Pumped storage unit shaft system operating status monitoring method and system based on digital twin

Abstract

This application belongs to the field of hydraulic machinery status monitoring, and specifically discloses a method and system for monitoring the operating status of the shaft system of a pumped-storage unit based on digital twins. The method includes: establishing a multi-physics field coupled finite element full-order model of the shaft system of the pumped-storage unit, reducing the model order of the finite element full-order model, and using the multi-physics field coupled reduced-order model to construct a digital twin of the shaft system of the pumped-storage unit for real-time simulation; obtaining operating status data corresponding to the monitoring signal and establishing an operating status knowledge base of the pumped-storage unit; constructing an operating status monitoring system for the shaft system of the pumped-storage unit based on the established virtual-real interaction subsystem, three-dimensional visualization subsystem, and operating status knowledge base, and using sensors to transmit real-time data of the operating status monitoring system to evaluate the operating status of the pumped-storage unit in real time and realize operating status early warning of the pumped-storage unit. Through this application, the real-time performance of the operating status monitoring of the shaft system of the pumped-storage unit can be improved, thereby improving the monitoring efficiency.

Description

Technical Field

[0001] The present application belongs to the field of equipment detection, and more specifically, relates to a method and system for monitoring the operating status of the shaft system of a pumped storage unit based on digital twins. Background Art

[0002] With the large-scale development and utilization of new energy in my country, the construction of pumped-storage power stations needs to be accelerated. Pumped-storage power station units can pump water to store electricity when the grid load is high, and generate electricity for turbine operation when power conversion is needed. When the pumped-storage unit is in a complex transitional operating state, it is affected by multi-physical field factors such as flow field, structural field, and electromagnetic field. The operating parameters of the unit change dramatically, which can easily cause rapid transient changes in the flow field inside the pump-turbine, affecting the stable operation of the pumped-storage unit shaft system. In severe cases, it can cause damage to the unit shaft system structure. Therefore, it is necessary to monitor the operating status of the pumped-storage unit in real time and evaluate its operating status characteristics.

[0003] Currently, the commonly used monitoring method is usually to use physical sensors for data collection and data analysis. However, due to factors such as the complexity of the pumped storage power station operation system and the delay in sensor data acquisition, there are certain difficulties in extracting status data, making it difficult to ensure the real-time performance of system monitoring, which in turn leads to poor system monitoring efficiency. Summary of the Invention

[0004] In response to the defects of the existing technology, the purpose of this application is to provide a method for monitoring the operating status of the shaft system of a pumped storage unit based on digital twins, aiming to solve the problem that it is difficult to ensure the real-time performance of system monitoring, which leads to poor efficiency of system monitoring.

[0005] In a first aspect, the present application provides a method for monitoring the operating status of a shaft system of a pumped storage unit based on digital twins, comprising:

[0006] Establishing a multi-physics field coupled finite element full-order model of the pumped storage unit shaft system, and using the finite element full-order model to perform multi-physics field dynamic simulation analysis of the pumped storage unit under multiple working conditions based on fluid-structure coupling and electromechanical coupling to obtain simulation analysis results;

[0007] Based on the simulation analysis results, the finite element full-order model is reduced in order to establish a multi-physics field coupling reduced-order model, and the multi-physics field coupling reduced-order model is used to construct a digital twin of the pumped storage unit shaft system for real-time simulation;

[0008] Selecting a monitoring signal of a target type according to the data type during the actual operation of the pumped storage unit, obtaining operating status data corresponding to the monitoring signal, performing feature extraction and preprocessing on the operating status data, and establishing an operating status knowledge base of the pumped storage unit to determine the real-time operating status of the pumped storage unit;

[0009] Based on the established virtual-reality interaction subsystem, three-dimensional visualization subsystem, and operating status knowledge base, an operating status monitoring system for the pumped-storage unit shaft system is constructed. Sensors are used to transmit real-time data from the operating status monitoring system to assess the operating status of the pumped-storage unit in real time and provide early warning of the operating status of the pumped-storage unit.

[0010] Among them, the virtual-reality interaction subsystem is established using the digital twin and pumped storage unit equipment, and is used to realize data interaction between the digital twin and the pumped storage unit equipment based on the data interface; the three-dimensional visualization subsystem is used to perform three-dimensional display of various typical working conditions of the pumped storage unit shaft system.

[0011] Optionally, the multi-physics field coupled finite element full-order model of the pumped storage unit shaft system is established, and the multi-physics field dynamic simulation analysis of the pumped storage unit under multiple working conditions is performed on the finite element full-order model according to fluid-structure coupling and electromechanical coupling to obtain simulation analysis results, including:

[0012] Obtaining the design dimensions and design parameters of the shaft system of the pumped storage unit, as well as the operating parameters under various typical operating conditions;

[0013] Based on the design dimensions, design parameters and operating parameters, a three-dimensional model of the shaft system of the pumped storage unit is established;

[0014] Establishing finite element full-order models of different physical fields based on the three-dimensional model;

[0015] The finite element full-order models of the different physical fields are based on the fluid-solid coupling simulation and the electromechanical coupling simulation to establish a multi-physics field coupling finite element full-order model;

[0016] Based on the multi-physics field coupled finite element full-order model, multi-physics field dynamic simulation analysis of the pumped storage unit under multiple working conditions is performed to obtain simulation analysis results.

[0017] Optionally, performing model reduction on the finite element full-order model based on the simulation analysis result to establish a multi-physics field coupled reduced-order model includes:

[0018] Based on the simulation analysis results, the multi-physics field coupling finite element full-order model is reduced in order, and the multi-physics field coupling finite element full-order model includes a flow field full-order model, an electromagnetic field full-order model and a shafting full-order model;

[0019] The full-order flow field model is reduced in order by using an intrinsic orthogonal analysis method, the full-order electromagnetic field model is reduced in order by using an equivalent circuit model extraction method, and the full-order shafting model is reduced in order by using singular value decomposition;

[0020] The multi-physics field coupling reduced-order model is constructed based on the reduced-order flow field full-order model, the electromagnetic field full-order model and the shafting full-order model.

[0021] Optionally, selecting a monitoring signal of a target type according to a data type during the actual operation of the pumped storage unit and obtaining operating status data corresponding to the monitoring signal includes:

[0022] Determine the data type generated during the actual operation of the pumped storage unit, select the target type according to the needs, and obtain the monitoring signal of the target type; the monitoring signal of the target type includes: vibration signal, temperature signal, speed signal and radial runout signal;

[0023] The operating status data corresponding to the monitoring signal is obtained according to the sensor corresponding to each target type.

[0024] Optionally, the feature extraction and preprocessing of the operating status data to establish an operating status knowledge base of the pumped storage unit to determine the real-time operating status of the pumped storage unit includes:

[0025] The operation status data is stored in MySQL, a data table is established according to the target type corresponding to the operation status data, and feature extraction and preprocessing are performed on the operation status data to obtain feature data;

[0026] The characteristic data is clustered according to working conditions to obtain clustering results, and the operating status knowledge base is established based on the clustering results. The operating status knowledge base is used to compare with real-time operating data to determine the real-time operating status of the pumped storage unit.

[0027] Optionally, the virtual-reality interaction subsystem provides a data interface for users through a browser, and implements data interaction between the digital twin and the pumped storage unit equipment through Web Serve.

[0028] Optionally, the three-dimensional visualization subsystem is constructed based on a visualization platform, and the three-dimensional visualization subsystem is used to display the operating status of the digital twin of the pumped storage unit shaft system under various typical working conditions in real time through the virtual-reality interaction subsystem and sensor equipment.

[0029] In a second aspect, the present application provides a pumped storage unit shaft system operation status monitoring system based on digital twin, including a virtual-reality interaction subsystem, a three-dimensional visualization subsystem, and an operation status knowledge base;

[0030] Using sensors to transmit real-time data of the operation status monitoring system to evaluate the operation status of the pumped storage unit in real time and realize early warning of the operation status of the pumped storage unit;

[0031] Among them, the virtual-reality interaction subsystem is established using the digital twin and pumped storage unit equipment, and is used to realize data interaction of the virtual-reality interaction subsystem based on the data interface; the three-dimensional visualization subsystem is used to perform three-dimensional display of various typical working conditions of the pumped storage unit shaft system.

[0032] In a third aspect, the present application also provides a multi-sensor system, comprising a plurality of sensors for collecting monitoring signals, wherein the sensors are used to respectively extract the shaft system power generation signal of the pumped storage unit, the turbine speed signal, the inlet flow signal, the shaft system vibration signal and the radial runout signal; the sensors are also used to execute the steps of obtaining operating status data as described in any of the above items.

[0033] In a fourth aspect, the present application provides a computer-readable storage medium, which stores a computer program. When the computer program runs on a processor, the processor executes the method described in the first aspect or any possible implementation of the first aspect.

[0034] In a fifth aspect, the present application provides a computer program product, which, when executed on a processor, enables the processor to execute the method described in the first aspect or any possible implementation of the first aspect.

[0035] It can be understood that the beneficial effects of the second to fifth aspects mentioned above can be found in the relevant description of the first aspect mentioned above, and will not be repeated here.

[0036] In general, the above technical solutions conceived by this application have the following beneficial effects compared with the existing technologies:

[0037] (1) This application establishes an operating status knowledge base to help store and analyze historical data and determine the real-time operating status of the unit. It also establishes a virtual-reality interaction subsystem to achieve data interaction between the digital twin and the actual unit through a data interface, thereby enhancing the real-time and accuracy of monitoring and control. It also establishes a three-dimensional visualization subsystem to provide an intuitive and real-time display method, helping users to better monitor the real-time operating status and various typical working conditions of the pumped storage unit shaft system. This application processes the operating status data of the pumped storage unit in multiple dimensions through the operating status knowledge base, the virtual-reality interaction subsystem, and the three-dimensional visualization subsystem, thereby improving the real-time monitoring of the operating data of the pumped storage unit.

[0038] (2) This application establishes a finite element full-order model and a reduced-order model coupled with multiple physical fields, which can more accurately simulate the complex operating state of the pumped storage unit shaft system. Through simulation analysis, potential faults and weaknesses can be identified, thereby improving the operating reliability and safety of the equipment.

[0039] (3) The virtual-reality interaction subsystem in this application can effectively interact with the data of the digital twin and the actual equipment in real time, ensuring that the virtual model is always synchronized with the actual operation status, thereby improving the real-time nature of the monitoring data. The three-dimensional visualization subsystem in this application provides an intuitive working condition display, allowing operators to more clearly understand the status of the equipment and potential problems, thereby improving the overall monitoring efficiency of the system.

[0040] (4) This application establishes a finite element full-order model of the multi-physical field coupling of the shaft system of the pumped-storage unit, performs model reduction processing on the full-order model, establishes a fast numerical calculation model of the shaft system of the pumped-storage unit, and establishes a digital twin model of the shaft system of the pumped-storage unit based on the fast numerical calculation model of the shaft system of the pumped-storage unit to achieve real-time simulation of the shaft system of the pumped-storage unit. Based on the digital twin model, combined with the database and three-dimensional visualization system, a pumped-storage unit shaft system status monitoring system is established, which can analyze the shaft system operation status and response analysis in real time. The shaft system operation posture is intuitively and efficiently displayed to the operating personnel through legends, reports, cloud maps and statistical analysis, and the shaft system simulation results are displayed in real time. This application meets the requirements of real-time simulation, reduces working time costs, and can be actually applied to the operation status monitoring of pumped-storage power stations, reduce unit failures, and improve operation efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 This is a flow chart of a method for monitoring the shaft system operating status of a pumped storage unit based on digital twins provided in an embodiment of the present application;

[0042] Figure 2 It is a structural diagram of the pumped storage unit shaft system operation status monitoring system based on digital twin provided in an embodiment of the present application. DETAILED DESCRIPTION

[0043] In order to make the purpose, technical solutions and advantages of this application more clear, the following further describes this application in detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain this application and are not intended to limit this application.

[0044] The term "and / or" as used herein describes an association between related objects, indicating that three possible relationships exist. For example, "A and / or B" can represent: A exists alone, A and B exist simultaneously, or B exists alone. The symbol " / " as used herein indicates that the related objects are in an "or" relationship, for example, A / B means either A or B.

[0045] The terms "first" and "second" in this specification and claims are used to distinguish different objects rather than to describe a specific order of objects. For example, "first response message" and "second response message" are used to distinguish different response messages rather than to describe a specific order of response messages.

[0046] In the embodiments of this application, words such as "exemplary" or "for example" are used to indicate examples, illustrations, or descriptions. Any embodiment or design described as "exemplary" or "for example" in the embodiments of this application should not be interpreted as being preferred or advantageous over other embodiments or designs. Rather, the use of words such as "exemplary" or "for example" is intended to present the relevant concepts in a concrete manner.

[0047] In the description of the embodiments of the present application, unless otherwise specified, "multiple" means two or more, for example, multiple processing units means two or more processing units, etc.; multiple elements means two or more elements, etc.

[0048] Next, the technical solutions provided in the embodiments of this application are introduced.

[0049] Reference Figure 1 The present application provides a method for monitoring the operating status of a shaft system of a pumped storage unit based on digital twins, comprising:

[0050] S101. Establish a multi-physics field coupled finite element full-order model of the shaft system of the pumped storage unit, and perform a multi-physics field dynamic simulation analysis of the pumped storage unit under multiple working conditions according to the full-order finite element model based on fluid-solid coupling and electromechanical coupling to obtain simulation analysis results;

[0051] S102. Based on the simulation analysis results, the finite element full-order model is reduced in order to establish a multi-physics field coupling reduced-order model, and the multi-physics field coupling reduced-order model is used to construct a digital twin of the pumped storage unit shaft system for real-time simulation;

[0052] S103. Select a target type of monitoring signal according to the data type during the actual operation of the pumped storage unit, obtain the operating status data corresponding to the monitoring signal, perform feature extraction and preprocessing on the operating status data, and establish an operating status knowledge base of the pumped storage unit to determine the real-time operating status of the pumped storage unit;

[0053] S104. Build an operating status monitoring system for the pumped-storage unit shaft system based on the established virtual-reality interaction subsystem, three-dimensional visualization subsystem, and operating status knowledge base. Utilize sensors to transmit real-time data from the operating status monitoring system to assess the operating status of the pumped-storage unit in real time and provide early warning of the unit's operating status.

[0054] Among them, the virtual-reality interaction subsystem is established using the digital twin and pumped storage unit equipment, and is used to realize data interaction between the digital twin and the pumped storage unit equipment based on the data interface; the three-dimensional visualization subsystem is used to perform three-dimensional display of various typical working conditions of the pumped storage unit shaft system.

[0055] First, a full-order finite element model incorporating multi-physics coupling was established to conduct dynamic simulations of fluid-structure and electromechanical coupling. This approach aims to capture the complex behavior of the unit under various operating conditions and provide foundational data for further analysis. The goal of this step is to create a mathematical model that simulates the behavior of the pumped-storage unit shaft system under the influence of multiple physical fields (such as fluid, structural, and electromagnetic).

[0056] Based on the simulation results, the full-order model was reduced to simplify the calculation process. The reduced-order model was used to construct a digital twin of the pumped-storage unit shaft system, enabling real-time simulation and monitoring.

[0057] Furthermore, appropriate monitoring signals, such as vibration, temperature, speed, and radial runout, are selected. Data is acquired from actual operation using appropriate sensors, and feature extraction and preprocessing are performed on this data. An operating status knowledge base is established for real-time evaluation and analysis of the unit's operating status.

[0058] Finally, the monitoring system was constructed. By combining the virtual-reality interaction subsystem, the 3D visualization subsystem, and the operating status knowledge base, a comprehensive operating status monitoring system was established. Sensors transmit real-time data, while the system assesses unit status and issues early warnings. The virtual-reality interaction subsystem facilitates data exchange between the digital twin and the actual equipment. The 3D visualization subsystem provides a 3D display of operating conditions, helping operators more intuitively understand equipment status and potential issues.

[0059] This application establishes a finite element full-order model of the multi-physical field coupling of the shaft system of the pumped-storage unit, performs model reduction processing on the full-order model, establishes a fast numerical calculation model of the shaft system of the pumped-storage unit, and establishes a digital twin model of the shaft system of the pumped-storage unit based on the fast numerical calculation model of the shaft system of the pumped-storage unit to achieve real-time simulation of the shaft system of the pumped-storage unit. Based on the digital twin model, combined with the database and three-dimensional visualization system, a pumped-storage unit shaft system status monitoring system is established, which can analyze the shaft system operation status and response analysis in real time. The shaft system operation posture is intuitively and efficiently displayed to the operating personnel through legends, reports, cloud maps and statistical analysis, and the shaft system simulation results are displayed in real time. This application meets the real-time simulation requirements, reduces working time costs, and can be actually applied to the operation status monitoring of pumped-storage power stations, reduce unit failures, and improve operation efficiency.

[0060] Furthermore, the multi-physics field coupling finite element full-order model of the pumped storage unit shaft system is established, and the multi-physics field dynamic simulation analysis of the pumped storage unit under multiple working conditions is performed on the finite element full-order model according to fluid-solid coupling and electromechanical coupling to obtain simulation analysis results, including:

[0061] Obtaining the design dimensions and design parameters of the shaft system of the pumped storage unit, as well as the operating parameters under various typical operating conditions;

[0062] Based on the design dimensions, design parameters and operating parameters, a three-dimensional model of the shaft system of the pumped storage unit is established;

[0063] Establishing finite element full-order models of different physical fields based on the three-dimensional model;

[0064] The finite element full-order models of the different physical fields are based on the fluid-solid coupling simulation and the electromechanical coupling simulation to establish a multi-physics field coupling finite element full-order model;

[0065] Based on the multi-physics field coupled finite element full-order model, multi-physics field dynamic simulation analysis of the pumped storage unit under multiple working conditions is performed to obtain simulation analysis results.

[0066] The specific process is as follows:

[0067] Step S201. Collect the design drawings of the pumped storage unit, perform 3D structural modeling of the entire flow path of the pump turbine using the 3D modeling software UG, and construct a fluid calculation domain model, including the pressure pipe, volute, seat ring, water guide mechanism, runner, tailwater pipe, etc., refine the key flow components and extract the water body model.

[0068] Step S202: Based on the design drawings of the pumped storage unit, a three-dimensional model of the pumped storage unit shaft system is constructed using the three-dimensional design software UG. This model mainly includes the upper shaft of the unit shaft system, the generator motor rotor, the rotor bracket, the water bearing on the turbine shaft, the upper guide bearing on the motor shaft, the lower guide bearing on the motor shaft, the thrust bearing, the pump turbine runner, etc.

[0069] Step S203. Considering that the main concern in engineering practice is the radial vibration of the stator, this application adopts a two-dimensional finite element motor model and builds a two-dimensional plane model of the hydro-generator through Maxwell's Rmxprt component. The model is based on two basic assumptions as follows: (1) the axial lengths of the stator and rotor are equal; (2) the magnetic field in each cross section of the motor is a two-dimensional parallel plane field.

[0070] Step S204. ICEM is used to perform structured meshing on the three-dimensional fluid domain model of the pumped storage unit shaft system, and the mesh is locally refined. The three-dimensional structural model of the pumped storage unit shaft system is meshed using the built-in meshing tool in Ansys. An adaptive meshing method is used for the two-dimensional motor model, and local mesh refinement is performed in the magnetic material area, which has a greater impact on the calculation results. Based on the mesh model of the pumped storage unit shaft system, boundary conditions and external loads are applied to construct a full-order finite element model. Based on the fluid-solid coupling calculation method, fluid dynamics calculations are performed at multiple typical operating points to analyze the flow field distribution within the pump-turbine under different flow rates and flow velocities. The acquired flow field information is transferred to the solid computational domain for solution, and the dynamic response of the runner under the action of fluid-solid coupling is obtained. Electromagnetic field calculations are performed in MAXWELL, the ANSYS electromagnetic field simulation software. The time-varying electromagnetic force obtained by the simulation calculation is input as excitation into the three-dimensional structural field. Transient dynamic analysis is then performed in ANSYS workbench to obtain the vibration characteristics of the shaft system under electromagnetic action. A multi-physics coupling model of the shaft system of a pumped storage unit is established by combining the hydraulic characteristics, electromagnetic characteristics, and shaft system natural vibration characteristics.

[0071] Optionally, performing model reduction on the finite element full-order model based on the simulation analysis result to establish a multi-physics field coupled reduced-order model includes:

[0072] Based on the simulation analysis results, the multi-physics field coupling finite element full-order model is reduced in order, and the multi-physics field coupling finite element full-order model includes a flow field full-order model, an electromagnetic field full-order model and a shafting full-order model;

[0073] The full-order flow field model is reduced in order by using an intrinsic orthogonal analysis method, the full-order electromagnetic field model is reduced in order by using an equivalent circuit model extraction method, and the full-order shafting model is reduced in order by using singular value decomposition;

[0074] The multi-physics field coupling reduced-order model is constructed based on the reduced-order flow field full-order model, the electromagnetic field full-order model and the shafting full-order model.

[0075] Specifically, the order reduction process in this embodiment is as follows:

[0076] Step S301: Reduce the full-order finite element model of the pump-turbine fluid domain. Based on the Proper Orthogonality (POD) dynamic order reduction model (ROM) method, CFD transient calculations are used to extract the spatial parameters of the pump-turbine flow field and the snapshot matrix. This then completes POD modal decomposition, completes the fluid domain order reduction model, and constructs a rapid calculation model of the pump-turbine fluid domain for the pumped-storage unit.

[0077] Step S302: Reduce the order of the electromagnetic field model of the pumped storage unit using an equivalent circuit extraction (ECE) model reduction method.

[0078] The motor operating parameter information is extracted from the finite element calculation results. The electromagnetic field operating data is trained, and ECE extraction is performed on the training data. An ECE ROM model is established to achieve model reduction of the electromagnetic field of the pumped storage unit.

[0079] Step S303: Based on the finite element model of the pumped storage unit shaft system, the shaft system model is reduced using singular value decomposition (SVD). Based on the shaft system finite element calculation results, multiple data sets are extracted as training data to construct a snapshot matrix. SVD decomposition is performed on the snapshot matrix to establish a vector basis for the field solution of any input parameter in the design space. The surrogate model is used to predict the corresponding coefficients of each reduced-order basis in the ROM to complete the reduction of the pumped storage unit shaft system model.

[0080] Step S304. Combine the reduced-order model of multiple physical fields to construct a multi-physical field coupling reduced-order model of the pumped-storage unit shaft system, establish a fast numerical calculation model of the multi-physical field of the pumped-storage unit shaft system, and realize the establishment of a digital twin.

[0081] Optionally, selecting a monitoring signal of a target type according to a data type during the actual operation of the pumped storage unit and obtaining operating status data corresponding to the monitoring signal includes:

[0082] Determine the data type generated during the actual operation of the pumped storage unit, select the target type according to the needs, and obtain the monitoring signal of the target type; the monitoring signal of the target type includes: vibration signal, temperature signal, speed signal and radial runout signal;

[0083] The operating status data corresponding to the monitoring signal is obtained according to the sensor corresponding to each target type.

[0084] Specifically, the method for obtaining the running status data is as follows:

[0085] Step S401: Analyze the data types generated during the actual operation of the pumped storage unit and select corresponding monitoring data as input parameters based on the unit's monitoring requirements. The monitoring data includes unit inlet flow monitoring, shaft vibration monitoring, electromagnetic voltage monitoring, temperature monitoring, turbine speed monitoring, etc.

[0086] Step S402: Build a multi-sensor system based on the data to be monitored, select appropriate sensor models, accuracy and sensitivity, and collect corresponding signals accurately and efficiently.

[0087] Optionally, the feature extraction and preprocessing of the operating status data to establish an operating status knowledge base of the pumped storage unit to determine the real-time operating status of the pumped storage unit includes:

[0088] The operation status data is stored in MySQL, a data table is established according to the target type corresponding to the operation status data, and feature extraction and preprocessing are performed on the operation status data to obtain feature data;

[0089] The characteristic data is clustered according to working conditions to obtain clustering results, and the operating status knowledge base is established based on the clustering results. The operating status knowledge base is used to compare with real-time operating data to determine the real-time operating status of the pumped storage unit.

[0090] Specifically, the method for establishing the operating status knowledge base in this embodiment includes:

[0091] Step S501: Record the shaft system operating status data of the pumped storage unit through a multi-sensor system, establish a data transmission system, and transmit the monitoring data collected by the sensors to the database for storage through optical fiber switches and network cables.

[0092] Step S502: Receive data transmitted by the data sensor, record the characteristic signal data of the time period, and use the multi-source heterogeneous database system MySQL to store, process and extract the signal data to establish the pumped storage unit shaft system operation status database.

[0093] Step S503: Utilize the database synchronization mechanism to transfer data from the database to the pumped storage unit shaft system virtual-real interaction system via the data switch. When the unit begins operation, the database can be accessed in real time to view the main shaft operating status data, which is used to drive the digital twin model in real time.

[0094] Optionally, the virtual-reality interaction subsystem provides a data interface for users through a browser, and implements data interaction between the digital twin and the pumped storage unit equipment through Web Serve.

[0095] Specifically, the virtual-reality interaction subsystem in this embodiment adopts a B / S architecture, which establishes a system platform model based on a Web browser and uses the Web browser to concentrate the core parts of the system function implementation on the server.

[0096] It should be further explained that the virtual-reality interaction subsystem development tool in this embodiment uses OpenGL, selects Windows system as the development platform, selects Python as the programming language, and selects PyCharm as the integrated development environment to realize the virtual-reality interaction system of the pumped storage unit axis system.

[0097] Optionally, the three-dimensional visualization subsystem is constructed based on a visualization platform, and the three-dimensional visualization subsystem is used to display the operating status of the digital twin of the pumped storage unit shaft system under various typical working conditions in real time through the virtual-reality interaction subsystem and sensor equipment.

[0098] Specifically, the process of establishing the 3D visualization subsystem in this embodiment is as follows:

[0099] A 3D model of the pumped-storage turbine shaft system, constructed using the 3D modeling software UG, was imported into 3ds Max, where it was assigned appropriate materials and textures. The 3ds Max model was exported as an .fbx file, which was then imported into Unity3D for rendering of the main shaft, completing the virtual model. Based on an analysis of the dynamic behavior of the actual turbine shaft system, the virtual model was synchronized with the physical model in real time, enabling users to accurately and clearly understand the main shaft's operating status.

[0100] Reference Figure 2 , the present application provides a pumped storage unit shaft system operation status monitoring system based on digital twin, including a virtual-reality interaction subsystem 210, a three-dimensional visualization subsystem 220 and an operation status knowledge base 230;

[0101] Using sensors to transmit real-time data of the operation status monitoring system to evaluate the operation status of the pumped storage unit in real time and realize early warning of the operation status of the pumped storage unit;

[0102] Among them, the virtual-reality interaction subsystem is established using the digital twin and pumped storage unit equipment, and is used to realize data interaction of the virtual-reality interaction subsystem based on the data interface; the three-dimensional visualization subsystem is used to perform three-dimensional display of various typical working conditions of the pumped storage unit shaft system.

[0103] Specifically, the process of implementing monitoring by the operating status monitoring system in the embodiment of the present application is as follows:

[0104] Step S601: Build a digital twin-based pumped-storage unit shaft system operating status monitoring system using Unity3D, combining the operating status database, the digital twin virtual-reality interaction system, and the 3D visualization model. Write a control script to develop and design the required functions. The system includes four functional modules: a status data acquisition and drive module, a virtual-reality interaction and data transmission module, a status monitoring module, and a 3D visualization module.

[0105] Step S602: Real-time operating data is collected through a multi-sensor system, and an operating status database is constructed. A data acquisition system is developed to connect the operating status database with the virtual-reality interaction system and the 3D visualization system. Based on real-time monitoring data from the pumped-storage unit shaft system during actual operation, the shaft system virtual system is driven in real time through data-driven functionality within the digital twin system.

[0106] Step S603: Using real-time data monitored by the multi-sensor system as input parameters, combined with a multi-physics coupled reduced-order model of the pumped-storage turbine shaft system, rapid numerical calculations are performed on the real-time operating conditions. Using a data-driven program, the rapid numerical calculation results are displayed in real time in a 3D visualization module through a virtual-reality interactive system to demonstrate the dynamic response characteristics of the turbine shaft system.

[0107] Step S604. Develop a status monitoring page where you can view the real-time operating status of the pumped storage unit shaft system. Real-time three-dimensional visualization is achieved based on data collected by multiple sensors, including real-time display of curve trends of important parameters such as the unit shaft system inlet flow, inlet pressure, outlet flow, outlet pressure, and runner speed. Pre-process the rapid numerical calculation results in the virtual-reality interactive system, and display the real-time operating status of the unit shaft system in the form of legends, reports, and tables according to user needs, including information such as tailwater pipe pressure pulsation, turbine blade pressure, and axis motion trajectory. Real-time display of shaft system stress distribution cloud maps, deformation distribution cloud maps, vibration distribution cloud maps, etc., and compare them with normal conditions.

[0108] Step S605. The 3D visualization function module page includes a panoramic 3D display of the pumped-storage turbine shaft system virtual model, a user interaction window, and a status monitoring window. The panoramic 3D display of the virtual model allows for a 360° display of the pumped-storage turbine shaft system 3D model by sliding the mouse. It also includes transparency, exploded view, and highlighting functions. The transparency function changes the model's transparency based on the user's selected transparency level, allowing the user to fully observe the internal structure of the turbine shaft system. The exploded view function allows the user to gain a comprehensive, multi-level, and multi-architecture understanding of the turbine shaft system's internal structure, assembly sequence, and assembly path. The highlighting function highlights model components based on the user's component information requirements without affecting other rendering results, allowing the user to clearly and intuitively grasp relevant information about the selected component. The user interaction system allows the user to select the operating status parameters they wish to monitor, which are displayed in real time in the status monitoring window. The status monitoring window monitors the turbine shaft system's operating status in real time and provides user viewing. When the unit starts running, the digital twin model obtains real-time data as input parameters based on the multi-sensor system, connects with the three-dimensional visualization function through the virtual-reality interaction system, and displays the status information of the main shaft in real time on the window in the form of tables, legends, reports and cloud maps.

[0109] The present application also provides a multi-sensor system, comprising a plurality of sensors for collecting monitoring signals, wherein the sensors are used to respectively extract the shaft system power generation signal, turbine speed signal, inlet flow signal, shaft system vibration signal and radial runout signal of the pumped storage unit; the sensors are also used to execute the steps of obtaining operating status data as described in any of the above items.

[0110] Based on the method in the above embodiment, an embodiment of the present application provides a computer-readable storage medium, which stores a computer program. When the computer program runs on a processor, the processor executes the method in the above embodiment.

[0111] Based on the method in the above embodiment, an embodiment of the present application provides a computer program product. When the computer program product runs on a processor, the processor executes the method in the above embodiment.

[0112] It is understood that the processor in the embodiments of the present application may be a central processing unit (CPU), or may be other general-purpose processors, digital signal processors (DSP), application-specific integrated circuits (ASIC), field programmable gate arrays (FPGA), or other programmable logic devices, transistor logic devices, hardware components, or any combination thereof. The general-purpose processor may be a microprocessor or any conventional processor.

[0113] The method steps in the embodiments of the present application can be implemented by hardware or by a processor executing software instructions. The software instructions can be composed of corresponding software modules, which can be stored in random access memory (RAM), flash memory, read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), registers, hard disks, mobile hard disks, CD-ROMs or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor so that the processor can read information from the storage medium and write information to the storage medium. Of course, the storage medium can also be a component of the processor. The processor and the storage medium can be located in an ASIC.

[0114] In the above embodiments, it can be implemented in whole or in part by software, hardware, firmware or any combination thereof. When implemented using software, it can be implemented in whole or in part in the form of a computer program product. The computer program product includes one or more computer instructions. When the computer program instructions are loaded and executed on a computer, the process or function described in the embodiment of the present application is generated in whole or in part. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted via the computer-readable storage medium. The computer instructions can be transmitted from one website, computer, server or data center to another website, computer, server or data center via a wired (e.g., coaxial cable, optical fiber, digital subscriber line (DSL)) or wireless (e.g., infrared, wireless, microwave, etc.) method. The computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center that includes one or more available media integrated. The available medium can be a magnetic medium (e.g., a floppy disk, a hard disk, a tape), an optical medium (e.g., a DVD), or a semiconductor medium (e.g., a solid state drive (SSD)).

[0115] It will be understood that the various numerical numbers involved in the embodiments of the present application are merely distinctions for the convenience of description and are not intended to limit the scope of the embodiments of the present application.

[0116] It is easy for those skilled in the art to understand that the above is only a preferred embodiment of the present application and is not intended to limit the present application. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present application should be included in the scope of protection of the present application.

Claims

1. A method for monitoring the shaft system operating status of a pumped storage unit based on digital twin, characterized in that: include: Establishing a multi-physics field coupled finite element full-order model of the pumped storage unit shaft system, and using the finite element full-order model to perform multi-physics field dynamic simulation analysis of the pumped storage unit under multiple working conditions based on fluid-structure coupling and electromechanical coupling to obtain simulation analysis results; Based on the simulation analysis results, the finite element full-order model is reduced in order to establish a multi-physics field coupling reduced-order model, and the multi-physics field coupling reduced-order model is used to construct a digital twin of the pumped storage unit shaft system for real-time simulation; Determine the data type generated during the actual operation of the pumped storage unit, select the target type according to the needs, and obtain the monitoring signal of the target type; The target type monitoring signals include: vibration signal, temperature signal, speed signal and radial runout signal; Acquire the operating status data corresponding to the monitoring signal according to the sensor corresponding to each target type; The operation status data is stored in MySQL, a data table is established according to the target type corresponding to the operation status data, and feature extraction and preprocessing are performed on the operation status data to obtain feature data; Performing operating condition clustering on the characteristic data to obtain clustering results, establishing an operating status knowledge base based on the clustering results, and using the operating status knowledge base for comparison with real-time operating data to determine the real-time operating status of the pumped storage unit; Establishing a virtual-reality interaction subsystem and a three-dimensional visualization subsystem; the virtual-reality interaction subsystem is established using the digital twin and the pumped-storage unit equipment, and is used to achieve real-time data interaction between the digital twin and the pumped-storage unit equipment based on a data interface, ensuring that the virtual model is always synchronized with the actual operating conditions; the three-dimensional visualization subsystem is used to display the operating status of the digital twin of the pumped-storage unit shaft system under various typical operating conditions in real time through the virtual-reality interaction subsystem and sensor equipment; Based on the established virtual-reality interaction subsystem, three-dimensional visualization subsystem and operation status knowledge base, an operation status monitoring system for the pumped storage unit shaft system is constructed. Sensors are used to transmit real-time data of the operation status monitoring system to evaluate the operation status of the pumped storage unit in real time and realize operation status early warning of the pumped storage unit.

2. The method for monitoring the shaft system operation status of a pumped storage unit based on digital twin according to claim 1 is characterized in that: The multi-physics field coupling finite element full-order model of the pumped storage unit shaft system is established, and the multi-physics field dynamic simulation analysis of the pumped storage unit under multiple working conditions is performed on the finite element full-order model according to fluid-solid coupling and electromechanical coupling to obtain simulation analysis results, including: Obtaining design parameters of the shaft system of the pumped storage unit and operating parameters under various typical operating conditions; Based on the design parameters and operating parameters, a three-dimensional model of the shaft system of the pumped storage unit is established; Establishing finite element full-order models of different physical fields based on the three-dimensional model; The finite element full-order models of the different physical fields are based on the fluid-solid coupling simulation and the electromechanical coupling simulation to establish a multi-physics field coupling finite element full-order model; Based on the multi-physics field coupled finite element full-order model, multi-physics field dynamic simulation analysis of the pumped storage unit under multiple working conditions is performed to obtain simulation analysis results.

3. The method for monitoring the shaft system operation status of a pumped storage unit based on digital twin according to claim 1 is characterized in that: The step of reducing the finite element full-order model based on the simulation analysis results to establish a multi-physics field coupled reduced-order model includes: Based on the simulation analysis results, the multi-physics field coupling finite element full-order model is reduced in order, and the multi-physics field coupling finite element full-order model includes a flow field full-order model, an electromagnetic field full-order model and a shafting full-order model; The full-order flow field model is reduced in order by using an intrinsic orthogonal analysis method, the full-order electromagnetic field model is reduced in order by using an equivalent circuit model extraction method, and the full-order shafting model is reduced in order by using singular value decomposition; The multi-physics field coupling reduced-order model is constructed based on the reduced-order flow field full-order model, the electromagnetic field full-order model and the shafting full-order model.

4. The method for monitoring the shaft system operation status of a pumped storage unit based on digital twin according to claim 1, characterized in that: The virtual-reality interaction subsystem provides a data interface for users through a browser.

5. A pumped storage unit shaft system operating status monitoring system based on digital twin, used to implement the pumped storage unit shaft system operating status monitoring method according to any one of claims 1 to 4, characterized in that: Including virtual-reality interaction subsystem, 3D visualization subsystem and operation status knowledge base; It also includes multiple sensors for collecting monitoring signals, which are specifically used to extract the pumped storage unit shaft system power generation signal, turbine speed signal, inlet flow signal, shaft system vibration signal and radial runout signal respectively.

6. A computer-readable storage medium storing a computer program, characterized in that: When the computer program is run on a processor, the processor is caused to perform the method according to any one of claims 1 to 4.

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