High-precision line laser wind turbine blade profile detection and analysis system

Abstract

The present invention discloses a high-precision line laser wind turbine blade profile detection and analysis system, which relates to the technical field of wind turbine blade profile quality inspection. In the present invention: the motion path of the line laser profile scanner on the displacement transmission mechanism is provided with a start acceleration zone, a uniform speed stabilization zone and a stop deceleration zone. The photoelectric receiving modules on both sides contain CCD light sensing modules, which preset their position parameters and obtain the scanner position information in real time, and adjust the power of the horizontal laser module according to the distance between the scanner and the CCD light sensing module. After the scanner enters the uniform speed stabilization zone, it obtains and analyzes the starting and movement of the geometric center point of the light sensing area, compares the displacement difference with the preset reference value to judge the motion state, marks the position point if abnormal, and alarms if multiple abnormalities occur. The present invention can more keenly capture tiny changes in motion state, and facilitates timely and accurate discovery of detection problems after motion state abnormalities occur, thereby further ensuring the accuracy of wind turbine blade profile scanning.

Description

Technical Field

[0001] The present invention relates to the technical field of wind turbine blade profile quality inspection, and in particular to a high-precision line laser wind turbine blade profile detection and analysis system. Background Art

[0002] After the wind turbine blades are processed and manufactured, a line laser profile scanner can be used to scan and detect the profile parameters of the wind turbine blades. The line laser profile scanner mainly uses line laser measurement technology to measure wind turbine blades. Line laser measurement technology is based on the principle of laser triangulation reflection. By emitting a line laser to illuminate the surface of the wind turbine blade to be measured, the camera built into the sensor obtains the laser reflected from the target surface from a certain angle. Due to the different distances from different positions on the blade surface to the sensor, the reflected laser will fall on different positions in the camera imaging area, thus forming a triangle. Using the sensor parameters pre-calibrated at the factory, the height of each point on the laser profile formed by the laser irradiation on the blade surface can be calculated, thereby obtaining the 3D profile data of the blade.

[0003] When installing a line laser profile scanner, a corresponding displacement transmission mechanism is also required. When the displacement transmission mechanism drives the line laser profile scanner to move, it is necessary to ensure that the movement state of the line laser profile scanner is very stable to avoid shaking or vibration affecting the accuracy of the scanning results. However, during installation, the operator can only make rough judgments based on experience and cannot accurately guarantee the installation quality to obtain accurate scanning results.

[0004] Traditional detection methods involve installing a vibration detector within the linear laser profiler to check the stability of the scanner's motion. However, vibration detectors are generally classified into acceleration, velocity, and displacement types. These detectors are typically used for conventional, more pronounced vibration intensities. Therefore, traditional methods are not ideal for significantly improving the accuracy of linear laser profiler scanning of wind turbine blades.

[0005] In summary, how to more accurately monitor the motion state of the line laser profile scanner and ensure the parameter accuracy of the line laser profile scanner in scanning the wind turbine blade profile has become a problem that needs to be solved. Summary of the Invention

[0006] In order to solve the above technical problems, the present invention provides a high-precision line laser wind turbine blade contour detection and analysis system, which can more keenly capture tiny changes in motion state. After abnormal motion state occurs, it is convenient to detect problems in a timely and accurate manner, thereby further ensuring the accuracy of wind turbine blade contour scanning.

[0007] To solve the above technical problems, the present invention is achieved through the following technical solutions:

[0008] The present invention provides a high-precision line laser wind turbine blade profile detection and analysis system, including the following contents:

[0009] The line laser profile scanner scans and detects the profile parameters of the wind turbine blade, and the displacement transmission mechanism drives the line laser profile scanner to move.

[0010] (1) The system presets a displacement transmission mechanism to drive the line laser profile scanner through the starting acceleration zone, uniform speed stabilization zone, and stopping deceleration zone. Among them, the wind turbine blades to be detected are placed directly below the uniform speed stabilization zone, and the starting ends of the wind turbine blades to be detected are all located within the uniform speed stabilization zone. In order to ensure that the line laser profile scanner is in a stable motion state when scanning and detecting the wind turbine blades, the starting phase and the stopping phase of the line laser profile scanner are independently assigned to an area. Because the displacement transmission mechanism starts to drive the line laser profile scanner to move and brakes the line laser profile scanner, it may cause the line laser profile scanner to generate corresponding vibrations, so the starting and braking of the line laser profile scanner need to be completely independent, and a buffer area at a certain distance relative to the normal detection area is set.

[0011] (2) A photoelectric receiving module with a CCD light sensing module is fixedly installed on both sides of the displacement transmission mechanism, and the system presets fixed position parameters of the CCD light sensing module relative to the moving path of the linear laser profile scanner.

[0012] (3) The system obtains the position information of the line laser profile scanner in the displacement transmission mechanism in real time.

[0013] (4) The system analyzes the real-time distance parameter L between the line laser profiler and the CCD light sensing module, and adjusts the laser output power P of the horizontal laser module on the corresponding side of the line laser profiler according to the distance parameter L. The real-time laser output power F(P) of the horizontal laser module is equal to the real-time distance parameter L.

[0014] (5) When the line laser profile scanner leaves the starting acceleration zone and enters the uniform speed stable zone, the system obtains the light-sensitive area excited by the horizontal laser module irradiating the CCD light-sensitive module and analyzes the geometric center point M of the light-sensitive area. 起始 :(X 起始 , Y 起始 ).

[0015] (6) The line laser profile scanner enters the uniform speed stable area and moves at a uniform speed. The system obtains the light-sensitive area excited by the CCD light-sensitive module irradiated by the horizontal laser module in real time and analyzes the geometric center point M of the light-sensitive area. 运动 :(X 运动 , Y 运动 ).

[0016] ㈦Analyze the displacement difference of the geometric center point Determine the displacement difference ΔM of the geometric center point and the reference displacement difference ΔM preset by the system 参考 The difference.

[0017] If ΔM≤ΔM 参考 , the motion state of the line laser profile scanner at the current position is stable.

[0018] If ΔM>ΔM 参考 , then the motion state of the line laser profile scanner at the current position is abnormal, and the system marks the current position point W of the line laser profile scanner 异常 After completing a scan and inspection of the entire wind turbine blade, the entire wind turbine blade is scanned and inspected again. If the abnormal motion state occurs at the same position point for at least three consecutive times, an alarm prompt message is output, and the abnormal position point information is output.

[0019] As an optimal technical solution of the present invention: the starting acceleration zone includes the starting stroke starting point, the stopping deceleration zone includes the stopping stroke end point, and the uniform speed stabilization zone includes the uniform speed stroke starting point located at the end position of the starting acceleration zone and the uniform speed stroke end point located at the beginning position of the stopping deceleration zone.

[0020] As a preferred technical solution of the present invention, two photoelectric receiving modules are independently positioned in the peripheral area of ​​the displacement transmission mechanism, and a horizontal laser module is fixedly mounted on each side of the line laser profiler. The CCD light sensing module of one photoelectric receiving module is aligned with the horizontal laser module on one side of the line laser profiler, while the CCD light sensing module of the other photoelectric receiving module is aligned with the horizontal laser module on the other side of the line laser profiler.

[0021] As a preferred technical solution of the present invention: a fixed support frame for fixing the photoelectric receiving module is arranged below the photoelectric receiving module, and the fixed support frame and the displacement transmission mechanism are located on different installation platforms.

[0022] As a preferred technical solution of the present invention: after the line laser profile scanner enters the uniform speed stable area, the system simultaneously obtains the information of the light-sensitive areas excited by the two photoelectric receiving modules, and the geometric center point displacement difference generated by the geometric center point of any light-sensitive area is compared with the reference displacement difference ΔM 参考 When the difference is abnormal, the system determines that the motion state of the line laser profile scanner is abnormal.

[0023] As a preferred technical solution of the present invention, after the line laser profiler enters the stop and deceleration zone, the horizontal laser module ceases to emit laser light, and the line laser profiler stops moving after reaching the end of its travel range in the stop and deceleration zone. When the line laser profiler moves in the reverse direction, the stop and deceleration zone it entered becomes the starting acceleration zone for another scan and test, and the starting acceleration zone during the previous scan and test becomes the stop and deceleration zone.

[0024] As a preferred technical solution of the present invention: when pre-installing the line laser profile scanner, the horizontal laser module and the photoelectric receiving module, a horizontal monitoring device is used to ensure that they are in a horizontal state after installation.

[0025] Compared with the existing technology, the beneficial effects of the present invention are:

[0026] 1. The present invention sets up independent starting and braking phases and provides buffers by presetting the starting acceleration zone, uniform speed stabilization zone and stopping deceleration zone, effectively avoiding the interference of these vibrations on scanning, allowing the scanner to move smoothly in the uniform speed stabilization zone, thereby improving scanning accuracy.

[0027] 2. This method utilizes a photoelectric receiving module and a horizontal laser module to monitor the distance between the line laser profile scanner and the CCD light sensing module in real time, adjusts the laser power to ensure reception, and accurately determines the motion state by analyzing the displacement difference between the geometric center point of the light sensing area and a preset reference displacement difference. Compared to traditional detection methods, this method can more sensitively capture subtle changes in motion state, facilitating timely and accurate detection of motion anomalies, thereby further ensuring the accuracy of wind turbine blade profile scanning.

[0028] 3. In the present invention, the laser is allowed to fall on the area near the center of the CCD light sensing module, which reduces the difficulty of installation and debugging, improves the stability and accuracy of the system after installation, and ensures that the overall performance of the system meets the detection requirements of the motion state of the linear laser profile scanner. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 A dynamic diagram of the blade profile detection and analysis system in the present invention Figure 1 .

[0030] Figure 2 A dynamic diagram of the blade profile detection and analysis system in the present invention Figure 2 .

[0031] Figure 3 for Figure 1 Schematic diagram of the structure with a partial enlargement at point A in the middle.

[0032] Figure 4 A dynamic diagram of the CCD light sensing module in the present invention Figure 1 .

[0033] Figure 5 A dynamic diagram of the CCD light sensing module in the present invention Figure 2 .

[0034] Among them: 1-line laser profile scanner; 2-displacement transmission mechanism, 201-start acceleration zone, 2011-start stroke starting point, 202-uniform speed stabilization zone, 2021-uniform speed stroke starting point, 2022-uniform speed stroke end point, 203-stop deceleration zone, 2031-stop stroke end point; 3-horizontal laser module; 4-wind turbine blade; 5-fixed support frame; 6-photoelectric receiving module; 601-CCD light sensing module, 602-CCD light sensing pixel unit, 603-light sensing area, 604-geometric center point. DETAILED DESCRIPTION

[0035] In order to make the purpose, technical solutions and advantages of the present invention more clear, the following Figures 1 to 5 It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0036] Example 1: The present invention designs a high-precision line laser wind turbine blade profile detection and analysis system. The specific system architecture and core control content are as follows:

[0037] (1) System architecture and hardware layout

[0038] The high-precision line laser wind turbine blade profile detection and analysis system primarily consists of a line laser profile scanner 1, a displacement transmission mechanism 2, a horizontal laser module 3, a photoelectric receiving module 6, and a fixed support frame 5. The line laser profile scanner 1 is the core detection component. It uses the displacement transmission mechanism 2 to move along the length of the wind turbine blade 4, thereby comprehensively scanning the blade profile. The displacement transmission mechanism 2 utilizes a combination of high-precision guide rails and a drive motor to ensure smooth and accurate movement of the line laser profile scanner 1.

[0039] Horizontal laser modules 3 are fixedly mounted on either side of the linear laser profiler 1. Any vibrations from the linear laser profiler 1 are reflected on the horizontal laser modules 3, which then emit laser light to the photoelectric receiver modules 6 on either side. The photoelectric receiver modules 6 are secured to the periphery of the displacement transmission mechanism 2 via fixed supports 5. These fixed supports 5 and the displacement transmission mechanism 2 are mounted on separate platforms to prevent vibrations generated by the movement of the displacement transmission mechanism 2 from being transmitted to the photoelectric receiver modules 6 and affecting detection accuracy.

[0040] (2) Area Division and Motion Control

[0041] The displacement transmission mechanism 2 divides the motion path into a starting acceleration zone 201, a uniform speed stabilization zone 202, and a stopping deceleration zone 203. The starting acceleration zone 201 starts from the starting stroke starting point 2011. The drive motor gradually increases the speed in this zone, so that the line laser profile scanner 1 starts smoothly. Before reaching the uniform speed stroke starting point 2021, the line laser profile scanner 1 can completely reach a stable motion state. The uniform speed stabilization zone 202 is between the uniform speed stroke starting point 2021 at the end of the starting acceleration zone 201 and the uniform speed stroke end point 2022 at the beginning of the stopping deceleration zone 203. In this zone, the line laser profile scanner 1 maintains uniform motion to ensure the accuracy of the scan data. The stopping deceleration zone 203 starts from the uniform speed stroke end point 2022 to the stopping stroke end point 2031. The drive motor controls the line laser profile scanner 1 to gradually decelerate and stop or brake through a corresponding rapid braking method.

[0042] The system achieves precise motion control of the line laser profiler 1 in different areas by controlling the speed and direction of movement of the drive motor. Simultaneously, the system acquires real-time position information of the line laser profiler 1 on the displacement transmission mechanism 2. This is achieved through a position sensor (such as a grating ruler) mounted on the guide rail, allowing subsequent detection and control operations based on this position information.

[0043] (3) Photoelectric detection and laser power adjustment

[0044] The CCD light sensing module 601 in the photoelectric receiving module 6 is composed of a large number of CCD photosensitive pixel units 602 distributed in a matrix, and each pixel unit has a preset coordinate position.

[0045] When the line laser profile scanner 1 moves, the system analyzes the distance parameter L between it and the CCD light sensing module 601 in real time.

[0046] The laser output power P of the horizontal laser module 3 is adjusted based on the distance parameter L. Specifically, the relationship is F(P)∝L, meaning that the longer the distance, the greater the laser output power. By adjusting the laser power, the CCD light sensor module 601 can effectively and accurately receive the laser radiation emitted by the horizontal laser module 3, thereby accurately determining the motion state of the line laser profiler 1.

[0047] ㈣Motion status monitoring and exception handling

[0048] When the line laser profile scanner 1 leaves the starting acceleration zone 201 and enters the uniform speed stable zone 202, the system obtains the light sensing area 603 excited by the horizontal laser module 3 irradiating the CCD light sensing module 601 and determines its geometric center point M start (X 起始 , Y 起始 In the uniform stability zone 202, the system continuously obtains the movement of the geometric center point M of the light sensing area 603 (X 运动 , Y运动 ), calculate the displacement difference of the geometric center point

[0049] Compare ΔM with the preset reference displacement difference ΔM 参考 Compare. If ΔM≤ΔM 参考 , indicating that the motion state of the line laser profile scanner 1 is stable and normal scanning and detection can continue (the normal scanning here refers to the normal scanning without abnormal position points. If abnormal position points appear, the scanning will continue).

[0050] If ΔM > ΔM reference, the current location W is marked as abnormal. After completing a scan of wind turbine blade 4, the system automatically rescans the entire blade 4. If the same location W is abnormal three or more times in a row, the system outputs an alarm and records the abnormal data for subsequent analysis.

[0051] like Figure 4 , when the line laser profile scanner leaves the starting acceleration zone and enters the uniform speed stable zone, the light sensing area where the CCD light sensing module is excited is [S 11 ~S 44 ], the geometric center point falls into S 32 Position, the geometric center point M of the light-sensing area 起始 It's S 32 .

[0052] like Figure 5 When the line laser profile scanner moves in the uniform stability zone, at any moment, the photosensitive area of ​​the CCD photosensitive module excited is [S 12 , S 13 , S 14 , S 15 , S 22 , S 23 , S 24 , S 25 , S 32 , S 33 , S 34 , S 35 , S 42 , S 43 , S 44 , S 45 ], the geometric center point falls into S 13 Position, the geometric center point M of the light-sensing area 运动 It's S 13 .

[0053] Then analyze the displacement difference ΔM of the geometric center point and the difference ΔM from the reference displacement preset by the system. 参考 The difference between the two values ​​can be used to determine whether the motion state of the line laser profile scanner is abnormal.

[0054] (V) System operation under special working conditions

[0055] When the line laser profile scanner 1 enters the stop and deceleration zone 203, the system controls the horizontal laser module 3 to stop emitting laser light, which can reduce energy consumption and avoid unnecessary laser irradiation. After reaching the stop stroke end 2031, the line laser profile scanner 1 stops moving.

[0056] When reverse scanning detection is required, the original stop deceleration zone 203 entered by the line laser profile scanner 1 becomes the new start acceleration zone 201, and the original start acceleration zone 201 becomes the new stop deceleration zone 203. The system adjusts the motion control and detection logic accordingly to ensure the smooth progress of the reverse scanning detection.

[0057] (6) Installation, debugging and accuracy assurance

[0058] When installing the line laser profile scanner 1, the horizontal laser module 3, and the photoelectric receiving module 6, use a high-precision level monitoring device (such as a level or electronic level) to ensure that they are in a horizontal state after installation. The laser emitted by the horizontal laser module 3 does not need to be precisely aligned with the center position of the CCD light sensing module 601; as long as it can fall in an area close to the center position of the CCD light sensing module 601, it can be installed more easily. During the system debugging phase, each component is calibrated and optimized, including laser power calibration, CCD light sensing module 601 pixel coordinate calibration, etc., to ensure that the system can meet the high-precision wind turbine blade profile detection requirements during operation.

[0059] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. High-precision line laser wind turbine blade profile detection and analysis system. The line laser profile scanner scans and detects the profile parameters of wind turbine blades. The displacement transmission mechanism drives the line laser profile scanner to move. It is characterized by: (1) The system presets a displacement transmission mechanism to drive the linear laser profile scanner through a starting acceleration zone, a uniform speed stabilization zone, and a stopping deceleration zone; The wind turbine blades to be tested are placed directly below the uniform speed stability zone, and the starting ends of the wind turbine blades to be tested are all within the uniform speed stability zone; (ii) A photoelectric receiving module with a CCD light sensing module is fixedly installed on both sides of the displacement transmission mechanism, and the system presets fixed position parameters of the CCD light sensing module relative to the moving path of the line laser profile scanner; Two photoelectric receiving modules are independently configured in the peripheral area of ​​the displacement transmission mechanism, and a horizontal laser module is fixedly installed on both sides of the line laser profile scanner; The CCD light sensing module of one photoelectric receiving module is aligned with the horizontal laser module on one side of the line laser profile scanner, and the CCD light sensing module of the other photoelectric receiving module is aligned with the horizontal laser module on the other side of the line laser profile scanner; (3) The system obtains the position information of the line laser profile scanner in the displacement transmission mechanism in real time; (iv) The system analyzes the real-time distance parameter L between the line laser profile scanner and the CCD light sensing module, and adjusts the laser output power P of the horizontal laser module on the corresponding side of the line laser profile scanner according to the distance parameter L; Among them, the real-time laser output power F(P) of the horizontal laser module ∝ the real-time distance parameter L; When the line laser profile scanner leaves the starting acceleration zone and enters the uniform speed stable zone, the system obtains the light-sensitive area excited by the horizontal laser module irradiating the CCD light-sensitive module and analyzes the geometric center point M of the light-sensitive area. 起始 :(X 起始 , Y 起始 ); ㈥The line laser profile scanner enters the uniform speed stable area and moves at a uniform speed. The system obtains the light-sensing area excited by the horizontal laser module to the CCD light-sensing module in real time and analyzes the geometric center point M of the light-sensing area. 运动 :(X 运动 , Y 运动 ); ㈦Analyze the displacement difference of the geometric center point Determine the displacement difference ΔM of the geometric center point and the reference displacement difference ΔM preset by the system 参考 The difference between If ΔM≤ΔM 参考 , then the motion state of the line laser profile scanner at the current position is stable; If ΔM>ΔM 参考 , then the motion state of the line laser profile scanner at the current position is abnormal, and the system marks the current position point W of the line laser profile scanner 异常 After completing a scan and inspection of the entire wind turbine blade, the entire wind turbine blade is scanned and inspected again. If the abnormal motion state occurs at the same position point for at least three consecutive times, an alarm prompt message is output, and the abnormal position point information is output.

2. The high-precision line laser wind turbine blade profile detection and analysis system according to claim 1 is characterized by: in, The starting acceleration zone includes the starting stroke starting point, the stopping deceleration zone includes the stopping stroke end point, and the uniform speed stabilization zone includes the uniform speed stroke starting point located at the end position of the starting acceleration zone and the uniform speed stroke end point located at the beginning position of the stopping deceleration zone.

3. The high-precision line laser wind turbine blade profile detection and analysis system according to claim 1 is characterized by: A fixed support frame for fixing the photoelectric receiving module is arranged below the photoelectric receiving module, and the fixed support frame and the displacement transmission mechanism are located on different installation platforms.

4. The high-precision line laser wind turbine blade profile detection and analysis system according to claim 1 is characterized by: After the line laser profile scanner enters the uniform speed stable area, the system simultaneously obtains the light-sensing area information excited by the two photoelectric receiving modules. The geometric center point displacement difference generated by the geometric center point of any light-sensing area and the reference displacement difference ΔM 参考 When the difference is abnormal, the system determines that the motion state of the line laser profile scanner is abnormal.

5. The high-precision line laser wind turbine blade profile detection and analysis system according to claim 1 is characterized by: After the line laser profile scanner enters the stop and deceleration zone, the horizontal laser module does not need to continue emitting laser light, and the line laser profile scanner stops moving after reaching the end of the stop stroke in the stop and deceleration zone; When the line laser profile scanner moves in the reverse direction, the stop deceleration zone that the line laser profile scanner enters becomes the start acceleration zone for scanning and detecting again, and the start acceleration zone during the last scanning and detecting becomes the stop deceleration zone.

6. The high-precision line laser wind turbine blade profile detection and analysis system according to claim 1 is characterized by: When pre-installing the line laser profile scanner, horizontal laser module, and photoelectric receiving module, use a level monitoring device to ensure that they are in a level state after installation.

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