Hydraulic generator thrust bearing stress adjusting system and method suitable for pillar bolt supporting structure

Abstract

The invention relates to a hydro-generator thrust bearing stress adjusting method and system suitable for a pillar bolt supporting structure, and the method and system achieve the full-automatic collection of the stress state of a thrust bearing through employing a distributed wireless collection terminal, and greatly improve the collection efficiency of the displacement of a sensor. In addition, unit level data are combined, the adjustment amount of the supporting column bolt of each thrust bearing bush can be automatically calculated, and therefore great convenience is provided for the thrust bearing stress adjustment process in the hydroelectric generating set overhaul process. In addition, a wireless network is constructed based on a low-power-consumption Zigbee communication technology, the endurance time of wireless equipment is effectively prolonged, and the stability and economical efficiency of the system are enhanced. According to the scheme disclosed by the invention, the overhaul efficiency and quality of the water-turbine generator set can be remarkably improved, and the method is suitable for daily maintenance and overhaul operation of a large hydropower station.

Description

Technical Field

[0001] The invention relates to the technical field of force adjustment of a hydraulic generator thrust bearing, and in particular to a hydraulic generator thrust bearing force adjustment system and method suitable for a support bolt support structure. Background Art

[0002] In a hydro-turbine generator set, the thrust bearing does not have self-regulating capability. When the unit is running, the thrust bearing is unevenly stressed, which will cause large temperature differences among the thrust bearings. In severe cases, it may even cause bearing burnout accidents. Therefore, thrust bearing force adjustment is mainly used in the cranking of the hydro-turbine unit after repair and in the trial operation process before power generation, to ensure that the thrust bearings are in a balanced state before the unit is officially put into operation, thereby ensuring the normal operation of the unit.

[0003] The mainstream force adjustment method for rigid pillar thrust bearings currently used in China is: 24 displacement sensors are respectively inserted into the pillar bolts under the 24 thrust bearings at the bottom of the thrust bearing to measure the force (displacement) of each thrust bearing. Each displacement sensor is connected to a handheld stress measuring instrument through a transmitter tube. The displacement data of the displacement sensor is displayed on the display screen of the handheld stress measuring instrument and recorded by the maintenance personnel. During the force adjustment process, the maintenance personnel need to collect the initial displacement data of the displacement sensor once when the generator rotor is lifted; collect the final displacement data of the support sensor once when the generator rotor falls and the thrust bearing is under pressure. Then the maintenance personnel will calculate the displacement value of each thrust bearing from the recorded data, thereby calculating the height that each bearing needs to be adjusted, and then repeat the above steps until the displacement of each bearing is less than the allowable deformation value.

[0004] However, the thrust bearing equipment used above has a low level of intelligence and requires human support. During each thrust bearing force adjustment process of the rotor lifting and falling, maintenance personnel need to collect 48 sets of sensor data and enter them into a table for calculation. Generally, a thrust bearing force adjustment requires multiple rotor lifting and falling, and repeated measurements and adjustments are required to complete the balance adjustment of the thrust bearing. Maintenance personnel need to repeatedly plug and unplug the handheld strain gauge hundreds of times to collect data, which consumes a lot of manpower and time during the maintenance process, making the overall maintenance efficiency low. In addition, due to the repeated plugging and unplugging of the displacement sensor and the handheld stress gauge, the connection interface will also suffer from poor contact and wear after long-term use. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide an automatic intelligent calculation system and method for adjusting the force balance of the thrust bearing during the maintenance of a hydropower unit, so as to overcome the inconvenience and complexity of the existing mode of manually collecting sensor data of the thrust bearing during the maintenance process.

[0006] In order to solve the above technical problems, the technical solution adopted by the present invention is: a method for adjusting the force of a thrust bearing of a hydro-turbine generator applicable to a support bolt support structure, comprising the following steps: 1) The PC workstation software is started, and the wireless monitoring system for thrust bearing force measurement performs software initialization and hardware connection synchronization; 2) When the rotor is lifted, the operating system software and the wireless monitoring system for measuring the force of the thrust bearing automatically collect the initial displacement data of the thrust bearing for 5 consecutive times, and obtain the average initial value after filtering the average value to improve the validity and reliability of the measurement data; 3) When the rotor is lowered, the operating system software and the wireless monitoring system for measuring the force of the thrust bearing automatically collect the final displacement data of the thrust bearing for 5 consecutive times, and obtain the average final value after filtering the average value to improve the validity and reliability of the measurement data; 4) After completing the measurement of the initial displacement value and the final displacement value of the thrust bush, the system software automatically calculates the force conditions of each bearing bush, and further calculates the displacement deviation of the bearing bush through the obtained displacement value; 5) After the bearing force calculation is completed, the software system judges and corrects the displacement deviation data of each bearing; 6) When some thrust washers have large displacement deviations, the user adjusts the thrust washer bolts according to the bolt adjustment angle calculated by the software, and then repeats steps 2)-5) until the displacement deviation meets the requirements; 7) When the displacement deviation meets the requirements, the thrust bearing force adjustment test can be ended after confirmation by the user. The user completes the filling of the test conclusion on the software, and the system automatically saves the force adjustment data.

[0007] In a preferred solution, in step 5), when all bearing shells meet the deviation requirements, the force adjustment of the thrust bearing can be completed after confirmation by the user; When any thrust washer has a large deviation, the software will use color to display and distinguish the deviation of each thrust washer.

[0008] In the preferred solution, when any thrust bearing has a large deviation, the software automatically calculates the thrust bearing bolt adjustment angle that must be adjusted, providing suggestions and basis for bearing adjustment.

[0009] In a preferred solution, in step 4), the bearing force calculation method includes: 1) Calculation of thrust bearing force adjustment considering the measured values ​​of the combined image level When the maintenance personnel are adjusting the force of the thrust bearing ALSTOM unit and using a level meter to assist in adjusting the level of the unit, they can add a level meter measurement value input box through the system settings. The thrust bearing force adjustment calculation function will give the force adjustment value in combination with the level meter measurement value. 2) Thrust bearing force adjustment calculation based only on displacement sensor measurement values When the generator rotor is lifted up, the current displacement sensor position in each bearing support bolt of the thrust bearing should be corrected to 0 and regarded as the initial position. ; When the generator rotor is lowered, the sensor probes in the bearing support bolts are displaced, and the final displacement value of the sensor at this moment is recorded. , where the subscript F represents the final value, 0 represents the initial value, and i represents the sensor number; There are 24 displacement sensors installed in the thrust bearing, and the displacement of the ith displacement sensor is recorded as: ; The average value of the sensor displacement is: ; Then the deviation value of the displacement sensor under each bearing is recorded as: ; 1) When When the bearing deviation is greater than or equal to 0.03mm, the system software will prompt that the bearing deviation is too large and must be adjusted. The system software will mark the corresponding bearing stress state in red. 2) When 0.02mm≤ When the deviation is less than 0.03mm, the system software prompts that the bearing shell has a large deviation, but the corresponding bearing shell bolts do not need to be adjusted, and the stress state is marked in yellow; 3) When When the displacement is less than 0.02mm, the system software will mark the corresponding bearing stress state in green, indicating that the bearing displacement deviation is small and no adjustment is required; Finally, the software automatically calculates the adjustment amount of each support bolt .

[0010] In the preferred solution, the calculation process of adjusting the thrust bearing force taking into account the measured value of the combined image level is as follows: 1) Place the coincidence level on the rotor flange surface near the upper end axis in the +Y and +X directions; 2) Turn the unit by turning the gear, and the level meter will rotate with the unit. After removing the external force and shutting down the high-pressure oil load-reducing system, the maintenance personnel manually input the level reading of the point at the same time as reading the swing. ,in Indicated in Level readings measured at points, total measuring points; 3) After the level measurement is completed, ; The software calculates the horizontal composite value of the eight measuring points according to the above formula and azimuth ; 4) The data of the level meter is input into the system. The subsequent steps are the same as the thrust bearing force adjustment calculation based only on the displacement sensor measurement value. The calculation formula becomes: ; in For the The coarse adjustment of the support bolts, Indicates The actual adjustment amount of each support bolt is Indicates the center pitch circle radius of the support bolt. Indicates the azimuth of the centerline of the strut bolt.

[0011] A force adjustment system based on the above-mentioned force adjustment method for the thrust bearing of a hydro-turbine generator applicable to a pillar bolt support structure includes a displacement sensor arranged in a pillar bolt below multiple thrust bearings at the bottom of the thrust bearing. The multiple displacement sensors correspond one to one and are wired to multiple distributed wireless acquisition terminals. The multiple distributed wireless acquisition terminals communicate with the same wireless gateway, and the wireless gateway communicates with an on-site PC via Wifi.

[0012] In a preferred solution, the distributed wireless acquisition terminal conditions and amplifies the analog signal generated by the displacement sensor, converts the analog-to-digital signal into a digital signal, and then transmits the digital signal to the wireless gateway via ZigBee wireless.

[0013] In the preferred solution, the wireless acquisition terminal has the function of self-organizing network when powered on, and adopts the Mesh self-organizing network method. Each wireless acquisition terminal assumes the function of a router and is connected to the next network node. The wireless gateway assumes the function of a coordinator to establish a ZigBee network. The acquisition terminal far away from the wireless gateway increases the communication distance of the network by connecting to multi-level routing.

[0014] The present invention provides a system and method for adjusting the force of a thrust bearing of a hydro-turbine generator applicable to a support bolt support structure. By adopting the method and system, the following beneficial effects are achieved: (1) The wireless data acquisition hardware system for the bolted thrust bearing of the rigid support of the turbine unit replaces manual data acquisition of distributed sensors and collects the sensor data wirelessly and remotely through the wireless data acquisition terminal; (2) The supporting intelligent computing software can be run on the on-site PC. The on-site PC obtains the data from the sensor wireless acquisition terminal through the wireless gateway, and intelligently calculates based on the collected data to obtain the adjustment amount of each thrust bearing and determine whether each bearing needs to be adjusted; (3) The thrust bearing force adjustment calculation method is based on the existing thrust bearing force adjustment calculation formula of the hydropower plant. The thrust bearing force adjustment process is intelligentized and simplified. It supports the input of the measurement data of the coincidence level meter, and the actual and accurate bearing adjustment value is calculated by combining the horizontal value measured by the coincidence level meter; (4) The wireless communication technology between the wireless acquisition terminal and the wireless gateway adopts ZigBee technology. ZigBee with low power consumption and fast transmission rate can be well applied to wireless acquisition scenarios; (5) Mesh self-organizing network is used for networking between hardware devices. Wireless hardware devices are arranged inside the lower frame of the turbine. Mesh networking is very suitable for scenarios with long networking distances and large areas, and fully guarantees the stability of the self-organizing network. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present invention will be further described below in conjunction with the accompanying drawings and embodiments: Figure 1 This is the overall hardware topology of the patent of this invention.

[0016] Figure 2 The invention provides the patented thrust bearing force adjustment steps and method. DETAILED DESCRIPTION

[0017] Embodiment 1: A method for adjusting the force of a thrust bearing of a hydraulic generator applicable to a support bolt support structure comprises the following steps: 1) The PC workstation software is started, and the wireless monitoring system for thrust bearing force measurement performs software initialization and hardware connection synchronization; 2) When the rotor is lifted, the operating system software and the wireless monitoring system for measuring the force of the thrust bearing automatically collect the initial displacement data of the thrust bearing for 5 consecutive times, and obtain the average initial value after filtering the average value to improve the validity and reliability of the measurement data; 3) When the rotor is lowered, the operating system software and the wireless monitoring system for measuring the force of the thrust bearing automatically collect the final displacement data of the thrust bearing for 5 consecutive times, and obtain the average final value after filtering the average value to improve the validity and reliability of the measurement data; 4) After completing the measurement of the initial displacement value and the final displacement value of the thrust bush, the system software automatically calculates the force condition (i.e., displacement value) of each bearing bush, and further calculates the displacement deviation of the bearing bush through the obtained displacement value; 5) After the bearing force calculation is completed, the software system judges and corrects the displacement deviation data of each bearing; 6) When some thrust washers have large displacement deviations, the user adjusts the thrust washer bolts according to the bolt adjustment angle calculated by the software, and then repeats steps 2)-5) until the displacement deviation meets the requirements; 7) When the displacement deviation meets the requirements, the thrust bearing force adjustment test can be ended after confirmation by the user. The user completes the filling of the test conclusion on the software, and the system automatically saves the force adjustment data.

[0018] In the step 5), when all bearing shells meet the deviation requirements, the force adjustment of the thrust bearing can be completed after confirmation by the user; When any thrust washer has a large deviation, the software will use color to display and distinguish the deviation of each thrust washer (the specific color setting can use red, yellow and green color matching, red means the deviation is too large and must be adjusted, yellow means the deviation is large and no adjustment is required, and green means the deviation is small and no adjustment is required).

[0019] In the preferred solution, when any thrust bearing has a large deviation, the software automatically calculates the thrust bearing bolt adjustment angle that must be adjusted, providing suggestions and basis for bearing adjustment.

[0020] Embodiment 2: Based on step 4) in Example 1, the force adjustment calculation mainly includes two calculation methods: the thrust bearing force adjustment calculation considering the measurement value of the combined image level instrument and the thrust bearing force adjustment calculation based only on the measurement value of the displacement sensor. 1) Calculation of thrust bearing force adjustment considering the measured values ​​of the combined image level: When the maintenance personnel are adjusting the force of the thrust bearing ALSTOM unit and using a level meter to assist in adjusting the level of the unit, they can add a level meter measurement value input box through the system settings. The thrust bearing force adjustment calculation function will give the force adjustment value in combination with the level meter measurement value. 2) Calculation of thrust bearing force adjustment based only on displacement sensor measurement (i.e., thrust bearing force adjustment without considering the coincidence level): When the generator rotor is lifted up, the current displacement sensor position in each bearing support bolt of the thrust bearing should be corrected to 0 and regarded as the initial position. ; When the generator rotor is lowered, the sensor probes in the bearing support bolts are displaced, and the final displacement value of the sensor at this moment is recorded. , where the subscript F represents the final value, 0 represents the initial value, and i represents the sensor number; There are 24 displacement sensors installed in the thrust bearing, and the displacement of the ith displacement sensor is recorded as: ; The average value of the sensor displacement is: ; Then the deviation value of the displacement sensor under each bearing is recorded as: ; 1) When When the bearing deviation is greater than or equal to 0.03mm, the system software will prompt that the bearing deviation is too large and must be adjusted. The system software will mark the corresponding bearing stress state in red. 2) When 0.02mm≤ When the deviation is less than 0.03mm, the system software prompts that the bearing shell has a large deviation, but the corresponding bearing shell bolts do not need to be adjusted, and the stress state is marked in yellow; 3) When When the displacement is less than 0.02mm, the system software will mark the corresponding bearing stress state in green, indicating that the bearing displacement deviation is small and no adjustment is required; Finally, the software automatically calculates the adjustment amount of each support bolt .

[0021] The specific process of the thrust bearing force adjustment calculation considering the measured value of the combined image level instrument mentioned above is as follows: 1) Place the coincidence level on the rotor flange surface close to the upper shaft in the +Y and +X directions (or on the flange surface of the thrust head); 2) Turn the unit by turning the gear, and the level meter will rotate with the unit. (Right now After removing the external force and shutting down the high-pressure oil load-reducing system, the maintenance personnel manually input the level reading of the point while reading the swing. ,in Indicated in Level readings measured at points, total measuring points; 3) After the level measurement is completed, ; The software calculates the horizontal composite value of the eight measuring points according to the above formula and azimuth ; 4) The data of the level meter is input into the system. The subsequent steps are the same as the thrust bearing force adjustment calculation based only on the displacement sensor measurement value. The calculation formula becomes: ; in For the The coarse adjustment of the support bolts, Indicates The actual adjustment amount of each support bolt is Indicates the center pitch circle radius of the support bolt. Indicates the azimuth of the centerline of the support bolt (i.e. +X is 0° and +Y is 90°).

[0022] Embodiment 3: Based on embodiments 1 and 2, the specific structure of the force adjustment system for the thrust bearing of a hydro-turbine generator is as follows: The system includes displacement sensors arranged in the support bolts below multiple thrust bearings at the bottom of the thrust bearing. The multiple displacement sensors correspond one to one and are wired to multiple distributed wireless acquisition terminals. The multiple distributed wireless acquisition terminals communicate with the same wireless gateway, and the wireless gateway communicates with the on-site PC via Wifi.

[0023] In a preferred solution, the distributed wireless acquisition terminal conditions and amplifies the analog signal generated by the displacement sensor, converts the analog-to-digital signal into a digital signal, and then transmits the digital signal to the wireless gateway via ZigBee wireless.

[0024] In the preferred solution, the wireless acquisition terminal has the function of self-organizing network when powered on, and adopts the Mesh self-organizing network method. Each wireless acquisition terminal assumes the function of a router and is connected to the next network node. The wireless gateway assumes the function of a coordinator to establish a ZigBee network. The acquisition terminal far away from the wireless gateway increases the communication distance of the network by connecting to multi-level routing.

[0025] The patent of the present invention realizes the fully automatic collection of the force state of the thrust bearing, improves the collection efficiency of the sensor displacement, and can automatically calculate the support bolt adjustment amount of each bearing shell, which provides great convenience for the thrust bearing force adjustment process during the maintenance of the hydropower unit. In addition, the present invention is based on the low-power Zigbee communication technology network, which greatly improves the battery life of the entire set of wireless equipment.

Claims

1. A method for adjusting the force of a thrust bearing of a hydro-turbine generator applicable to a support bolt support structure, characterized in that The following steps are involved: 1) The PC workstation software is started, and the wireless monitoring system for thrust bearing force measurement performs software initialization and hardware connection synchronization; 2) When the rotor is lifted, the operating system software and the wireless monitoring system for measuring the force of the thrust bearing automatically collect the initial displacement data of the thrust bearing for 5 consecutive times, and obtain the average initial value after filtering the average value to improve the validity and reliability of the measurement data; 3) When the rotor is lowered, the operating system software and the wireless monitoring system for measuring the force of the thrust bearing automatically collect the final displacement data of the thrust bearing for 5 consecutive times, and obtain the average final value after filtering the average value to improve the validity and reliability of the measurement data; 4) After completing the measurement of the initial displacement value and the final displacement value of the thrust bush, the system software automatically calculates the force conditions of each bearing bush, and further calculates the displacement deviation of the bearing bush through the obtained displacement value; 5) After the bearing force calculation is completed, the software system judges and corrects the displacement deviation data of each bearing; 6) When some thrust washers have large displacement deviations, the user adjusts the thrust washer bolts according to the bolt adjustment angle calculated by the software, and then repeats steps 2)-5) until the displacement deviation meets the requirements; 7) When the displacement deviation meets the requirements, the thrust bearing force adjustment test can be ended after confirmation by the user. The user completes the filling of the test conclusion on the software, and the system automatically saves the force adjustment data.

2. A method for adjusting the force of a thrust bearing of a hydro-turbine generator applicable to a support bolt support structure according to claim 1, characterized in that: In the step 5), when all bearing shells meet the deviation requirements, the force adjustment of the thrust bearing can be completed after confirmation by the user; When any thrust washer has a large deviation, the software will use color to display and distinguish the deviation of each thrust washer.

3. A method for adjusting the force of a thrust bearing of a hydro-turbine generator applicable to a support bolt support structure according to claim 2, characterized in that: When any thrust bearing has a large deviation, the software automatically calculates the thrust bearing bolt adjustment angle that must be adjusted, providing suggestions and basis for bearing adjustment.

4. The method for adjusting the force of a thrust bearing of a hydraulic generator applicable to a support bolt support structure according to claim 1, characterized in that: In step 4), the bearing force calculation method includes: 1) Calculation of thrust bearing force adjustment considering the measured values ​​of the combined image level When the maintenance personnel are adjusting the force of the thrust bearing ALSTOM unit and using a level meter to assist in adjusting the level of the unit, they can add a level meter measurement value input box through the system settings. The thrust bearing force adjustment calculation function will give the force adjustment value in combination with the level meter measurement value. 2) Thrust bearing force adjustment calculation based only on displacement sensor measurement values When the generator rotor is lifted up, the current displacement sensor position in each bearing support bolt of the thrust bearing should be corrected to 0 and regarded as the initial position. ; When the generator rotor is lowered, the sensor probes in the bearing support bolts are displaced, and the final displacement value of the sensor at this moment is recorded. , where the subscript F represents the final value, 0 represents the initial value, and i represents the sensor number; There are 24 displacement sensors installed in the thrust bearing, and the displacement of the ith displacement sensor is recorded as: ； The average value of the sensor displacement is: ； Then the deviation value of the displacement sensor under each bearing is recorded as: ； 1) When When the bearing deviation is greater than or equal to 0.03mm, the system software will prompt that the bearing deviation is too large and must be adjusted. The system software will mark the corresponding bearing stress state in red. 2) When 0.02mm≤ When the deviation is less than 0.03mm, the system software prompts that the bearing shell has a large deviation, but the corresponding bearing shell bolts do not need to be adjusted, and the stress state is marked in yellow; 3) When When the displacement is less than 0.02mm, the system software will mark the corresponding bearing stress state in green, indicating that the bearing displacement deviation is small and no adjustment is required; Finally, the software automatically calculates the adjustment amount of each support bolt .

5. The method for adjusting the force of a thrust bearing of a hydraulic generator applicable to a support bolt support structure according to claim 4, characterized in that: The calculation process of thrust bearing force adjustment considering the measured value of the combined image level is as follows: 1) Place the coincidence level on the rotor flange surface near the upper end axis in the +Y and +X directions; 2) Turn the unit by turning the gear, and the level meter will rotate with the unit. After removing the external force and shutting down the high-pressure oil load-reducing system, the maintenance personnel manually input the level reading of the point at the same time as reading the swing. ,in Indicated in Level readings measured at points, total measuring points; 3) After the level measurement is completed, ； The software calculates the horizontal composite value of the eight measuring points according to the above formula and azimuth ; 4) The data of the level meter is input into the system. The subsequent steps are the same as the thrust bearing force adjustment calculation based only on the displacement sensor measurement value. The calculation formula becomes: ； in For the The coarse adjustment of the support bolts, Indicates The actual adjustment amount of each support bolt is Indicates the center pitch circle radius of the support bolt. Indicates the azimuth of the centerline of the strut bolt.

6. A force adjustment system for a thrust bearing of a hydro-turbine generator applicable to a support bolt support structure according to claims 1 to 6, characterized in that: The system includes displacement sensors arranged in the support bolts below multiple thrust bearings at the bottom of the thrust bearing. The multiple displacement sensors correspond one to one and are wired to multiple distributed wireless acquisition terminals. The multiple distributed wireless acquisition terminals communicate with the same wireless gateway, and the wireless gateway communicates with the on-site PC via Wifi.

7. A force adjustment system for a thrust bearing of a hydro-turbine generator applicable to a support bolt support structure according to claim 6, characterized in that: The distributed wireless acquisition terminal conditions and amplifies the analog signal generated by the displacement sensor, converts the analog signal into a digital signal, and then transmits it to the wireless gateway via ZigBee wireless.

8. The force adjustment system for the thrust bearing of a hydraulic generator applicable to a support bolt support structure according to claim 6, characterized in that: The wireless acquisition terminal has the function of self-organizing network when powered on, and adopts the Mesh self-organizing network method. Each wireless acquisition terminal assumes the function of a router and is connected to the next network node. The wireless gateway assumes the function of a coordinator to establish a ZigBee network. The acquisition terminal far away from the wireless gateway increases the communication distance of the network by connecting to a multi-level router.

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