A method for intelligent monitoring of speed controllers

Abstract

This invention relates to the field of hydropower technology and discloses an intelligent monitoring method for a governor, comprising: deploying signal acquisition components and actuators; forming a continuous curve over time based on signal data acquired by the signal acquisition components; wherein the signal data includes oil pressure, flow rate, oil temperature, oil level, oil quality, noise, odor, opening degree, current, and voltage; performing fault diagnosis and early warning based on the continuous curve and / or video data acquired by the infrared camera; and activating an emergency response plan and performing emergency response operations when the set activation conditions are met, based on the real-time acquired signal data. This invention can further improve safety and reliability and make its operation management, maintenance, and repair work as intelligent as possible, thereby ensuring the long-term stable operation of the hydropower station.

Description

Technical Field

[0001] This invention relates to the field of hydropower technology, and in particular to a method for intelligent monitoring of speed governors. Background Technology

[0002] Small hydropower has evolved into a clean, carbon-free, and environmentally friendly renewable energy source, becoming an indispensable part of the power industry. As a key component of small hydropower, the speed governor has undergone significant technological advancements, evolving from fully manual to electromechanical-hydraulic and then to microcomputer-based speed governors. With the continuous development of AI technology, speed governors require further modifications and upgrades to ensure safer, more comprehensive, and more intelligent operation.

[0003] As a key device for regulating water flow, the governor's accurate and timely control of water volume is a fundamental condition for ensuring normal power generation. In emergency shutdowns, closing the guide vanes too slowly can lead to excessive speed and equipment damage, while closing the governor too quickly can cause excessive water hammer in the pressure pipeline, resulting in a major safety accident such as pipe rupture. In special circumstances such as system disconnection and all units shutting down due to accidents, resulting in the loss of plant power, the governor's ability to maintain sufficient oil pressure to ensure the restoration of plant power is a critical factor for the safety of small hydropower plants. Furthermore, when many small hydropower plants shed load at remote points in the system, because the collected grid frequency and generator frequency are equal, the governor may not adjust its opening to reduce the speed in time, only initiating emergency adjustment when the speed becomes too high, potentially leading to runaway accidents. Improper operation during maintenance can also cause safety accidents.

[0004] Most of the speed governors currently in use are microcomputer-based, and while their technology has improved, various factors, including software and hardware, result in low reliability and significant safety risks. They generally do not meet the technical requirements for "unmanned operation." Furthermore, there is a severe shortage of skilled personnel in speed governor operation at various power plants, making operation and maintenance difficult. Even if "unmanned operation or minimal staffing" is implemented, the safety risks remain substantial. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent monitoring method for speed governors to further improve safety and reliability, and to make their operation management, inspection and maintenance as intelligent as possible, thereby ensuring the long-term stable operation of hydropower stations.

[0006] To achieve the above objectives, the following technical solution is adopted:

[0007] A method for intelligent monitoring of a speed controller, the method comprising:

[0008] The signal acquisition components are deployed as follows: oil pressure sensors and flow meters are installed on the governor's oil filling pipe, oil supply pipe, and oil return pipe, respectively; an opening sensor and a noise meter are installed in the water turbine room; an infrared camera is installed on the top of the governor's oil tank; an infrared thermometer, a noise meter, and an electronic nose are installed outside the oil pump motor; a switching current transformer and a voltage transformer are installed in the main electrical circuit of the oil pump motor, respectively; and switching current transformers are installed in the secondary circuit of the generator outlet current transformer and the secondary circuit of the current transformer on the power grid line.

[0009] Based on the signal data collected by the signal acquisition component, a continuous curve is formed over time; wherein, the signal data includes at least one of oil pressure, flow rate, oil temperature, oil level, oil quality, noise, odor, opening degree, current, and voltage;

[0010] Fault diagnosis and early warning are performed based on the continuous curve and / or the video data collected by the infrared camera;

[0011] Based on the set activation conditions and real-time collected signal data, the emergency response plan is activated when the set activation conditions are met.

[0012] Furthermore, based on the continuous curve and / or the video data acquired by the infrared camera, fault diagnosis and early warning are performed, including:

[0013] When the oil pressure drops to the first oil pressure threshold and oil flows out of the filling pipe, an emergency oil pressure warning is triggered.

[0014] When the oil pressure rises to the second oil pressure threshold, the oil pump motor has operating current and oil flows out of the filling pipe, an oil pressure over-risk warning is triggered.

[0015] When the oil pressure drops to the third oil pressure threshold and the main pump motor has no operating current, or when the oil pressure drops to the fourth oil pressure threshold and the standby pump motor has no operating current, or when the oil pressure rises to the fifth oil pressure threshold and the oil pump motor has operating current, or when the oil pump motor has operating current, the speed governor oil pressure does not rise and there is no oil flow in the oil supply pipe, or when the oil pump motor has operating current and there is no oil flow in the oil supply pipe, the average oil pressure rise rate is slower than before and exceeds the set threshold, or when the oil pump current is larger than the normal operating current or there is a phase loss, an abnormal oil supply warning will be issued.

[0016] When the oil pump motor operating current lasts for more than the set time, the flow meter detects that the amount of oil entering the oil storage tank increases beyond the set threshold, and the oil level in the tank decreases, a capsule abnormality warning is triggered.

[0017] When there is no oil flowing out of the oil supply pipe, the oil pressure drops and / or the oil level in the oil tank drops successively, and the oil supply volume of the oil supply pipe is greater than the oil return volume of the oil return pipe for multiple time periods, a pipeline oil leakage warning will be issued.

[0018] Based on the ambient temperature and oil temperature change curves, when the ambient temperature remains unchanged or decreases, the oil temperature in the oil tank rises. When the oil temperature exceeds 40°C, an abnormal oil temperature warning is issued.

[0019] When the speed controller receives a command that there is no oil flow in both the oil supply pipe and the oil return pipe and / or the valve does not operate, but there is oil flow in both the oil supply pipe and the oil return pipe, it will execute a valve failure warning.

[0020] When any signal acquisition component interrupts data upload or continuously generates abnormal data, an input information abnormality warning is executed.

[0021] When the guide vane opening changes continuously, the valve operates continuously, and there is oil flow in both the oil supply pipe and the oil return pipe, an opening slippage warning is executed.

[0022] When the ammeter, voltmeter, and wattmeter oscillate periodically and the oscillation amplitude exceeds the set amplitude, a system oscillation warning will be issued.

[0023] When the unit is running under load, if the guide vane opening gradually decreases without adjustment, a load slip warning will be issued.

[0024] When a remote governor operation command is detected, and there is no oil flow in the oil supply pipe and return pipe, and the guide vane opening does not change, a remote control failure warning is issued.

[0025] When the speed governor is running automatically in no-load condition and the frequency of the generator unit cannot be stabilized within the set frequency threshold range, an no-load frequency warning will be issued.

[0026] When an abnormal odor is detected exceeding the standard, an odor abnormality warning will be issued;

[0027] When a sound type or volume exceeds the limit, a sound anomaly warning will be issued.

[0028] Furthermore, based on the continuous curve and / or the video data acquired by the infrared camera, fault diagnosis and early warning are performed, including:

[0029] The following methods can be used to diagnose malfunctions in the hydraulic system's capsule:

[0030] Based on theoretical calculations and actual measurements, the function curves of the filling amount and capsule pressure of the two capsules and the function curve of the filling amount and time were obtained, and the total filling amount V0 of the two capsules from the pump start-up oil pressure to the rated oil pressure was calculated.

[0031] During actual operation, each time the pressure oil rises from the pump start-up pressure to the rated oil pressure, the flow rate measured by the flow meter and the corresponding time are used to calculate the actual oil filling amount V1 and compare it with the total oil filling amount V0 during the commissioning. If the difference exceeds the normal error and the oil filling time has increased compared to before, an abnormal capsule warning will be issued.

[0032] The actual oil filling amount of the faulty capsule is obtained by subtracting the oil filling amount V0 / 2 of one or two capsules during the original debugging from the actual oil filling amount. The function curve of the oil filling amount and capsule pressure obtained during debugging is used to verify the value and calculate the residual pressure value of the faulty capsule.

[0033] Based on the oil filling volume versus time function curve obtained from the debugging, the two pumps were started to pump oil separately. The pump with the shorter pumping time was identified, and the capsule closest to the pump with the shorter pumping time was identified as the faulty capsule.

[0034] Furthermore, before debugging based on theoretical calculations and actual measurements, methods for determining the bladder malfunction of the hydraulic system also include:

[0035] Ensure that two capsules of the same model are filled with nitrogen at the same pressure, and set that two pressure oil tanks of the same model have the same volume and are directly connected.

[0036] When the oil pump fills the oil tank with pressurized oil, the pressure on the two capsules is equal, the volume of nitrogen gas inside the capsules that is compressed and contracted is equal, and the volume of pressurized oil filled into the two pressure oil tanks is also equal.

[0037] Furthermore, based on the continuous curve and / or the video data acquired by the infrared camera, fault diagnosis and early warning are performed, including:

[0038] Based on the real-time monitoring of the three-phase current of the grid-connected line, when the three-phase current suddenly and rapidly drops to zero, and the rate of change and the starting point of change both exceed the set values, and the unit frequency and voltage rise rapidly, and the generator output circuit breaker is in the closed state, a remote load shedding alarm is immediately issued.

[0039] Furthermore, in the case of pipeline oil leak early warning, the method also includes: determining the amount of oil leak based on the difference in time function.

[0040] Furthermore, the amount of oil leakage is determined based on the time function of the leakage difference, including:

[0041] The amount of oil leakage in the oil pipeline per unit time is calculated by the difference between the equivalent oil supply to the servo unit by the oil supply pipeline and the oil return volume by the return pipeline per unit time.

[0042] When the amount of oil leakage in the pipeline exceeds the normal metering error per unit time, an oil leakage warning is immediately issued. Based on the leakage start time and using the difference in time function, the amount of oil that has been leaked is calculated.

[0043] Furthermore, based on the continuous curve and / or the video data acquired by the infrared camera, fault diagnosis and early warning are performed, including:

[0044] Under various power supply voltages, based on the current change during the process of the oil pressure rising from the start-up pressure to the rated oil pressure after the oil pump starts, multiple sets of current-time curves are formed and stored.

[0045] The actual current-time curve is obtained by detecting the power supply voltage, starting current, normal operating current and duration.

[0046] By comparing the actual current-time curve with the stored current-time curve, when multiple actual starting currents and operating currents are detected to be significantly higher than the stored curve current, or when a phase loss occurs and lasts for more than 2 seconds, or when a short circuit current occurs, or when the current exceeds the stall current and lasts for more than 1 second, an oil pump fault warning is immediately issued and the oil pump is controlled to stop running.

[0047] Furthermore, based on the set activation conditions and according to the real-time collected signal data, when the set activation conditions are met, the emergency response plan is activated, including:

[0048] When the speed governor executes the rapid oil supply command, and the speed governor oil pressure is lower than the sixth oil pressure threshold and the working pump motor has no working current, the backup oil pump is started in advance to pump oil, and stops pumping oil after the set pressure is reached.

[0049] When the plant's power supply is cut off due to an accident and the oil pressure drops to the starting pressure, immediately switch on the emergency power supply to pump oil.

[0050] When the ammeter, voltmeter, and wattmeter oscillate periodically, the opening degree is fixed after reducing the active load;

[0051] When the three-phase current of the outgoing current transformer is zero at the same time, the duration of the simultaneous zeroing is more than 10 seconds, the current in the 3 seconds before the simultaneous zeroing is not less than 10% of the rated current, and the unit frequency and voltage rise rapidly after the three-phase current is zero at the same time, an adjustment guide vane command is sent to the speed controller to limit the unit frequency to the set frequency threshold in advance.

[0052] If the oil pressure exceeds the set oil pressure threshold and the oil pump motor has normal operating current, the normally closed circuit of the oil pump thermal relay will be disconnected through the passive node after a 1-second delay, forcibly stopping the working oil pump.

[0053] If the oil pump motor current reaches the stall current or above, and there is no oil entering or exiting the oil filling pipe, and the oil filling pipe pressure does not rise, the normally closed circuit of the oil pump thermal relay is disconnected through the passive node after a 1-second delay, forcibly stopping the working oil pump.

[0054] If the short-circuit current does not disappear after an appropriate delay following the detection of an external short circuit, the active power is reduced to no-load, an external short circuit is triggered, and the switch fails to trip alarm.

[0055] The beneficial effects of this invention are:

[0056] This system monitors and verifies the correctness of the operation and maintenance process, effectively preventing misoperation and improving the intelligence level of the speed governor. It not only reduces labor intensity, increases work efficiency, and enhances the technical level of the speed governor, but also improves equipment safety performance through upgrades, significantly reducing safety risks and effectively preventing accidents.

[0057] This is mainly reflected in the following six aspects:

[0058] 1. More comprehensive operation monitoring

[0059] The current monitoring of small hydropower mainly focuses on the governor oil pressure and guide vane opening. However, this system also monitors oil level, oil temperature, oil quality, sound, odor, oil flow, motor current and duration, video, etc., making the monitoring content more comprehensive.

[0060] 2. More timely information feedback

[0061] Because all measuring elements in this system are installed independently and use real-time monitoring, the feedback time can be less than one second, which is much faster and more timely than the current manual monitoring. Through data analysis and calculation, the system can provide early warnings of equipment failures, allowing staff to detect problems before they occur and intervene or handle them in a timely manner, preventing equipment failures or accidents from happening at all.

[0062] 3. More accurate analysis and judgment

[0063] This system accurately determines the current status of the speed governor by independently installing multiple high-precision measuring devices and using various detection methods for mutual verification. This effectively avoids data errors caused by component failures or situations where communication interruptions of a measuring component prevent accurate assessment. For example, whether the oil pump is pumping oil can be detected through four completely different methods: motor main circuit current, oil filling pipe flow rate, oil tank level change, and oil pump sound. This effectively prevents misjudgments caused by faults in a single measuring circuit. Furthermore, while current small hydropower stations cannot detect capsule malfunctions during normal operation, this system can not only identify capsule malfunctions during normal operation but also pinpoint the specific capsule malfunction and calculate the current residual pressure value of the faulty capsule.

[0064] 4. More convenient information exchange

[0065] Through voice interaction devices, human-computer voice dialogue can be realized, and notifications can be sent directly to mobile phone text messages, enabling staff to make various choices or operations more quickly and conveniently, thereby improving work efficiency.

[0066] 5. Higher safety and reliability

[0067] During normal operation, this system can intervene in advance through advanced fault warning or emergency response functions, eliminating potential causes of accidents before they occur. Transparent safety covers are added to all fault-prone points at pipeline joints, ensuring that routine inspections are not hindered and that personnel are not directly injured in the event of accidental injection of pressurized oil. Furthermore, the addition of maintenance safety locks provides reliable safety measures during the implementation of the "two-ticket, three-system" procedure, effectively preventing accidents caused by misoperation during maintenance and achieving inherent safety for the speed governor.

[0068] 6. Higher work efficiency

[0069] This system uses artificial intelligence to replace professional personnel, and can perform multiple tasks simultaneously, such as operation monitoring, inspection, fault diagnosis, and emergency response. Not only are there many tasks, but the completion speed is also fast, resulting in high work efficiency. Attached Figure Description

[0070] Figure 1 This is a flowchart of a speed controller intelligent monitoring method according to an embodiment of the present invention.

[0071] Figure 2 The flowchart for performing fault diagnosis and early warning according to an embodiment of the present invention is shown. Figure 1 .

[0072] Figure 3 The flowchart for performing fault diagnosis and early warning according to an embodiment of the present invention is shown. Figure 2 .

[0073] Figure 4 A flowchart illustrating the execution of fault diagnosis and early warning according to an embodiment of the present invention is shown.

[0074] Figure 5 An overall structural diagram of an intelligent speed controller according to an embodiment of the present invention is shown.

[0075] Figure 6 A side view of an intelligent speed controller according to an embodiment of the present invention is shown.

[0076] Figure 7 A front view of an intelligent speed controller according to an embodiment of the present invention is shown. Detailed Implementation

[0077] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that, unless otherwise specified, the following embodiments and features described therein can be combined with each other.

[0078] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples.

[0079] This invention provides an intelligent monitoring method for speed governors. Based on the actual conditions of speed governors in the actual operation of hydropower stations, an intelligent monitoring system (hereinafter referred to as "this system") is constructed using various measuring elements, video equipment, intelligent monitors, actuators, and related connecting pipelines or wires. According to the working principles of each component or part of the speed governor, various operating parameters of the speed governor are determined through comprehensive analysis of multiple factors and comparison of full-cycle data curves. Intelligent equipment replaces on-duty personnel in completing all or part of the tasks such as operation monitoring, inspection, periodic meter reading, fault self-diagnosis, maintenance work guidance, early warning of accidents or faults, intelligent control, and emergency response. Furthermore, it enables voice dialogue interaction between humans and equipment through artificial intelligence.

[0080] like Figure 1 The diagram shown is a flowchart of a speed governor intelligent monitoring method according to an embodiment of the present invention. The speed governor intelligent monitoring method includes the following steps:

[0081] S100. The signal acquisition components are deployed as follows: oil pressure sensors and flow meters are installed on the governor's oil filling pipe, oil supply pipe, and oil return pipe, respectively; an opening sensor and a noise meter are installed in the water turbine room; an infrared camera is installed on the top of the governor's oil tank; an infrared thermometer, a noise meter, and an electronic nose are installed outside the oil pump motor; a switching current transformer and a voltage transformer are installed in the main electrical circuit of the oil pump motor, respectively; and a switching current transformer is installed in the secondary circuit of the generator outlet current transformer and the secondary circuit of the current transformer on the power grid line.

[0082] S200. Based on the signal data collected by the signal acquisition component, a continuous curve is formed over time; wherein, the signal data includes oil pressure, flow rate, oil temperature, oil level, oil quality, noise, odor, opening degree, current, and voltage.

[0083] It should be noted that the above-mentioned signal data such as oil pressure, flow rate, oil temperature, oil level, oil quality, noise, odor, opening degree, current, and voltage are collected by various signal acquisition components. The signal data collected by each signal acquisition component are formed into a continuous curve over time, resulting in multiple sets of signal time curves of signal data collected by different signal acquisition components. In subsequent steps, these signal time curves will be used to perform automated fault diagnosis and early warning and serve as the basis for initiating emergency response plans.

[0084] In some embodiments, the intelligent monitoring method for the speed governor further includes: installing maintenance anti-misoperation locks on the speed governor's main oil supply valve and pressure relief valve, and connecting the position information and electromagnetic command transmission line to the speed governor's intelligent monitor to provide reliable interlocking for the speed governor's maintenance safety. Transparent protective covers are installed at each high-pressure pipeline joint to ensure that high-pressure oil does not fly arbitrarily and injure people in the event of an accident.

[0085] S300. Perform fault diagnosis and early warning based on the continuous curve and / or the video data collected by the infrared camera.

[0086] For example, the intelligent controller communicates with the power plant's existing microcomputer monitoring system to obtain unit operating parameters and the transmission and reception of speed control valve action commands. In this application scenario, the speed controller monitor sets normal ranges for relevant operating data under various states according to the actual power plant operating procedures. First, it uses real-time monitored operating parameters combined with odor and sound detection to check for abnormalities in the speed controller. Then, it uses cameras to monitor key parts of the speed controller in real time and judges whether the speed controller's appearance is normal through image comparison. When a comprehensive judgment is made and normality is confirmed, the operating indicator lights up green; otherwise, the operating indicator lights up red, thus realizing intelligent monitoring of speed controller operation. The speed controller monitor uploads key operating data to the microcomputer monitoring host computer in real time. Since the host computer automatically saves the data every hour, it realizes intelligent meter reading.

[0087] In some embodiments, cameras can be used for regular inspections to fully check the appearance of the speed controller and read relevant meter parameters. This includes checking for oil leaks, foreign object intrusion, and any remaining foreign objects. By combining this information with data on temperature, noise, and odor, the system can comprehensively determine whether the speed controller is operating normally, thus achieving intelligent inspection.

[0088] In some embodiments, such as Figure 2 and Figure 3 As shown, fault diagnosis and early warning are performed based on the continuous curve and / or the video data collected by the infrared camera, including the following steps S201 to S215.

[0089] S201. When the oil pressure drops to the first oil pressure threshold and oil flows out of the filling pipe, an emergency oil pressure warning is executed.

[0090] S202. When the oil pressure rises to the second oil pressure threshold, the oil pump motor has working current and oil flows out of the oil filling pipe, an oil pressure over-high warning is executed.

[0091] S203. When the oil pressure drops to the third oil pressure threshold and the main pump motor has no operating current, or when the oil pressure drops to the fourth oil pressure threshold and the standby pump motor has no operating current, or when the oil pressure rises to the fifth oil pressure threshold and the oil pump motor has operating current, or when the oil pump motor has operating current, the speed governor oil pressure does not rise and there is no oil flow in the oil supply pipe, or when the oil pump motor has operating current and there is no oil flow in the oil supply pipe, the average oil pressure rise rate is slower than before and exceeds the set threshold, or when the oil pump current is larger than the normal operating current or there is a phase loss, an abnormal oil supply warning will be executed.

[0092] S204. When the oil pump motor operating current lasts for more than the set time, the flow meter detects that the amount of oil entering the oil storage tank increases beyond the set threshold, and the oil level in the tank decreases, a capsule abnormality warning is executed.

[0093] S205. When there is no oil flowing out of the oil supply pipe, the oil pressure drops and / or the oil level in the oil tank drops successively, and the oil supply volume of the oil supply pipe is greater than the oil return volume of the oil return pipe for multiple time periods, a pipeline oil leakage warning shall be executed.

[0094] S206. Based on the ambient temperature and oil temperature change curves, when the ambient temperature remains unchanged or decreases, the oil temperature in the oil tank rises, and when the oil temperature exceeds 40°C, an abnormal oil temperature warning is issued.

[0095] S207. When the speed controller receives a command that there is no oil flow in both the oil supply pipe and the oil return pipe and / or the valve does not operate, but there is oil flow in both the oil supply pipe and the oil return pipe, a valve fault warning is executed.

[0096] S208. When any signal acquisition component interrupts data upload or continuously generates abnormal data, execute an input information abnormality warning.

[0097] S209. When the guide vane opening changes continuously and the valve operates continuously, and there is oil flow in both the oil supply pipe and the oil return pipe, execute the opening pumping warning.

[0098] S210. When the ammeter, voltmeter, and wattmeter oscillate periodically and the oscillation amplitude exceeds the set amplitude, a system oscillation warning will be issued.

[0099] S211. When the unit is running under load, if the guide vane opening gradually decreases without adjustment, a load slip warning will be executed.

[0100] S212. When a remote governor operation command is detected, and there is no oil flow in the oil supply pipe and return pipe, and the guide vane opening does not change, a remote control failure warning is executed.

[0101] S213. When the speed governor is running automatically in no-load condition and the frequency of the generator unit cannot be stabilized within the set frequency threshold range, an no-load frequency warning is executed.

[0102] S214. When an abnormal odor is detected exceeding the standard, an odor abnormality warning will be issued;

[0103] S215. When the sound type or volume exceeds the limit, execute the sound abnormality warning.

[0104] It should be noted that the above steps S201 to S215 can be implemented by a speed controller intelligent monitor configured on the basis of the original speed controller. Steps S201 to S215 are not executed sequentially, but in parallel. That is, each time the measured signal data (continuous curve or video data) is received, steps S201 to S215 are judged simultaneously, thereby improving the efficiency of data processing.

[0105] After the fault diagnosis and warning are processed through steps S201 to S215, different operations will be performed according to the determined warning type. For example, a display can be added to show the warning content and handling suggestions when the fault diagnosis and warning are processed, as shown in Table 1 below.

[0106] Table 1 Fault Diagnosis and Early Warning Items

[0107]

[0108]

[0109]

[0110] Therefore, this invention can monitor the operating status of the speed governor from multiple aspects during normal operation by real-time monitoring of various operating parameters such as oil level, oil temperature, oil quality, sound, odor, oil flow, motor current and duration, and video. By using preset programs to compare the time function curves of each parameter and the upper and lower limit values, abnormal situations can be detected in a timely manner, and potential accidents or faults can be detected in advance. This gives the staff enough time to eliminate hidden dangers and eliminate accidents in their infancy, thus changing the maintenance work from "accident maintenance" to "condition maintenance".

[0111] In some embodiments, accurate diagnosis of hydraulic device capsule faults can be achieved based on the signal data collected in step S200. Specifically, due to their small volume and limited cost, small hydropower hydraulic device capsules are not equipped with pressure monitoring, and the capsules are always sealed in the oil tank during operation, making them unobservable until a major problem occurs and affects operation. After this modification, the pressure of nitrogen filling two identical capsules is made equal, and the two identical oil tanks are set to have equal volumes and are directly connected. When the oil pump fills the oil tanks with pressurized oil, the pressure on the capsules in the two oil tanks is equal, and the volume of nitrogen gas inside the capsules under pressure is also equal. Therefore, the volume of pressurized oil filled in the two pressure oil tanks is also equal. After the system modification, the flow meter on the oil filling pipeline allows for debugging during installation and commissioning through a combination of theoretical calculations and actual measurements. Individual capsules are used to measure the oil filling volume (calculated by integrating the flow rate and time duration at different pressures as the pump fills the pressure oil from the start-up pressure of 13.5 MPa to the rated oil pressure of 16 MPa) and the oil pressure change curves, generating oil filling volume-pressure function curves and oil filling volume-time function curves. Then, two capsules are filled with nitrogen to the rated pressure and equal pressures. Different oil pumps are then used to fill the two oil tanks (from 13.5 MPa to the rated oil pressure of 16 MPa), generating oil filling volume-pressure function curves and oil filling volume-time function curves for each pump. The total oil filling volume V0 for the two pressure oil tanks from 13.5 MPa to the rated oil pressure of 16 MPa is calculated, as is the required oil filling volume V0 / 2 for each pressure oil tank from 13.5 MPa to the rated oil pressure of 16 MPa.

[0112] During actual operation, each time the pressurized oil pressure increases from the pump start-up pressure of 13.5 MPa to the rated oil pressure of 16 MPa, the actual filling volume V1 is calculated using the flow rate measured by the flow meter and the corresponding time. This is compared with the filling volume V0 from the initial commissioning. If the difference exceeds the normal error range (e.g., 10%) and the filling time has significantly increased, a capsule malfunction warning is issued. By subtracting the initial commissioning filling volume V0 / 2 from the actual filling volume of one oil tank, the actual filling volume of the faulty capsule is obtained. This is then checked using the existing capsule filling volume-pressure function curve to calculate the residual pressure value of the faulty capsule. Furthermore, considering the different oil supply path lengths when different oil pumps start, the faulty capsule takes longer to fill from different paths. Combining the filling volume-time function curves measured during commissioning, comparing the starting time of the two pumps, the pump with the shorter start-up time is closer to the faulty capsule, thus identifying which capsule has malfunctioned. In summary, this method can not only detect capsule malfunctions that were previously impossible to identify, but also determine which capsule is malfunctioning and the current pressure in MPa, thus accurately diagnosing capsule malfunctions in hydraulic systems.

[0113] In some embodiments, during the fault diagnosis and early warning process, the remote load shedding is determined by setting the rate of change of the current to zero. Specifically, when a small hydropower unit suddenly sheds load, the three-phase current rapidly becomes zero, and the unit frequency and voltage rise rapidly with a considerable rate of change. During normal operation, the current will not be reduced to exactly zero when the load is increased or decreased; even if it is reduced to zero, the decrease is slow, and the current before the circuit breaker is disconnected is generally less than 10% of the rated value. This system monitors the three-phase current of the grid-connected line in real time. When it detects that the three-phase current suddenly and rapidly becomes zero, and the rate of change and the starting point of change both exceed the set values, and the unit frequency and voltage rise rapidly, and the generator outlet circuit breaker is in the closed state, it immediately issues a remote load shedding alarm.

[0114] In some embodiments, the oil leakage is determined by an equivalent quantity difference-time function. Specifically, flow meters are installed in the filling, supply, and return oil lines. The oil leakage per unit time can be calculated by the difference between the equivalent oil supply from the supply line to the relay unit per unit time (first, the volume of oil per unit volume at each pressure is measured experimentally, and then compared with the volume at the original pressure to obtain the volume coefficient, ultimately forming a pressure-coefficient curve; then, the measured oil supply at each pressure is converted into unpressurized oil volume using the pressure-coefficient curve, which is the equivalent oil volume) and the return oil volume from the return oil line. When the calculated oil leakage exceeds the normal measurement error, an oil leakage warning is immediately issued. Based on the leak initiation time and the product of the oil volume difference per unit time and the time duration, the amount of oil already leaked is calculated.

[0115] In some embodiments, a current method is used for oil pump fault diagnosis. Specifically, current transformers and voltage transformers are added to the main circuit of the oil pump motor to monitor the changes in current and voltage during normal start-up and oil filling. Under various power supply voltages, the current changes as the oil pressure rises from 13.5 MPa to 16 MPa after pump start-up are recorded, forming and storing multiple sets of current-time curves. By detecting the magnitude and duration of the power supply voltage, starting current, and normal operating current, the actual current-time curve is compared with the stored current-time curve. When multiple instances of significantly increased actual starting current and operating current compared to the stored curve are detected; current phase loss occurs for 2 seconds; short-circuit current occurs; or current exceeds the stall current for 1 second, an oil pump fault warning is immediately issued, and the oil pump is automatically stopped.

[0116] S400: Based on the set activation conditions and according to the real-time collected signal data, when the set activation conditions are met, the emergency response plan is activated.

[0117] In this embodiment, an emergency response function has been added compared to the traditional speed controller. When an emergency is detected, in order to ensure safety, the system automatically executes multiple emergency operation commands quickly to eliminate safety hazards and prevent safety accidents, thereby realizing the intelligentization of emergency response work.

[0118] In some embodiments, such as Figure 4 As shown, based on the real-time collected signal data, when the set activation conditions are met, the emergency response plan is activated, including:

[0119] S401. When the speed governor executes the fast oil supply command, and the speed governor oil pressure is lower than the sixth oil pressure threshold and the working pump motor has no working current, the backup oil pump is started in advance to pump oil, and the pumping stops after the set pressure is reached.

[0120] S402. When the plant's power supply is lost due to an accident shutdown, and the oil pressure drops to the starting pressure, immediately switch on the emergency power supply to pump oil.

[0121] S403. When the ammeter, voltmeter, and wattmeter oscillate periodically, reduce the active load and then fix the opening degree.

[0122] S404. When the three-phase current of the outgoing current transformer is zero at the same time, the duration of the simultaneous zeroing is more than 10 seconds, the current in the 3 seconds before the simultaneous zeroing is not less than 10% of the rated current, and the unit frequency and voltage rise rapidly after the three-phase current is zero at the same time, the speed controller sends an adjustment guide vane command to limit the unit frequency to the set frequency threshold in advance.

[0123] S405. When the oil pressure exceeds the set oil pressure threshold and the oil pump motor has normal operating current, the normally closed circuit of the oil pump thermal relay is disconnected through the passive node after a 1-second delay, forcibly stopping the working oil pump.

[0124] S406. If the oil pump motor current reaches the stall current or above, and there is no oil entering or exiting the oil filling pipe, and the oil filling pipe pressure does not rise, the normally closed circuit of the oil pump thermal relay is disconnected through the passive node after a 1-second delay, forcibly stopping the working oil pump.

[0125] S407. If the short-circuit current does not disappear after an appropriate delay following the detection of an external short circuit in the generator main circuit, the active power is reduced to no-load, and an external short circuit is detected, triggering a generator switch failure to trip alarm.

[0126] In this embodiment, different activation conditions are set to trigger the corresponding emergency response type. In actual implementation, the above steps S401-S407 can be configured in the speed controller intelligent monitor, and the speed controller intelligent monitor can then be connected to the speed controller to send corresponding instructions to the speed controller to execute the corresponding emergency response content.

[0127] For example, corresponding to steps S401-S407 above, the emergency response content, emergency response type and response purpose corresponding to the activation conditions are shown in Table 2.

[0128] Table 2 Emergency Response Plan

[0129]

[0130]

[0131] In some embodiments, the intelligent monitor can communicate directly with people via a voice interaction system, and in emergencies, it can also notify relevant responsible personnel via modern communication methods. This facilitates the use of the intelligent monitoring system by staff to complete various tasks.

[0132] In some embodiments, an intelligent speed controller is provided, the structure of which is as follows: Figures 5 to 7 As shown, this intelligent speed controller adds acquisition, execution, and control components not present in the original speed controller, while maintaining the overall structure and function of the intelligent speed controller. The control component controls the execution component to perform corresponding operations based on the signals acquired by the acquisition component, thereby improving the reliability and safety of the speed controller. The specific control methods of the control component have been described in detail in the above embodiments and will not be repeated here. The installation location of each acquisition component should fully consider the existing equipment, ensuring that the information acquisition function is fully utilized and the information is accurate and complete, while the installed components do not affect the aesthetics of the original equipment or increase safety hazards. The execution commands output by the control component are directly connected to the original equipment, and the relevant processing is completed through the original equipment, avoiding conflicts with the original equipment's commands.

[0133] Specifically, the intelligent speed controller includes an oil tank 1, an intelligent oil level gauge 2, a safety valve 3, a motor 4, an oil pump 5, an oil filter 6, a check valve 7, a drain valve 8, an oil reservoir 9, an oil pressure sensor for the filling pipe 10, an oil pressure sensor for the supply pipe 11, a clamp-type flow meter for the supply pipe 12, a clamp-type flow meter for the return pipe 13, a clamp-type flow meter for the filling pipe 14, an oil supply valve 15, an energy storage capsule 16, an energy storage capsule 2 17, a hydraulic valve group 18, a hydraulic cylinder 19, an opening sensor 20, an electrical contact pressure gauge 21, an infrared thermometer 22, an electronic nose 23, and an infrared camera 24. This hydraulic system is powered by an oil pump, achieves precise control of oil flow direction and flow rate through multiple valves and sensors, and ensures the safe and stable operation of the system through various monitoring devices. The energy storage capsules may be used to absorb shocks or store energy, and the intelligent oil level gauge and oil tank ensure that the system has sufficient hydraulic oil and monitor the oil level in real time.

[0134] Hydraulic oil enters the motor 4 from the oil tank 9 through the drain valve 8 to drive the oil pump. The oil pump pumps the hydraulic oil to the oil filter 6 and the check valve 7. The hydraulic oil passing through the check valve 7 flows to the No. 1 energy storage capsule (16), the No. 2 energy storage capsule 17, and the hydraulic valve group 18, respectively. The hydraulic valve group 18 controls the direction and flow rate of the oil, and the oil supply valve 15 ensures system safety. The oil pressure sensor 10 for the filling pipe, the oil pressure sensor 11 for the supply pipe, the clamp flow meter 14 for the filling pipe, and the clamp flow meter 12 for the supply pipe monitor the pressure and flow rate of the filling pipe and the supply pipe, respectively. The opening sensor 20, the infrared thermometer 22, the electrical contact pressure gauge 21, the electronic nose 23, and the infrared camera 24 are used to monitor various operating parameters of the system.

[0135] The functions of each component involved are as follows:

[0136] Left side

[0137] Oil tank 9: Stores hydraulic oil.

[0138] Oil drain valve (with maintenance safety lock) 8: Used for oil draining and has a function to prevent misoperation. Motor 4: Provides power source.

[0139] Safety valve 3: Ensures system pressure safety.

[0140] Oil pump (not marked): pumps hydraulic oil to provide the pressure required by the system.

[0141] Oil filter 6: Controls the flow of oil to achieve system regulation.

[0142] One-way valve 7: Allows hydraulic oil to flow in one direction and prevents backflow.

[0143] Oil-filled pipe clamp flow meter 14: measures the flow rate of the oil-filled pipe.

[0144] Oil pressure sensor 10 for filling pipe: monitors the oil pressure in the filling pipe.

[0145] 1# Energy Storage Capsule 16: Stores energy, potentially for system regulation.

[0146] #2 Energy Storage Capsule 17: Also used for storing energy.

[0147] Hydraulic valve assembly 18: Contains multiple hydraulic control valves for precise control of hydraulic fluid flow. Oil supply valve (with maintenance safety lock) 15: Controls oil supply and has anti-misoperation function. Opening sensor 20: Monitors the opening degree of the hydraulic system.

[0148] Infrared thermometer 22: measures system temperature.

[0149] Electrical contact pressure gauge 21: monitors system pressure.

[0150] Electronic nose 23: Used to monitor the odor parameters of oils.

[0151] Infrared camera 24: Monitors the working status of the hydraulic system.

[0152] Oil tank 1: Stores hydraulic oil for system use.

[0153] Smart Oil Level Indicator 2: Monitors and displays oil level in real time.

Claims

1. A method for intelligent monitoring of a speed controller, characterized in that, The method includes: The signal acquisition components and actuators are deployed as follows: oil pressure sensors and flow meters are installed on the governor's oil filling pipe, oil supply pipe, and oil return pipe, respectively; an opening sensor and a noise meter are installed in the water turbine room; an infrared camera is installed on the top of the governor's oil tank; an infrared thermometer, a noise meter, and an electronic nose are installed outside the oil pump motor; a switching current transformer and a voltage transformer are installed in the main electrical circuit of the oil pump motor, respectively; and switching current transformers are installed in the secondary circuit of the generator outlet current transformer and the secondary circuit of the current transformer on the power grid line. Based on the signal data acquired by the signal acquisition component, a continuous curve is formed over time; wherein, the signal data includes at least one of oil pressure, flow rate, oil temperature, oil level, oil quality, noise, odor, opening degree, current, and voltage; Fault diagnosis and early warning are performed based on the continuous curve and / or the video data collected by the infrared camera; Based on the set activation conditions and according to the real-time collected signal data, when the set activation conditions are met, the emergency response plan is activated and the corresponding emergency response is executed. Based on the continuous curve and / or the video data acquired by the infrared camera, perform fault diagnosis and early warning, including: The following methods can be used to diagnose malfunctions in the hydraulic system's capsule: Based on theoretical calculations and actual measurements, the function curves of the filling amount and capsule pressure of the two capsules and the function curve of the filling amount and time were obtained, and the total filling amount V0 of the two capsules from the pump start-up oil pressure to the rated oil pressure was calculated. During actual operation, each time the pressure oil rises from the pump start-up pressure to the rated oil pressure, the flow rate measured by the flow meter and the corresponding time are used to calculate the actual oil filling amount V1 and compare it with the total oil filling amount V0 during the commissioning. If the difference exceeds the normal error and the oil filling time has increased compared to before, an abnormal capsule warning will be issued. The actual oil filling amount of the faulty capsule is obtained by subtracting the total oil filling amount V0 / 2 of the two capsules during the original debugging from the actual oil filling amount. The function curve of the oil filling amount and capsule pressure obtained during debugging is used to verify the value and calculate the residual pressure value of the faulty capsule. Based on the oil filling volume versus time function curve obtained from the debugging, the two pumps were started to pump oil separately. The pump with the shorter pumping time was identified, and the capsule closest to the pump with the shorter pumping time was identified as the faulty capsule.

2. The intelligent monitoring method for a speed controller as described in claim 1, characterized in that, Based on the continuous curve and / or the video data acquired by the infrared camera, perform advanced fault diagnosis and early warning before the accident occurs, including: When the oil pressure in the governor's charging pipe drops to the first oil pressure threshold and oil flows out of the charging pipe, an emergency oil pressure warning is triggered. When the oil pressure in the governor's charging pipe rises to the second oil pressure threshold, the oil pump motor has operating current and oil flows out of the charging pipe, an oil pressure over-high warning is triggered. When the oil pressure in the governor's charging pipe drops to the third oil pressure threshold and the main pump motor has no operating current, or when the oil pressure in the governor's charging pipe drops to the fourth oil pressure threshold and the standby pump motor has no operating current, or when the oil pressure in the governor's charging pipe rises to the fifth oil pressure threshold and the oil pump motor has operating current, or when the oil pump motor has operating current, the oil pressure in the governor's charging pipe does not rise and there is no oil flow in the oil supply pipe, or when the oil pump motor has operating current and there is oil flow in the oil supply pipe, but the average rate of increase of the governor's charging pipe oil pressure is slower than before and exceeds the set threshold, or when the oil pump current is larger than the normal operating current or there is a phase loss, an abnormal oil supply warning will be issued. When the oil pump motor operating current lasts for more than the set time, the flow meter detects that the amount of oil entering the speed regulator tank has increased beyond the set threshold, and the oil level in the tank drops, an abnormal capsule warning is triggered. When there is no oil flowing out of the oil supply pipe, the oil pressure in the governor charging pipe drops and / or the oil level in the oil tank drops successively, and the oil supply volume of the oil supply pipe is greater than the oil return volume of the return pipe for multiple time periods, a pipeline oil leakage warning will be issued. Based on the ambient temperature and oil temperature change curves, when the ambient temperature remains unchanged or decreases, the oil temperature in the oil tank rises. When the oil temperature exceeds 40°C, an abnormal oil temperature warning is issued. When the speed governor receives a command that there is no oil flow in both the oil supply and return pipes, or no valve action command, but there is oil flow in both the oil supply and return pipes, a valve fault warning will be issued. When any signal acquisition component interrupts data upload or continuously generates abnormal data, an input information abnormality warning is executed. When the guide vane opening changes continuously and the valve operates continuously, and there is oil flow in both the oil supply pipe and the oil return pipe, an opening slippage warning is executed. When the ammeter, voltmeter, and wattmeter oscillate periodically and the oscillation amplitude exceeds the set amplitude, a system oscillation warning will be issued. When the unit is running under load, if the guide vane opening gradually decreases without adjustment, a load slip warning will be issued. When a remote governor operation command is detected, and there is no oil flow in the oil supply pipe and return pipe, and the guide vane opening does not change, a remote control failure warning is issued. When the speed governor is running automatically under no-load conditions and the unit frequency cannot be stabilized within the set frequency threshold range, an no-load frequency warning is executed. When an abnormal odor is detected exceeding the standard, an odor abnormality warning is issued; When a sound type or volume exceeds the limit, a sound anomaly warning will be issued.

3. The intelligent monitoring method for a speed controller as described in claim 1, characterized in that, Before debugging based on theoretical calculations and actual measurements, methods for diagnosing bladder failures in hydraulic systems also include: Ensure that two capsules of the same model are filled with nitrogen at the same pressure, and set that two pressure oil tanks of the same model have the same volume and are directly connected. When the oil pump fills the oil tank with pressurized oil, the pressure on the two capsules is equal, the volume of nitrogen gas inside the capsules that is compressed and contracted is equal, and the volume of pressurized oil filled into the two pressure oil tanks is also equal.

4. The intelligent monitoring method for a speed controller as described in claim 1, characterized in that, Based on the continuous curve and / or the video data acquired by the infrared camera, perform fault diagnosis and early warning, including: Based on the real-time monitoring of the three-phase current of the grid-connected line, when the three-phase current suddenly and rapidly drops to zero, and the rate of change and the starting point of change both exceed the set values, and the unit frequency and voltage rise rapidly, and the generator output circuit breaker is in the closed state, a remote load shedding alarm is immediately issued.

5. The intelligent monitoring method for a speed controller as described in claim 2, characterized in that, When providing an early warning of oil leaks in pipelines, the method further includes: determining the amount of oil leak based on a time difference function.

6. The intelligent monitoring method for a speed controller as described in claim 5, characterized in that, Determining the amount of oil leakage based on the time difference function includes: The amount of oil leakage in the oil pipeline per unit time is calculated by the difference between the equivalent oil supply to the servo unit by the oil supply pipeline and the oil return volume by the return pipeline per unit time. When the amount of oil leakage in the oil supply or return pipeline exceeds the normal measurement error per unit time, an oil leakage warning is immediately issued. Based on the leakage start time and using the measurement difference time function, the amount of oil that has been leaked is calculated.

7. The intelligent monitoring method for a speed controller as described in claim 1, characterized in that, Based on the continuous curve and / or the video data acquired by the infrared camera, perform fault diagnosis and early warning, including: Under various power supply voltages, based on the current change during the process of the oil pressure in the governor's oil filling pipe rising from the pump start-up pressure to the rated oil pressure after the oil pump starts, multiple sets of current-time curves are formed and stored. The actual current-time curve is obtained by detecting the power supply voltage, starting current, normal operating current and duration. By comparing the actual current-time curve with the stored current-time curve, when multiple actual starting currents and operating currents are detected to be significantly higher than the stored curve current, or when a phase loss occurs and lasts for more than 2 seconds, or when a short circuit current occurs, or when the current exceeds the stall current and lasts for more than 1 second, an oil pump fault warning is immediately issued and the oil pump is controlled to stop running.

8. The intelligent monitoring method for a speed controller as described in claim 1, characterized in that, Based on the set activation conditions and according to the real-time collected signal data, when the set activation conditions are met, the emergency response plan is activated, including: When the speed governor executes the rapid oil supply command, and the oil pressure in the speed governor's oil filling pipe is lower than the sixth oil pressure threshold and the working pump motor has no operating current, the backup oil pump is started in advance to pump oil, and stops pumping oil after the set pressure is reached. When the plant's power supply is cut off due to an accident and the oil pressure in the governor's charging pipe drops to the starting pressure, immediately switch on the emergency power supply to pump oil. When the ammeter, voltmeter, and wattmeter oscillate periodically, the opening degree is fixed after reducing the active load; When the three-phase current of the outgoing current transformer is zero at the same time, the duration of the simultaneous zeroing is more than 10 seconds, the current in the 3 seconds before the simultaneous zeroing is not less than 10% of the rated current, and the unit frequency and voltage rise rapidly after the three-phase current is zero at the same time, an adjustment guide vane command is sent to the speed controller to limit the unit frequency to the set frequency threshold in advance. If the oil pressure in the governor's charging pipe exceeds the set oil pressure threshold and the oil pump motor has normal operating current, the normally closed circuit of the oil pump thermal relay will be disconnected through the passive node after a 1-second delay, forcibly stopping the working oil pump. If the oil pump motor current reaches the stall current or above, and there is no oil entering or exiting the oil filling pipe, and the oil filling pipe pressure does not rise, the normally closed circuit of the oil pump thermal relay is disconnected through the passive node after a 1-second delay, forcibly stopping the working oil pump. If the short-circuit current does not disappear after an appropriate delay following the detection of an external short circuit in the generator main circuit, the active power is reduced to no-load, triggering an external short circuit and causing the generator output switch to fail to trip and trigger an alarm.

9. The intelligent monitoring method for a speed controller as described in claim 1, characterized in that, The method also includes: installing maintenance anti-misoperation locks on the governor's main oil supply valve and pressure relief valve, and connecting the position information and electromagnetic command transmission line to the governor's intelligent monitor to provide a reliable interlock for governor maintenance safety.

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