preset contact coefficient is another threshold value set to determine whether it is necessary to stop adjusting the contact angle of the probe. When the contact coefficient is greater than this value, it means that the contact condition has reached a satisfactory level and the adjustment process can be stopped. If the second preset contact coefficient is 0.85 and the measured contact coefficient is 0.88, the system will stop the angle adjustment.

[0121] In this embodiment, the third preset contact coefficient is a threshold for determining the probe position adjustment. When the contact coefficient exceeds this value, it indicates that the probe position adjustment has reached an ideal state and further adjustment can be stopped. Assume that the third preset contact coefficient is 0.90. If the actual contact coefficient is 0.92, the system will stop adjusting the probe along the bolt axis.

[0122] The beneficial effects of the above technical solution are: through the intelligent parameter adjustment mechanism, the accuracy and efficiency of flaw detection are significantly improved; by dynamically adjusting the applied pressure and contact angle, the optimal contact between the probe and the bolt is ensured, the transmission effect of the ultrasonic signal is enhanced; based on the real-time feedback of the contact coefficient, the automated adjustment process reduces human errors, optimizes the reliability of the detection results, and thereby improves the safety and maintenance efficiency of wind turbines.

[0123] Example 8

[0124] An embodiment of the present invention provides a blade bolt flaw detection system for a wind turbine, and a flaw detection report, including: basic information of the flaw detection event, description of the detection object, ultrasonic probe parameters, detection process and parameters, flaw detection data, flaw detection data analysis and evaluation results, flaw detection conclusions and suggestions, and appendix.

[0125] In this embodiment, the basic information of the flaw detection event: report number: the unique number of each flaw detection test, detection time: the specific detection date and time, detection personnel: the name and qualification certification information of the detection operator, equipment information: the ultrasonic probe model, frequency range, and detection instrument brand and serial number used, wind turbine model: the corresponding generator and blade information, bolt number: the number and position of the detected bolt or threaded component;

[0126] In this embodiment, the detection object is described as follows: 3D model of the bolt: a bolt model generated by 3D scanning, used to assist positioning detection, geometric parameters of the bolt: including length, diameter, thread type and pitch, surface roughness, etc., shape coefficient: a shape coefficient calculated based on the geometric parameters;

[0127] In this embodiment, the ultrasonic probe parameters are: probe frequency: the probe operating frequency adapted to the bolt (e.g., 1-10 MHz), contact coefficient: the contact effect between the probe and the bolt determined based on the shape coefficient and the probe parameters, coupling agent type: a coupling agent used to enhance signal conduction (e.g., water, gel), calibration data: including comparative data of the calibration block and the standard sample;

[0128] In this embodiment, the detection process and parameters are as follows: scanning mode: such as point scanning, line scanning or spiral scanning mode, detection path: marking the moving track of the probe on the bolt, flaw detection sensitivity: the adopted gain, detection depth range and signal threshold, environmental conditions: environmental information such as temperature and humidity during detection;

[0129] In this embodiment, the flaw detection data: original waveform and A-Scan / B-Scan diagram: display the ultrasonic signal obtained during the detection process, defect location diagram: indicate the possible defect locations on the bolt (such as cracks, pores, delamination, etc.), defect type: determine the type and nature of the defect (surface cracks, internal inclusions, etc.) according to the signal characteristics, defect size: including specific data such as length, depth and width, defect severity rating: grade the severity of the defect according to international standards (such as ISO or ASME);

[0130] In this embodiment, the flaw detection data analysis and evaluation results are as follows: Signal analysis: judging the material integrity through signal attenuation and reflection intensity analysis; Trend analysis: if it is a periodic detection, then the comparison with the previous data is listed to judge the defect development; Life prediction: predicting the remaining service life of the bolt based on the defect evaluation and the working conditions of the bolt; Maintenance suggestion: making repair or replacement suggestions based on the flaw detection results.

[0131] In this embodiment, the flaw detection conclusion and suggestion: the test result determines whether the bolt passes the test and whether further inspection or replacement is needed; the repair measure suggestion: whether tightening, lubrication, replacement or other maintenance measures are needed; the next inspection suggestion: the recommended next inspection cycle and maintenance plan.

[0132] In this embodiment, Appendix: NDT images and scanned models: 3D bolt models and defect images, Standards and specifications references: based on the inspection standards (such as ISO, ASME), Inspection record signatures: signatures and certifications of inspectors and reviewers.

[0133] The beneficial effects of the above technical solution are: providing comprehensive detection information through systematic flaw detection reports, ensuring the transparency and traceability of the flaw detection process, and detailed records of ultrasonic probe parameters and detection data. Combined with data analysis and evaluation results, it provides users with reliable defect identification and evaluation, and then formulates accurate maintenance recommendations, which significantly improves the safety and operating efficiency of wind turbines and has high practical application value.

[0134] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A blade bolt flaw detection system for a wind turbine, characterized in that: include: 3D scanning module: scans the bolt based on a preset scanning device to generate a 3D model of the bolt; Probe matching module: Extract the geometric parameters of the bolt based on the three-dimensional model of the bolt, and then determine the shape coefficient of the bolt, and match the corresponding ultrasonic probe based on the shape coefficient of the bolt; Coefficient determination module: analyzing the matched ultrasonic probe to obtain ultrasonic probe parameters, and determining the contact coefficient of the ultrasonic probe based on the ultrasonic probe parameters; Flaw detection operation module: Determine the contact parameters based on the contact coefficient of the ultrasonic probe, and perform ultrasonic flaw detection based on the ultrasonic probe and contact parameters corresponding to the bolt; Flaw detection analysis module: obtains and analyzes flaw detection data, and then generates a three-dimensional flaw detection model and a flaw detection report.

2. A blade bolt flaw detection system for a wind turbine according to claim 1, characterized in that: 3D scanning module, including: Bolt processing unit: clean the bolt surface, remove dirt and oil, and spray matte powder; Bolt scanning unit: Based on the preset high-resolution 3D scanner, aim the scanner at the bolt, start the scanning program, use the preset laser and camera technology and scan the bolt at multiple angles according to the geometric features of the bolt, record the scanning data, and generate point cloud data of the bolt; Model generation unit: import the point cloud data into the computer, use the preset data processing software to perform point cloud registration, denoising and filtering, and then generate a three-dimensional model of the bolt.

3. A blade bolt flaw detection system for a wind turbine according to claim 1, characterized in that: Probe matching module, including: Parameter extraction unit: extracts the geometric parameters of the bolt from the generated 3D model based on a preset extraction method; Coefficient determination unit: based on the extracted geometric parameters, determine the shape coefficient of the bolt; Probe matching unit: Based on the determined shape coefficient, an ultrasonic probe suitable for the bolt is selected from the preset ultrasonic probe database.

4. A blade bolt flaw detection system for a wind turbine according to claim 3, characterized in that: Coefficient determination unit, including: Based on the extracted geometric parameters, determine the shape coefficient of the bolt: Among them, K is the shape coefficient of the bolt, R1 is the average roughness of the bolt surface, T is the thread depth, D is t is the diameter of the thread, D m is the preset maximum diameter of the thread, E is the elastic coefficient of the bolt material, θ is the temperature coefficient of the environment, L is the effective length of the bolt, D is the average diameter of the bolt, V is the volume of the bolt, ρ is the density of the bolt material, α is the influence coefficient of temperature on the bolt, T1 is the ambient temperature, and T0 is the preset reference temperature.

5. The blade bolt flaw detection system for a wind turbine according to claim 1, characterized in that: The coefficient determination module includes: Parameter acquisition unit: acquires probe parameters of a matching ultrasonic probe based on a preset ultrasonic probe database; Coefficient determination unit: According to the geometric parameters of the bolt and the selected ultrasonic probe parameters, the contact conditions are analyzed to determine the contact coefficient: Among them, K c is the contact coefficient, A is the effective contact area of ​​the ultrasonic probe, P is the contact pressure applied by the probe, C f is the surface lubrication coefficient of the ultrasonic probe, R a is the roughness coefficient of the bolt surface, D is the average diameter of the bolt, μ is the friction coefficient of the bolt material, and L1 is the preset target contact length.

6. A blade bolt flaw detection system for a wind turbine according to claim 1, characterized in that: Flaw detection operation module, including: Parameter acquisition unit: determines the basic contact parameters of the ultrasonic probe based on the preset equipment manual; A parameter adjustment unit: adjusting a basic contact parameter of the ultrasonic probe based on the determined contact coefficient; Flaw detection preparation unit: Apply an appropriate amount of ultrasonic coupling agent on the bolt surface, install a matching ultrasonic probe, start the ultrasonic flaw detector, and perform flaw detection based on the preset scanning path.

7. A blade bolt flaw detection system for a wind turbine according to claim 6, characterized in that: Parameter adjustment unit, including: The first adjustment subunit: when the contact coefficient is less than the first preset contact coefficient, the pressure applied by the probe to the bolt surface is gradually adjusted based on the preset frequency; Angle acquisition subunit: determines the corresponding contact angle coefficient based on the contact coefficient and the preset coefficient-angle coefficient database, and obtains the optimal contact angle range based on the preset contact angle coefficient-angle range data table; The second adjustment subunit is used for gradually adjusting the contact angle between the probe and the bolt surface based on a preset single adjustment angle within the optimal contact angle range, and stops adjusting when the contact coefficient is greater than a second preset contact coefficient; The third adjustment subunit: according to the shape characteristics of the bolt, gradually adjust the position of the probe along the axial direction of the bolt, and stop adjusting when the contact coefficient is greater than the third preset contact coefficient.

8. A blade bolt flaw detection system for a wind turbine according to claim 1, characterized in that: The flaw detection report includes: basic information of the flaw detection event, description of the detection object, ultrasonic probe parameters, detection process and parameters, flaw detection data, flaw detection data analysis and evaluation results, flaw detection conclusions and suggestions, and appendix.

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