Fatigue life simulation processing method, device and system of wind turbine generator test bed

Abstract

The invention provides a fatigue life simulation processing method, device and system for a wind turbine generator test bed, and is applied to the technical field of wind turbine generator test bed simulation. The method comprises the following steps: in response to acquired pre-stored static test simulation data of each structural sub-component of a wind turbine generator test bed under a static working condition, calling a fatigue calculation service corresponding to each structural sub-component to monitor actual load data transmitted by a field side of the wind turbine generator test bed, based on the monitored actual load data and static test simulation data, performing fatigue life analysis and evaluation of each structural subcomponent in parallel to obtain a fatigue life simulation result of each structural subcomponent; and sending the fatigue life simulation result of each structural sub-component to the wind turbine generator test bed field side to perform real-time rendering display. The problems that in the fatigue life test process of the wind turbine generator test bed, the requirement for hardware computing resources is high, the test efficiency is low, and the real-time visualization result display requirement cannot be met are solved.

Description

Technical Field

[0001] The invention relates to the technical field of wind turbine test bench simulation, and in particular to a fatigue life simulation processing method, device and system for a wind turbine test bench. Background Art

[0002] As offshore wind turbines develop towards larger and deeper seas, the overall performance test of wind turbines is particularly urgent and important. Due to the harsh offshore environment, the overall on-site testing technology is extremely difficult. Therefore, conducting full-scale ground tests on wind turbines has become a general consensus and development trend in the industry.

[0003] Currently, full-scale ground tests of offshore wind turbines are conducted on offshore wind turbine ground test benches. However, during long-term operation, offshore wind turbine ground test benches must withstand cyclic stress caused by huge loading forces. Long-term operation will inevitably lead to stress fatigue damage of the structure. Therefore, it is very important to evaluate the structural fatigue life of the ground test bench for the safety of the unit. At present, most full-scale ground tests of wind turbines are conducted by establishing a refined finite element model of the structure to analyze and evaluate the overall fatigue life. This method requires finite element modeling of complex structures, resulting in an extremely large amount of data in the processing process, and very high requirements for hardware computing resources; and the test efficiency is low, which cannot meet the needs of real-time visualization of results. Summary of the invention

[0004] In order to overcome the problems of high requirements for hardware computing resources and low test efficiency during the fatigue life test of the above-mentioned full-scale ground test of wind turbines, and inability to meet the needs of real-time visualization of results display, the present invention provides a fatigue life simulation processing method, device and system for a wind turbine test bench.

[0005] In one aspect, the present invention provides a fatigue life simulation processing method for a wind turbine test bench, comprising:

[0006] In response to obtaining the pre-stored static test simulation data of each structural subcomponent of the wind turbine test bench under static working conditions, calling the fatigue calculation service corresponding to each structural subcomponent to monitor the actual load data of each structural subcomponent transmitted from the on-site side of the wind turbine test bench, and performing fatigue life analysis and evaluation of each structural subcomponent in parallel based on the monitored actual load data of the structural subcomponent and the static test simulation data, so as to obtain the fatigue life simulation result of each structural subcomponent;

[0007] Sending the fatigue life simulation results of each structural subcomponent to the on-site side of the wind turbine test bench, so as to perform real-time rendering and display of the fatigue life simulation results of each structural subcomponent at the on-site side of the wind turbine test bench;

[0008] Wherein, the wind turbine test bench is built for target structural parts of the wind turbine.

[0009] Optionally, the wind turbine test bench is a ground test bench for an offshore wind turbine transmission chain, and each of the structural subcomponents includes a motor rotor, a motor stator, a coupling, a connecting rod, a flange and a loading plate.

[0010] Optionally, before sending the fatigue life simulation results of each structural subcomponent to the on-site side of the wind turbine test bench, the method further includes:

[0011] Convert the format of fatigue life simulation results of each structural sub-component to obtain fatigue life simulation results in the target format;

[0012] Sending fatigue life simulation results of each structural subcomponent to the on-site side of the wind turbine test bench includes:

[0013] The fatigue life simulation result in the target format is sent to the functional model unit at the on-site side of the wind turbine test bench, so as to perform real-time rendering and display of the fatigue life simulation result in the target format through a visualization program encapsulated in the functional model unit.

[0014] Optionally, before obtaining the pre-stored static test simulation data of each structural subcomponent of the wind turbine test bench under static conditions, the method further includes:

[0015] Constructing finite element models of various structural subcomponents of the wind turbine test bench;

[0016] Based on computer-aided engineering and finite element models of each structural subcomponent, static test simulation of each structural subcomponent under static working conditions is performed to obtain static test simulation data of each structural subcomponent;

[0017] Store static test simulation data of each structural subcomponent.

[0018] Optionally, the fatigue life analysis and evaluation of each structural subcomponent is implemented through a distributed system, and the fatigue life analysis and evaluation of each structural subcomponent is performed in parallel based on the monitored actual load data of the structural subcomponent and the static test simulation data, including:

[0019] Monitor the task progress and resource usage of each computing node in the distributed system in real time;

[0020] Receiving the available status data of each computing node in the distributed system reported regularly;

[0021] Based on the task progress, resource usage and available status data of each computing node in the current distributed system, fatigue life analysis and evaluation of each structural subcomponent are performed, and the corresponding fatigue calculation tasks are distributed and executed in parallel.

[0022] Optionally, the actual load data of each structural subcomponent is actual load history data sent by the functional model unit, and the static test simulation data of each structural subcomponent is stress distribution data of each structural subcomponent. The fatigue life analysis and evaluation of each structural subcomponent is performed in parallel based on the monitored actual load data and static test simulation data of the structural subcomponent, including:

[0023] For each fatigue calculation service, obtaining corresponding stress history data based on the stress distribution data of the structural subcomponent and the actual load history data of the structural subcomponent;

[0024] The stress history data are transformed into corresponding stress amplitudes by rain flow counting method;

[0025] Calculating the cycle service life of the structural subcomponent based on the stress amplitude corresponding to the stress history data, the stress correction method and the SN curve parameters of the structural subcomponent;

[0026] Based on the cyclic service life of the structural subcomponent and the linear damage accumulation theory, the fatigue damage value of the structural subcomponent is obtained.

[0027] On the other hand, the present invention also provides a fatigue life simulation processing device for a wind turbine test bench, comprising: a processing module and a control module, wherein:

[0028] The processing module is used for, in response to obtaining the pre-stored static test simulation data of each structural sub-component of the wind turbine test bench under static working conditions, calling the fatigue calculation service corresponding to each structural sub-component to monitor the actual load data of each structural sub-component transmitted from the on-site side of the wind turbine test bench, and performing fatigue life analysis and evaluation of each structural sub-component in parallel based on the monitored actual load data of the structural sub-component and the static test simulation data, to obtain the fatigue life simulation result of each structural sub-component;

[0029] The control module is used to send the fatigue life simulation results of each structural subcomponent to the on-site side of the wind turbine test bench, so as to perform real-time rendering and display of the fatigue life simulation results of each structural subcomponent at the on-site side of the wind turbine test bench;

[0030] Wherein, the wind turbine test bench is built for target structural parts of the wind turbine.

[0031] Optionally, the processing module is specifically used for:

[0032] In response to acquiring static test simulation data of each structural subcomponent, sending a preparation completion signal to the control module;

[0033] The control module is specifically used for: in response to receiving the preparation completion signal, monitoring the actual load data of each structural sub-component transmitted by the functional model unit on the on-site side of the wind turbine test bench based on a predetermined communication protocol; and for sending the actual load data of each structural sub-component to the corresponding fatigue calculation service in the processing module through the fixed port corresponding to the structural sub-component.

[0034] On the other hand, the present invention further provides a fatigue life simulation processing system for a wind turbine test bench, the system comprising the fatigue life simulation processing device described in the above embodiment.

[0035] Optionally, the system further comprises a control subsystem on the field side of the wind turbine test bench, and the control subsystem exchanges data with the fatigue life simulation processing device by building a Modelica platform and encapsulating a functional model unit in the Modelica platform.

[0036] Optionally, the functional model unit is used to receive actual load data of each structural sub-component from the Modelica platform through the FMI interface and record the load history of each structural sub-component to form corresponding actual load history data, and send the actual load history data to the fatigue life simulation processing device.

[0037] Optionally, the control subsystem is further used for:

[0038] Based on the fatigue life simulation results of each structural subcomponent, determining whether the structural subcomponent meets the actual use requirements of the wind turbine generator set;

[0039] If the structural subcomponents do not meet the actual use requirements of the wind turbine generator set, the structural design parameters of the structural subcomponents are adjusted based on the fatigue life simulation results of the structural subcomponents.

[0040] On the other hand, the present invention also provides an electronic device, comprising: at least one processor and a memory; the memory and the processor are connected via a bus;

[0041] The memory is used to store one or more programs;

[0042] When the one or more programs are executed by the at least one processor, any one of the above-mentioned fatigue life simulation processing methods for a wind turbine test bench is implemented.

[0043] On the other hand, the present invention further provides a readable storage medium having an execution program stored thereon, and when the execution program is executed, the fatigue life simulation processing method of the wind turbine test bench described in any one of the above items is implemented.

[0044] Compared with the prior art, the present invention has the following beneficial effects:

[0045] The present invention provides a fatigue life simulation processing method, device and system for a wind turbine test bench, which pre-stores static test simulation data of each structural sub-component of the wind turbine test bench under static working conditions, so that when performing fatigue life simulation test of structural parts, it is only necessary to obtain the pre-stored static test simulation data of each structural sub-component of the wind turbine test bench under static working conditions, thereby avoiding the situation that complex finite element modeling is required in each fatigue life simulation test process, greatly reducing the amount of data processing, thereby reducing the requirements of the test process on hardware resources and improving the test efficiency;

[0046] The present invention, in response to acquiring static test simulation data of each structural sub-component, calls the fatigue calculation service corresponding to each structural sub-component to monitor the actual load data of each structural sub-component transmitted from the on-site side of the wind turbine test bench, and performs fatigue life analysis and evaluation of each structural sub-component in parallel based on the monitored actual load data of the structural sub-component and the static test simulation data; sends the fatigue life simulation results of each structural sub-component to the on-site side of the wind turbine test bench, so as to perform real-time rendering and display of the fatigue life simulation results of each structural sub-component on the on-site side of the wind turbine test bench; and constructs a corresponding fatigue calculation service for each structural sub-component of the structural member, thereby realizing parallel processing of the actual load data transmitted in real time, improving the efficiency of the simulation test, and realizing real-time processing and visual display of the data, thereby meeting the real-time visual display requirements of the fatigue life simulation test results. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 This is one of the flow diagrams of a fatigue life simulation processing method of a wind turbine test bench of the present invention;

[0048] Figure 2 A schematic diagram of a fatigue life analysis and evaluation process of each structural subcomponent of a wind turbine test bench of the present invention;

[0049] Figure 3 The second flow chart of the fatigue life simulation processing method of a wind turbine test bench of the present invention;

[0050] Figure 4 The processing flow of fatigue calculation tasks of the fatigue life simulation processing system of the wind turbine test bench of the present invention;

[0051] Figure 5 A fatigue life monitoring cloud diagram of a coupling of a transmission chain of a wind turbine generator set according to an embodiment of the present invention;

[0052] Figure 6 A cloud diagram showing fatigue life monitoring of a loading plate of a transmission chain of a wind turbine generator system according to an embodiment of the present invention;

[0053] Figure 7 A cloud diagram showing fatigue life monitoring of a flange of a transmission chain of a wind turbine generator system according to an embodiment of the present invention;

[0054] Figure 8 It is a schematic structural diagram of the electronic device of the present invention. DETAILED DESCRIPTION

[0055] The specific implementation modes of the present invention are further described in detail below with reference to the accompanying drawings.

[0056] Embodiment 1:

[0057] The present invention provides a fatigue life simulation processing method for a wind turbine test bench, as shown in the schematic diagram Figure 1 As shown, including:

[0058] Step S110, in response to obtaining the pre-stored static test simulation data of each structural subcomponent of the wind turbine test bench under static conditions, calling the fatigue calculation service corresponding to each structural subcomponent to monitor the actual load data of each structural subcomponent transmitted from the on-site side of the wind turbine test bench, and performing fatigue life analysis and evaluation of each structural subcomponent in parallel based on the monitored actual load data of the structural subcomponent and the static test simulation data, to obtain fatigue life simulation results of each structural subcomponent;

[0059] Step S120, sending the fatigue life simulation results of each structural subcomponent to the on-site side of the wind turbine test bench, so as to perform real-time rendering and display of the fatigue life simulation results of each structural subcomponent at the on-site side of the wind turbine test bench;

[0060] Wherein, the wind turbine test bench is built for target structural parts of the wind turbine.

[0061] In this example implementation, the wind turbine test bench refers to a full-scale ground test bench for an offshore wind turbine, which is built for the target structural parts of the wind turbine, such as a ground test bench for the transmission chain of an offshore wind turbine. Each structural subcomponent refers to a subcomponent of the corresponding mechanical structure of the wind turbine test bench. For example, for the ground test bench for the transmission chain of an offshore wind turbine, the corresponding structural subcomponents include a motor rotor, a motor stator, a coupling, a connecting rod, a flange, a loading plate, etc. The actual load data can be generated by the on-site side of the wind turbine test bench based on the simulation of actual test parameters, or it can be the actual load data obtained by the on-site test of the wind turbine test bench. The on-site side of the wind turbine test bench refers to the control system or platform located at the site of the wind turbine test bench. Before the real-time simulation test, finite element modeling of each structural subcomponent and static tests under static conditions can be performed in advance to obtain static test simulation data of each structural subcomponent, and the static test simulation data of each structural subcomponent is stored. This process can be performed in advance on the current simulation platform. During real-time simulation testing, fatigue life simulation of each structural subcomponent is performed by directly obtaining pre-stored static test simulation data, which reduces the amount of data processing for real-time testing and greatly improves simulation efficiency. During real-time simulation testing, a corresponding fatigue calculation service is built for each structural subcomponent to process the fatigue life calculation of the corresponding structural subcomponent. The parallel execution of the corresponding fatigue calculation services of each structural subcomponent further accelerates the processing efficiency and meets the requirements of real-time processing. This example splits the fatigue calculation process into a part that is not affected by load data and a part that is affected by load data, and pre-processes the part that is not affected by load data, so that each fatigue life calculation process only needs to read the pre-stored data and update the calculation based on the load data, avoiding the finite element back-strip solution each time, greatly improving the calculation speed, and avoiding the problem of long waiting time in the finite element simulation calculation process.

[0062] In an example implementation, before sending the fatigue life simulation results of each structural subcomponent to the on-site side of the wind turbine test bench in step S120, the method further includes:

[0063] Convert the format of fatigue life simulation results of each structural sub-component to obtain fatigue life simulation results in the target format;

[0064] Sending fatigue life simulation results of each structural subcomponent to the on-site side of the wind turbine test bench includes:

[0065] The fatigue life simulation result in the target format is sent to the functional model unit at the on-site side of the wind turbine test bench, so as to perform real-time rendering and display of the fatigue life simulation result in the target format through a visualization program encapsulated in the functional model unit.

[0066] In this example implementation, it is possible to wait for all fatigue calculation services to complete calculations, collect all calculation results to obtain fatigue life simulation results of each structural subcomponent. The fatigue life simulation results of each structural subcomponent are converted into data format, such as converted into a Json file and sent to the on-site side of the wind turbine test bench (such as the on-site control system of the wind turbine test bench) through the functional model unit. The on-site side of the wind turbine test bench renders and visualizes the Json file corresponding to the fatigue life simulation results of each structural subcomponent through a visualization program encapsulated in the functional model unit (such as a general extensible finite element visualization program). For example, the fatigue life cloud map of each structural subcomponent can be displayed based on the finite element model of each structural subcomponent. In this way, real-time feedback display of the fatigue life simulation results of each structural subcomponent can be achieved, and the simulation results can be fed back to the technicians in real time according to the working conditions or the observation requirements of the engineers, so as to achieve real-time visualization display of the simulation test results, so that the on-site engineers can obtain the test results in time, quickly adjust the design scheme based on the results, speed up the design process, and shorten the structural development cycle.

[0067] In an exemplary implementation, before obtaining the pre-stored static test simulation data of each structural subcomponent of the wind turbine test bench under static conditions in step S110, the method further includes:

[0068] Constructing finite element models of various structural subcomponents of the wind turbine test bench;

[0069] Based on computer-aided engineering and finite element models of each structural subcomponent, static test simulation of each structural subcomponent under static working conditions is performed to obtain static test simulation data of each structural subcomponent;

[0070] Store static test simulation data of each structural subcomponent.

[0071] In this example implementation, before the real-time simulation test begins, finite element modeling and static tests of each structural subcomponent of the wind turbine test bench can be performed in advance, that is, fatigue pretreatment. Specifically, stress precalculation is performed first, and stress precalculation is the core part of fatigue pretreatment. Stress precalculation refers to the establishment of finite element models of each structural subcomponent in the absence of specific load data, which may include the establishment of geometric models, material properties and boundary conditions of each structural subcomponent. Static tests (tests under static conditions) are performed based on computer-aided engineering (CAE), that is, static tests are performed under different load directions, load sizes and constraint conditions, and finite element analysis is performed on each static condition to obtain simulation data (such as stress distribution) of each structural subcomponent under different static conditions, that is, the results of stress precalculation, and the results of stress precalculation are saved for subsequent reading and use. Exemplarily, the static test simulation data of each structural subcomponent is stored in the current simulation system memory. During the real-time simulation test, the static test simulation data of each structural subcomponent is read through the fatigue calculation service corresponding to each structural subcomponent to perform the subsequent fatigue calculation process. This example greatly reduces the amount of data processing by completing complex finite element model construction and static testing in advance, thereby reducing the requirements for hardware resources in the test process and improving test efficiency.

[0072] In some example implementations, the step S110 of performing fatigue life analysis and evaluation of each structural subcomponent in parallel based on the monitored actual load data of the structural subcomponent and the static test simulation data includes:

[0073] Monitor the task progress and resource usage of each computing node in the distributed system in real time;

[0074] Receiving the available status data of each computing node in the distributed system reported regularly;

[0075] Based on the task progress, resource usage and available status data of each computing node in the current distributed system, fatigue life analysis and evaluation of each structural subcomponent are performed, and the corresponding fatigue calculation tasks are distributed and executed in parallel.

[0076] In this example implementation, the fatigue life analysis and evaluation of each structural subcomponent can be implemented through a distributed system, that is, the fatigue life analysis and evaluation of each structural subcomponent is performed on a distributed system. Specifically, the task progress and resource usage of each computing node in the distributed system can be monitored in real time, and the resource usage of each computing node can be determined by the load situation. Each computing node can correspond to a physical server, and each computing node can also regularly report its own available status data, that is, whether it is available; the fatigue calculation tasks are distributed and processed based on the load balancing idea, so as to ensure the processing efficiency of each fatigue calculation task and the overall performance of the system.

[0077] In some example embodiments, the actual load data of each of the structural subcomponents is the actual load history data sent by the functional model unit, and the static test simulation data of each of the structural subcomponents is the stress distribution data of each of the structural subcomponents.

[0078] In this example implementation, the functional model unit (FMU) can export model files. The FMU format is a standardized model format that allows seamless collaborative simulation between different simulation tools. The functional model unit is used to exchange data between the wind turbine test bench on-site and the simulation processing system of this example. The actual load data is the actual load history data, that is, the load data changes over time. Different load data spectra will be generated according to the actual working conditions, such as load time history, amplitude, frequency and other data, which are used for each update calculation. Static test simulation data is stress distribution data.

[0079] On this basis, in some example implementations, the fatigue calculation services of step S110 perform fatigue life analysis and evaluation of each structural subcomponent in parallel based on the monitored actual load data of the structural subcomponent and the static test simulation data, including:

[0080] For each fatigue calculation service, obtaining corresponding stress history data based on the stress distribution data of the structural subcomponent and the actual load history data of the structural subcomponent;

[0081] The stress history data are transformed into corresponding stress amplitudes by rain flow counting method;

[0082] Calculating the cycle service life of the structural subcomponent based on the stress amplitude corresponding to the stress history data, the stress correction method and the SN curve parameters of the structural subcomponent;

[0083] Based on the cyclic service life of the structural subcomponent and the linear damage accumulation theory, the fatigue damage value of the structural subcomponent is obtained.

[0084] In this example implementation, each fatigue calculation service performs fatigue life analysis and evaluation of each structural subcomponent in parallel. Figure 2 As shown in the figure, the stress distribution data of each structural subcomponent combined with the actual load history data is used to obtain the change of stress over time, that is, the stress history data (stress time series). When the stress history is complex, the stress amplitude cannot be directly extracted from the stress time series, so it is necessary to convert it into the stress amplitude through a certain counting rule. The rain flow counting method can be used to identify the local load peaks and valleys, and the complex stress history can be decomposed into simple stress amplitudes. Then, the stress correction method and the material SN curve parameters are used to calculate the number of cycles of each structural subcomponent under the random load in this section according to the stress amplitude, so as to obtain the corresponding fatigue life. According to the linear damage accumulation theory (Miner's theorem), the fatigue damage value and the fatigue life are reciprocal to each other, that is, the fatigue damage value D = 1 / N, N is the fatigue life. Through the above process, the fatigue life and fatigue damage value of each structural subcomponent can be obtained to complete the fatigue life analysis and evaluation. The above process will affect the structural stress state due to the load changes under actual working conditions, which belongs to the part affected by the load data. This part is distinguished from the preprocessing part involving finite element calculation, so that the above process does not involve finite element calculation, which helps to improve the calculation efficiency.

[0085] The following is a specific example to illustrate the specific steps of a fatigue life simulation processing method of a wind turbine test bench of the present invention. Figure 3 As shown, the simulation processing method can be executed in the corresponding simulation subsystem (real-time simulation side), and the simulation subsystem can include two functional modules: fatigue calculation master control and fatigue calculation solution. The wind turbine test bench site side performs collaborative simulation with the simulation subsystem by building a Modelica platform. Specifically, the following processes can be included:

[0086] (1) Before the simulation subsystem is started, the geometric modeling of each structural subcomponent is performed using modeling software. CAE software can be used for static simulation to obtain static test simulation results as preprocessing results and store them. A domestically developed fatigue solver is used to build a fatigue calculation service and wait for it to be started.

[0087] (2) In response to the simulation subsystem being turned on, the fatigue life simulation processing flow of each structural subcomponent is started.

[0088] (3) Start the fatigue calculation master control, which is mainly responsible for controlling all calculation tasks of fatigue calculation. After starting, the corresponding fatigue calculation task is started for each subcomponent. Each subcomponent starts the fatigue calculation module separately, controls the life cycle of fatigue calculation, and allocates corresponding ports for each subcomponent for communication.

[0089] (4) The fatigue calculation and solution module is started for each sub-component to provide fatigue solution and calculation services for the corresponding sub-components. After starting, the calculation services of each sub-component are started, such as the fatigue calculation service of the traction motor stator and the fatigue calculation service of the main frame. Then, the module waits for the input of load data and solution signals.

[0090] (5) The fatigue calculation master control needs to select the most appropriate solution server and distribute the task to the solution server according to the current load and availability. Specifically, the fatigue calculation master control monitors the status of the solution server in real time, including task progress, resource usage, and any possible error status. The corresponding solution server regularly reports its status to the calculation controller.

[0091] (6) The fatigue calculation solution module uses a fixed port to communicate with the fatigue calculation master control. The fatigue calculation solution module reads the static test simulation results pre-stored in step (1). This process does not involve finite element back-strip solution, and the calculation speed is fast and does not require long waiting.

[0092] (7) When all static test simulation results are read and memory data is ready, the fatigue calculation solution module sends a preparation completion signal to the fatigue calculation master control.

[0093] (8) The fatigue calculation master control monitors the load spectrum data from the on-site side of the wind turbine test bench, and the load spectrum data is sent to the fatigue calculation master control via the network HTTP protocol. In this process, the process of receiving and sending data always exists.

[0094] (9) When the fatigue calculation master control receives the load spectrum data, it sends it to the fatigue calculation solution module for fatigue calculation. At this time, the fatigue calculation solution module receives the load spectrum data, and the calculation service that has been started obtains the solution instruction, and uses the domestically produced independent fatigue analysis program to perform fatigue life calculation.

[0095] (10) After the fatigue calculation solution module completes the calculation, it sends the result to the fatigue calculation master control. After all calculations are completed, the fatigue calculation master control collects all the calculation results, converts the results into a Json file, and sends them to the Modelica platform on the site of the wind turbine test bench, which is rendered and displayed through the FMU module and the main control software.

[0096] The fatigue life assessment of the main mechanical system of the ground test platform of the wind turbine (such as the transmission chain test platform) is particularly important for the structural health monitoring of the test platform. The traditional method of monitoring and evaluating the overall fatigue life of the structure has high requirements on computing resources, computing accuracy, and computing speed, and it is impossible to provide real-time feedback on the monitoring situation according to the working conditions or the observation needs of engineers. For example, the Chinese patent with application number 202311449920 and invention name "Fatigue life monitoring system and method for complex equipment parts based on digital twins" targets the core components of complex equipment by real-time collection of force, deformation and vibration data during actual operation and inputting them into the trained machine learning model to obtain the microscopic damage of components caused by changes in force loads, and conduct real-time monitoring of the health status or fatigue life of components. The implementation method is as follows: first, by establishing a virtual model of the components, multi-source signal data is collected from the actual working conditions, and the first data is obtained through digital-to-analog conversion and data preprocessing; then, the stress value of the component and the first fatigue life value are obtained through finite element calculation in the numerical calculation unit, and the data is integrated with material properties, dimensions, and influencing factor data to train the machine learning model; then the first data is input into the machine learning model to calculate the material coefficient, and finally the second fatigue life value is calculated. The training data set and numerical calculation (such as finite element calculation, fatigue calculation) process of the machine learning model used in the monitoring and evaluation technology of the overall fatigue life of the structure of this scheme have high requirements on computing resources. The operation speed in the conventional environment is slow and time-consuming, and it is difficult to obtain the monitoring status at any time according to engineering needs. In addition, the display and description of the real-time monitoring status is insufficient, and it is impossible to establish a fast and flexible monitoring plan that meets the needs of engineering personnel.

[0097] In view of the above problems, the present invention provides a method for quickly visualizing the fatigue life results of a wind turbine test bench simulation system, applies modern communication and network technologies, optimizes and combines sub-processes such as simulation analysis, fatigue analysis, and information network processing, and realizes rapid display and flexible evaluation of the fatigue life of the transmission chain mechanical system.

[0098] At present, the full-scale ground test technology of wind turbines is only mastered by a few countries, and there are no relevant reports on the fatigue life evaluation calculation of the test bench. The content of the present invention is aimed at the full-scale ground test platform of the transmission chain of a large-capacity offshore wind turbine that is under construction, breaking through the technical bottleneck of rapid fatigue life evaluation of the mechanical system of the test bench, and realizing real-time monitoring of the structure of the ground test bench. Specifically, through the pre-calculation of the finite element simulation process and saving the calculated data, the subsequent fatigue calculation process needs to be updated and calculated, and each update calculation link refers to the fatigue life analysis based on the pre-saved simulation data after each load change. These pre-saved data are repeatedly used in the subsequent fatigue calculation process, thereby avoiding the need to re-perform complex finite element analysis for each calculation, and realizing the rapid display and flexible evaluation and prediction of the fatigue life of the mechanical system of the wind turbine test bench (such as the transmission chain test bench).

[0099] Embodiment 2:

[0100] Based on the same inventive concept, the present invention also provides a fatigue life simulation processing device for a wind turbine test bench, comprising: a processing module and a control module, wherein:

[0101] The processing module is used for, in response to obtaining the pre-stored static test simulation data of each structural sub-component of the wind turbine test bench under static working conditions, calling the fatigue calculation service corresponding to each structural sub-component to monitor the actual load data of each structural sub-component transmitted from the on-site side of the wind turbine test bench, and performing fatigue life analysis and evaluation of each structural sub-component in parallel based on the monitored actual load data of the structural sub-component and the static test simulation data, to obtain the fatigue life simulation result of each structural sub-component;

[0102] The control module is used to send the fatigue life simulation results of each structural subcomponent to the on-site side of the wind turbine test bench, so as to perform real-time rendering and display of the fatigue life simulation results of each structural subcomponent at the on-site side of the wind turbine test bench;

[0103] Wherein, the wind turbine test bench is built for target structural parts of the wind turbine.

[0104] In this example, the control module is equivalent to Figure 3 The fatigue calculation master control in the processing module is equivalent to Figure 3 Fatigue calculation solution module in.

[0105] In a possible implementation manner, the processing module is specifically used to:

[0106] In response to acquiring static test simulation data of each structural subcomponent, sending a preparation completion signal to the control module;

[0107] The control module is specifically used for: in response to receiving the preparation completion signal, monitoring the actual load data of each structural sub-component transmitted by the functional model unit on the on-site side of the wind turbine test bench based on a predetermined communication protocol; and for sending the actual load data of each structural sub-component to the corresponding fatigue calculation service in the processing module through the fixed port corresponding to the structural sub-component.

[0108] In this example implementation, when the processing module has read all pre-stored static test simulation data, it can send a preparation completion signal to the control module to notify the control module that the data preparation is complete. After receiving the preparation completion signal, the control module listens to and receives the actual load data sent by the functional model unit, and the functional model unit can send the actual load data through the HTTP protocol. The control module sends the actual load data to the fatigue calculation service in the processing module through the fixed port pre-assigned to each sub-component, so that the fatigue calculation service begins fatigue life analysis and evaluation. This example avoids unnecessary communication processes between the control module and the field side by sending a preparation completion signal to the control module, saving communication overhead; and ensures accurate control of the fatigue calculation service of each sub-component by allocating different fixed communication ports to different sub-components.

[0109] In a possible implementation manner, the wind turbine test bench is a ground test bench for an offshore wind turbine transmission chain, and each of the structural subcomponents includes a motor rotor, a motor stator, a coupling, a connecting rod, a flange, and a loading plate.

[0110] In a possible implementation manner, the control module is specifically used to:

[0111] Convert the format of fatigue life simulation results of each structural sub-component to obtain fatigue life simulation results in the target format;

[0112] The fatigue life simulation result in the target format is sent to the functional model unit at the on-site side of the wind turbine test bench, so as to perform real-time rendering and display of the fatigue life simulation result in the target format through a visualization program encapsulated in the functional model unit.

[0113] In a possible implementation manner, the processing module is further used to construct a finite element model of each structural subcomponent of the wind turbine test bench before acquiring pre-stored static test simulation data of each structural subcomponent of the wind turbine test bench under static working conditions;

[0114] Based on computer-aided engineering and finite element models of each structural subcomponent, static test simulation of each structural subcomponent under static working conditions is performed to obtain static test simulation data of each structural subcomponent;

[0115] Store static test simulation data of each structural subcomponent;

[0116] In a possible implementation manner, the fatigue life analysis and evaluation of each of the structural subcomponents is implemented through a distributed system, and the control module is further used to:

[0117] Monitor the task progress and resource usage of each computing node in the distributed system in real time;

[0118] Receiving the available status data of each computing node in the distributed system reported regularly;

[0119] Based on the task progress, resource usage and available status data of each computing node in the current distributed system, fatigue life analysis and evaluation of each structural subcomponent are performed, and the corresponding fatigue calculation tasks are distributed and executed in parallel.

[0120] In a possible implementation manner, the actual load data of each of the structural subcomponents is the actual load history data sent by the functional model unit, and the static test simulation data of each of the structural subcomponents is the stress distribution data of each of the structural subcomponents.

[0121] In a possible implementation manner, the processing module is specifically used to:

[0122] For each fatigue calculation service, obtaining corresponding stress history data based on the stress distribution data of the structural subcomponent and the actual load history data of the structural subcomponent;

[0123] The stress history data are transformed into corresponding stress amplitudes by rain flow counting method;

[0124] Calculating the cycle service life of the structural subcomponent based on the stress amplitude corresponding to the stress history data, the stress correction method and the SN curve parameters of the structural subcomponent;

[0125] Based on the cyclic service life of the structural subcomponent and the linear damage accumulation theory, the fatigue damage value of the structural subcomponent is obtained.

[0126] Embodiment 3:

[0127] Based on the same inventive concept, the present invention also provides a fatigue life simulation processing system for a wind turbine test bench, the system comprising the fatigue life simulation processing device described in any implementation manner in Example 2.

[0128] In a possible implementation, the system further includes a control subsystem on the field side of the wind turbine test bench, and the control subsystem exchanges data with the fatigue life simulation processing device by building a Modelica platform and encapsulating a functional model unit in the Modelica platform.

[0129] In this example implementation, the Modelica platform provides an open, object-oriented, equation-based model library that can cross different fields and conveniently implement the modeling of complex physical systems. The FMU unit is encapsulated in the Modelica platform, and data interaction with the fatigue life simulation processing device is achieved through the FMU unit. This example ensures the collaborative simulation process of the fatigue life simulation processing device and the field side through the platform construction on the field side of the wind turbine test bench, and ensures the feasibility of the simulation process.

[0130] In a possible implementation, the functional model unit is used to receive actual load data of each structural sub-component from the Modelica platform through the FMI interface and record the load history of each structural sub-component to form corresponding actual load history data, and send the actual load history data to the fatigue life simulation processing device.

[0131] In this example implementation, the functional model unit exchanges data with the Modelica platform via the FMI interface. The functional model unit is also used to record the actual load data received through the FMI interface, convert it into load mileage data, and then send it to the fatigue life simulation processing device for fatigue life testing.

[0132] In some embodiments, the functional model unit can encapsulate a fast visualization module, such as a general extensible finite element visualization program, which collects and organizes the received data after receiving the simulation results sent by the fatigue life simulation processing device, and sends the organized results to the fast visualization program. The fast visualization program renders the data, obtains and displays the life monitoring status through visualization technology.

[0133] In a possible implementation manner, the control subsystem is further used for:

[0134] Based on the fatigue life simulation results of each structural subcomponent, determining whether the structural subcomponent meets the actual use requirements of the wind turbine generator set;

[0135] If the structural subcomponents do not meet the actual use requirements of the wind turbine generator set, the structural design parameters of the structural subcomponents are adjusted based on the fatigue life simulation results of the structural subcomponents.

[0136] In this example implementation, the wind turbine set will set usage requirements for the fatigue life of each structural subcomponent during actual use. For example, the fatigue life and fatigue damage value cannot be less than the corresponding threshold value, such as Figure 2As shown in the figure, if the use requirements are met, it means that the fatigue life of the sub-component structure of the current design is qualified and can be commercialized. Otherwise, the structural design parameters of the sub-components that do not meet the use requirements are adjusted and the simulation test is re-performed. The above process is repeated until the simulation results meet the use requirements. Through the ground test simulation test of wind turbines, new technologies, new designs, and new products can be tested and verified quickly and effectively, design problems and safety hazards can be discovered early, and the purpose of reducing technical risks, reducing product development costs, and shortening the R&D cycle can be achieved.

[0137] like Figure 4 As shown, the fatigue life simulation processing system of the wind turbine test bench of the present invention may include a Modelica platform built on the field side of the wind turbine and an FMU module encapsulated by the Modelica platform, as well as a fatigue calculation master control and a fatigue calculation solution module on the real-time simulation side. The FMU module is responsible for the transmission of load data and the encapsulation of the visualization module, and the fatigue calculation master control is responsible for creating fatigue calculation services, controlling the life cycle of fatigue calculation services, and assigning corresponding ports to each subcomponent to communicate with the fatigue calculation solution module. The fatigue calculation solution module is responsible for fatigue calculation solution services, and each module is linked and interacted with data through network communication technology. In short, according to the working load spectrum data transmitted by the FMU module, the fatigue calculation master control module is called to create a fatigue calculation task and monitor the task progress, the fatigue calculation solution module is called to calculate, and finally the fatigue result is obtained and returned to the FMU module, and the result is displayed in combination with the main control software of the Modelica platform. Since the finite element calculation part has been pre-calculated, the calculated simulation data is saved as a pre-processing result for subsequent reading and use. The subsequent fatigue calculation process needs to be updated and calculated, and each update calculation link refers to the fatigue life analysis and evaluation based on the pre-processing result after each load change. The preprocessing results are used repeatedly in the subsequent fatigue calculation process, thus avoiding the need to re-perform complex finite element analysis for each calculation and greatly reducing the amount of data processing.

[0138] The present invention provides scientific and normative guidance for the design of wind turbine structural parts through data transmission, data processing, load identification and fatigue assessment, and forms a fatigue life visualization scheme for the simulation platform; at the same time, it can provide all-round and time-divided fatigue life cloud map display, which can realize long-term evaluation and monitoring of the fatigue life of the wind turbine test bench, simplify the process from calculation to result output and display, and improve the efficiency of predicting and evaluating fatigue life.

[0139] Simulation experiment

[0140] The fatigue life simulation test of the sub-components of the transmission chain test bench is carried out by the method of the present invention, and the fatigue life monitoring cloud diagram of each sub-component is obtained as follows: Figure 5-7As shown, different colors in the figure represent different numbers of fatigue cycles of stress factors, which are used to characterize fatigue life. Different colors in the cloud map are used to characterize the horizontal distribution of the number of cycles of each sub-component. The larger the number of cycles, the longer the life. Figure 5 This is the fatigue life monitoring cloud diagram of the coupling of the wind turbine transmission chain. Figure 5 It can be seen that the coupling is in the high cycle fatigue range as a whole, and most parts of the coupling have a high number of fatigue cycles, about 10 8 (i.e. 1.000E+08) times, the number of fatigue cycles near the coupling main shaft and some small areas of the flange connection is slightly lower, about 10 7 This is on the order of times, indicating that the stress levels in these areas are relatively high and fatigue damage is likely to occur. Figure 6 This is the fatigue life monitoring cloud diagram of the loading plate of the wind turbine transmission chain. Figure 6 It can be seen that the loading plate as a whole is in the high cycle fatigue range, and the number of fatigue cycles in most parts of the loading plate is relatively high, about 10 8 The number of cycles near the connection between the loading plate and the flange is slightly lower, at 10 7 times, indicating that the stress level in this area is relatively high and fatigue damage is prone to occur. Figure 7 This is the fatigue life monitoring cloud diagram of the flange of the wind turbine transmission chain. Figure 7 It can be seen that the flange is in the high cycle fatigue range as a whole, and the number of fatigue cycles in most parts of the flange is relatively high, about 10 8 The number of cycles at the flange spindle and flange connection is slightly lower, about 10 7 The order of magnitude of times indicates that the stress level of this part is high and fatigue damage is prone to occur. It can be seen from the simulation results that the present invention can provide a monitoring cloud map of the fatigue life of each sub-component, which can intuitively reflect the overall and local fatigue life of each sub-component.

[0141] Example 4

[0142] like Figure 8 As shown, the present invention also provides an electronic device, which may be a computer device, a single-chip device, an intelligent mobile device, etc. The electronic device in this embodiment may include a processor, a memory, a transceiver component, etc. The memory, the processor, and the transceiver component are connected via a bus; the memory may be used to store an execution program, and an exemplary execution program may include instructions; the processor is used to execute the instructions stored in the memory. The memory may also be used to store data, which may be called and / or modified when the instructions are executed.

[0143] The processor may be a central processing unit (CPU), or other general-purpose processors, digital signal processors (DSP), application-specific integrated circuits (ASIC), field-programmable gate arrays (FPGA) or other programmable logic devices, discrete gates or transistor logic devices, discrete hardware components, etc. It is the computing core and control core of the terminal, which is suitable for implementing one or more instructions, specifically suitable for loading and executing one or more instructions in a storage medium to implement corresponding method flows or corresponding functions, so as to realize the steps of a fatigue life simulation processing method of a wind turbine test bench in the above-mentioned embodiment.

[0144] Example 5

[0145] Based on the same inventive concept, the present invention also provides a readable storage medium, specifically an electronic device readable storage medium (Memory), which is a memory device in an electronic device for storing programs and data. It can be understood that the storage medium here can include both built-in storage media in electronic devices and, of course, extended storage media supported by electronic devices. The storage medium provides a storage space, which stores the operating system of the terminal. In addition, one or more instructions suitable for being loaded and executed by a processor are also stored in the storage space, and these instructions can be one or more execution programs (including program codes). It should be noted that the storage medium here can be a high-speed RAM memory or a non-volatile memory, such as at least one disk memory. The processor loads and executes one or more instructions stored in the storage medium, which can implement the steps of a fatigue life simulation processing method for a wind turbine test bench in the above embodiment.

[0146] Those skilled in the art will appreciate that embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0147] The present invention is described with reference to flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to embodiments of the present invention. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0148] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0149] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0150] 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 its protection scope. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the field should understand that after reading the present invention, those skilled in the art can still make various changes, modifications or equivalent substitutions to the specific implementation methods of the application, but these changes, modifications or equivalent substitutions are all within the protection scope of the claims to be approved.

Claims

1. A fatigue life simulation processing method for a wind turbine test bench, characterized in that: include: In response to obtaining the pre-stored static test simulation data of each structural subcomponent of the wind turbine test bench under static working conditions, calling the fatigue calculation service corresponding to each structural subcomponent to monitor the actual load data of each structural subcomponent transmitted from the on-site side of the wind turbine test bench, and performing fatigue life analysis and evaluation of each structural subcomponent in parallel based on the monitored actual load data of the structural subcomponent and the static test simulation data, so as to obtain the fatigue life simulation result of each structural subcomponent; Sending the fatigue life simulation results of each structural subcomponent to the on-site side of the wind turbine test bench, so as to perform real-time rendering and display of the fatigue life simulation results of each structural subcomponent at the on-site side of the wind turbine test bench; Wherein, the wind turbine test bench is built for target structural parts of the wind turbine.

2. The method according to claim 1, characterized in that The wind turbine test bench is a ground test bench for the transmission chain of an offshore wind turbine, and each of the structural subcomponents includes a motor rotor, a motor stator, a coupling, a connecting rod, a flange and a loading plate.

3. The method according to claim 1 or 2, characterized in that: Before sending the fatigue life simulation results of each structural subcomponent to the on-site side of the wind turbine test bench, the method further includes: Convert the format of fatigue life simulation results of each structural sub-component to obtain fatigue life simulation results in the target format; Sending fatigue life simulation results of each structural subcomponent to the on-site side of the wind turbine test bench includes: The fatigue life simulation result in the target format is sent to the functional model unit at the on-site side of the wind turbine test bench, so as to perform real-time rendering and display of the fatigue life simulation result in the target format through a visualization program encapsulated in the functional model unit.

4. The method according to claim 3, characterized in that: Before obtaining the pre-stored static test simulation data of each structural subcomponent of the wind turbine test bench under static conditions, the method further includes: Constructing finite element models of various structural subcomponents of the wind turbine test bench; Based on computer-aided engineering and finite element models of each structural subcomponent, static test simulation of each structural subcomponent under static working conditions is performed to obtain static test simulation data of each structural subcomponent; Store static test simulation data of each structural subcomponent.

5. The method according to claim 2, characterized in that: The fatigue life analysis and evaluation of each structural subcomponent is implemented through a distributed system, and the fatigue life analysis and evaluation of each structural subcomponent is performed in parallel based on the monitored actual load data of the structural subcomponent and the static test simulation data, including: Monitor the task progress and resource usage of each computing node in the distributed system in real time; Receiving the available status data of each computing node in the distributed system reported regularly; Based on the task progress, resource usage and available status data of each computing node in the current distributed system, fatigue life analysis and evaluation of each structural subcomponent are performed, and the corresponding fatigue calculation tasks are distributed and executed in parallel.

6. The method according to claim 1 or 5, characterized in that: The actual load data of each structural subcomponent is the actual load history data sent by the functional model unit, and the static test simulation data of each structural subcomponent is the stress distribution data of each structural subcomponent. The fatigue life analysis and evaluation of each structural subcomponent is performed in parallel based on the monitored actual load data and static test simulation data of the structural subcomponent, including: For each fatigue calculation service, obtaining corresponding stress history data based on the stress distribution data of the structural subcomponent and the actual load history data of the structural subcomponent; The stress history data are transformed into corresponding stress amplitudes by rain flow counting method; Calculating the cycle service life of the structural subcomponent based on the stress amplitude corresponding to the stress history data, the stress correction method and the SN curve parameters of the structural subcomponent; Based on the cyclic service life of the structural subcomponent and the linear damage accumulation theory, the fatigue damage value of the structural subcomponent is obtained.

7. A fatigue life simulation processing device for a wind turbine test bench, characterized in that: include: A processing module and a control module, wherein: The processing module is used to, in response to obtaining the pre-stored static test simulation data of each structural sub-component of the wind turbine test bench under static working conditions, call the fatigue calculation service corresponding to each structural sub-component to monitor the actual load data of each structural sub-component transmitted from the on-site side of the wind turbine test bench, and perform fatigue life analysis and evaluation of each structural sub-component in parallel based on the monitored actual load data of the structural sub-component and the static test simulation data, so as to obtain the fatigue life simulation result of each structural sub-component; The control module is used to send the fatigue life simulation results of each structural subcomponent to the on-site side of the wind turbine test bench, so as to perform real-time rendering and display of the fatigue life simulation results of each structural subcomponent at the on-site side of the wind turbine test bench; Wherein, the wind turbine test bench is built for target structural parts of the wind turbine.

8. The device according to claim 7, characterized in that The processing module is specifically used for: In response to acquiring static test simulation data of each structural subcomponent, sending a preparation completion signal to the control module; The control module is specifically used to: in response to receiving the preparation completion signal, monitor the actual load data of each structural sub-component transmitted by the functional model unit based on a predetermined communication protocol at the on-site side of the wind turbine test bench; It is also used to send the actual load data of each structural subcomponent to the corresponding fatigue calculation service in the processing module through the fixed port corresponding to the structural subcomponent.

9. A fatigue life simulation processing system for a wind turbine test bench, characterized in that: The system includes the fatigue life simulation processing device according to claim 7 or 8.

10. The system according to claim 9, characterized in that The system also includes a control subsystem on the field side of the wind turbine test bench. The control subsystem exchanges data with the fatigue life simulation processing device by building a Modelica platform and encapsulating a functional model unit in the Modelica platform.

11. The system according to claim 10, characterized in that The functional model unit is used to receive the actual load data of each structural subcomponent from the Modelica platform through the FMI interface and record the load history of each structural subcomponent to form corresponding actual load history data, and send the actual load history data to the fatigue life simulation processing device.

12. The system according to claim 10, characterized in that The control subsystem is also used for: Based on the fatigue life simulation results of each structural subcomponent, determining whether the structural subcomponent meets the actual use requirements of the wind turbine generator set; If the structural subcomponents do not meet the actual use requirements of the wind turbine generator set, the structural design parameters of the structural subcomponents are adjusted based on the fatigue life simulation results of the structural subcomponents.

13. An electronic device, characterized in that: include: at least one processor and memory; The memory and the processor are connected via a bus; The memory is used to store one or more programs; When the one or more programs are executed by the at least one processor, the fatigue life simulation processing method of the wind turbine test bench according to any one of claims 1 to 6 is implemented.

14. A readable storage medium, characterized in that: An execution program is stored thereon, and when the execution program is executed, the fatigue life simulation processing method of the wind turbine test bench according to any one of claims 1 to 6 is implemented.

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