Variable-frequency high-power fan torque monitoring system

Abstract

The invention discloses a variable-frequency high-power fan torque monitoring system, and belongs to the technical field of mechanical part testing. Which comprises a fan moving blade, a fan main shaft and a power mechanism installed at the input end of the fan moving blade through the fan main shaft, and is characterized by further comprising a control subsystem and a signal measuring module used for measuring the torque value and the rotating speed of the fan main shaft, and the signal measuring module comprises a torque measuring assembly and a rotating speed measuring assembly; the torque measuring assembly and the rotating speed measuring assembly are installed at the two ends of a fan main shaft respectively, and the torque measuring assembly is located between the power mechanism and the fan main shaft. The torque measuring assembly and the rotating speed measuring assembly are respectively used for sending a measured torque value signal of the fan main shaft and a measured rotating speed signal of the fan main shaft to the control subsystem; according to the method, efficient, energy-saving, safe and stable operation of the variable-frequency high-power fan can be effectively ensured, and the method has high practical value.

Description

Technical Field

[0001] The present application relates to the technical field of mechanical component testing, and specifically to a variable frequency high-power fan torque monitoring system. Background Art

[0002] Variable frequency high-power fans are one of the important auxiliary equipment in thermal power plants. Their safe and stable operation is closely related to the operating conditions of the entire thermal power plant unit. Among them, the transmission components on the variable frequency high-power fans (for example, the fan main shaft) and the drive elements connected to the variable frequency high-power fans bear the important mechanical loads of the aforementioned entire unit. Torque is one of the physical quantities that measure the loads of various mechanical transmission shafts. It is also one of the physical quantities of the power output of rotating machinery. It determines the working performance and service life of the transmission shaft. Therefore, monitoring the numerical changes in the torque of variable frequency high-power fans is of practical significance for ensuring whether variable frequency high-power fans can operate efficiently, energy-saving, safely and stably. Traditional solutions fail to link electrical signal parameters with torque measurement, resulting in real-time protection lag or a high misjudgment rate, and the signal is easily interfered with in strong electromagnetic environments. Based on this, a new torque monitoring system that integrates electrical monitoring and electronic control protection is urgently needed. Summary of the Invention

[0003] In response to the above problems, the present application provides a variable frequency high-power wind turbine torque monitoring system to solve the technical problems raised in the background technology section of the present application.

[0004] To achieve the purpose of this application, this application provides the following technical solutions:

[0005] In a first aspect, the present application provides a variable frequency high-power wind turbine torque monitoring system, comprising: a wind turbine rotor blade, a wind turbine main shaft, and a power mechanism mounted to the input end of the wind turbine rotor blade through the wind turbine main shaft, characterized in that it also includes a control subsystem and a signal measurement module for measuring the torque value and speed of the wind turbine main shaft;

[0006] The signal measurement module includes a torque measurement component and a speed measurement component, which are respectively installed at both ends of the fan main shaft, and the torque measurement component is located between the power mechanism and the fan main shaft; wherein the torque measurement component and the speed measurement component respectively send the measured torque signal and speed signal to the control subsystem;

[0007] The control subsystem is electrically connected to the power mechanism. The control subsystem includes a built-in electrical parameter monitoring module for real-time acquisition of the power mechanism's current, voltage, and power factor signals. The control subsystem also includes a current-torque mathematical relationship model for comparison and determination of whether the real-time torque is reasonable.

[0008] The torque measurement component and the speed measurement component are used to send the measured torque value signal of the fan main shaft and the speed signal of the fan main shaft to the control subsystem respectively. The control subsystem is electrically connected to the power mechanism.

[0009] Furthermore, the speed measurement assembly includes a speed sensor and a magnetic wheel, which is fixedly mounted on the outside of the fan main shaft at the end away from the power mechanism. The speed sensor is used to measure the speed signal, which is then transmitted to the control subsystem through a conditioning circuit with EMI filtering. A time-frequency analysis model is used to extract key operating characteristic parameters from the preprocessed real-time operating data and real-time environmental data to obtain operating and environmental characteristics.

[0010] Furthermore, the rotation speed sensor is arranged on one side of the magnetic wheel, and the rotation speed sensor is electrically connected to the control subsystem.

[0011] Furthermore, a mounting bracket is sleeved on the outer side of the speed sensor, and the mounting bracket is fixedly connected to the speed sensor.

[0012] Furthermore, the torque measurement component includes a torque sensor, which is electrically connected to the control subsystem. The torque sensor is used to measure and obtain a torque signal, which is then sent to the control subsystem via a conditioning circuit with EMI filtering.

[0013] Furthermore, couplings are fixedly installed on both sides of the input end of the torque sensor, and the two couplings are fixedly connected to the output end of the power mechanism and the main shaft of the fan respectively.

[0014] Furthermore, the control subsystem adopts a DCS operating system; wherein, the control subsystem is provided with a control function and an alarm function, and the control subsystem is also provided with a redundant power switching structure of a main power supply and a UPS backup power supply.

[0015] Furthermore, a rated torque threshold and a rated speed threshold are preset in the control subsystem. When the received torque value exceeds the rated torque threshold, or the theoretical torque value calculated based on the speed signal exceeds the set range, the control subsystem sends a no-lift, no-lowering or shutdown instruction to the power mechanism and triggers the alarm device.

[0016] The comprehensive control strategy for torque alarm of a variable frequency high-power fan provided by this application achieves the following technical effects:

[0017] By introducing electrical measurement and control methods, mathematical modeling, anti-interference protection, and power supply guarantee mechanisms, the stability, intelligence, and fault tolerance of high-power wind turbine operations have been greatly improved, demonstrating significant engineering application value. When the high-power wind turbine is operating normally, the control subsystem controls the variable-frequency fan through open-loop control to ensure that the fan blades are in the optimal linear adjustment region. The control subsystem controls the fan blades through closed-loop control to maintain the controlled variable within a reasonable range while saving energy. When the control subsystem issues a command to the variable-frequency fan to prohibit raising or lowering the speed or to shut down the fan, the open-loop control maintains the current command, and the fan blades control the controlled variable through closed-loop control to ensure that the controlled variable is within a reasonable range, thus ensuring the safe and stable operation of the variable-frequency high-power wind turbine. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The accompanying drawings are used to provide a further understanding of the present application and constitute a part of the specification. Together with the embodiments of the present application, they are used to explain the present application and do not constitute a limitation of the present application.

[0019] Figure 1 This is a structural diagram of a variable frequency high-power wind turbine torque monitoring system disclosed in an embodiment of the present invention;

[0020] Figure 2 This is a system diagram of a variable frequency high-power wind turbine torque monitoring system disclosed in an embodiment of the present invention;

[0021] Figure 3 This is a schematic structural diagram of a torque measurement module disclosed in an embodiment of the present invention;

[0022] Figure 4 This is a schematic diagram of the installation of the speed measurement module disclosed in an embodiment of the present invention.

[0023] Reference numerals in the figure: 1. wind turbine blade; 2. wind turbine main shaft; 3. power mechanism; 4. control subsystem; 5. signal measurement module; 50. torque measurement component; 500. torque sensor; 501. coupling; 51. speed measurement component; 510. speed sensor; 511. magnetic wheel; 512. mounting bracket. DETAILED DESCRIPTION

[0024] To make the objectives, technical solutions, and advantages of this application more clear, the technical solutions of this application will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the embodiments described are only part of the embodiments of this application, not all of them. Based on the embodiments of this application, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of this application.

[0025] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the technical features indicated. Thus, a feature specified as "first" or "second" may explicitly or implicitly include one or more of such features; and in the description of this application, unless otherwise specified, "plurality" means two or more.

[0026] The variable frequency high-power wind turbine torque monitoring system provided by this specific embodiment greatly improves the stability, intelligence and fault tolerance of the high-power wind turbine operation, and has significant engineering application value. When the high-power wind turbine is operating normally, the control subsystem controls the variable frequency wind turbine to perform open-loop control to ensure that the wind turbine blades are in the optimal adjustment linear region. The control subsystem controls the wind turbine blades to perform closed-loop control to maintain the controlled variable within a reasonable range while saving energy. When the control subsystem issues a prohibition of raising or lowering or shutdown instruction to the variable frequency wind turbine, the open-loop control maintains the current instruction, and the wind turbine blades perform closed-loop control of the controlled variable to ensure that the controlled variable is within a reasonable range, thereby ensuring the safe and stable operation of the variable frequency high-power wind turbine.

[0027] See also Figures 1-4 The present invention provides a technical solution: a variable frequency high-power wind turbine torque monitoring system, comprising a wind turbine blade 1, a wind turbine main shaft 2, and a power mechanism 3 installed at the input end of the wind turbine blade 1 through the wind turbine main shaft 2. The power mechanism 3 is configured to facilitate the power mechanism 3 to output power so that the wind turbine main shaft 2 drives the wind turbine blade 1 to rotate. The system also includes a control subsystem 4 and a signal measurement module 5 for measuring the torque value and speed of the wind turbine main shaft 2. The signal measurement module 5 is configured to facilitate the signal measurement module 5 to collect the torque value and speed of the wind turbine main shaft 2, and convert them into electrical signals for transmission to the control subsystem 4.

[0028] The signal measurement module 5 includes a torque measurement component 50 and a speed measurement component 51. The torque measurement component 50 and the speed measurement component 51 are respectively installed at both ends of the fan main shaft 2, and the torque measurement component 50 is located between the power mechanism 3 and the fan main shaft 2. The arrangement of the torque measurement component 50 and the speed measurement component 51 facilitates the torque measurement component 50 to detect the torque applied to the fan main shaft 2, and the speed measurement component 51 to monitor the speed of the fan main shaft 2.

[0029] The torque measurement component 50 and the speed measurement component 51 are used to transmit the measured torque and speed signals of the fan main shaft 2, respectively, to the control subsystem 4, which is electrically connected to the power mechanism 3. The control subsystem 4 includes a built-in electrical parameter monitoring module, which is directly integrated into the power supply circuit of the power mechanism 3. This module is used to collect electrical signals from the power mechanism 3 in real time, including current, voltage, and power factor signals. These electrical signals are then synchronously uploaded to the control subsystem along with the torque and speed signals for load assessment and energy efficiency analysis.

[0030] The electrical parameter monitoring module includes a current detection unit, a voltage detection unit, and a power factor detection unit. The current detection unit uses a high-precision current transformer or Hall-effect sensor to collect the input phase current signal of the power mechanism 3 in real time. The voltage detection unit uses a voltage divider circuit or an isolated voltage sensor to monitor the input line voltage of the power mechanism 3 in real time. The power factor detection unit dynamically calculates the real-time power factor based on the phase difference between current and voltage. The electrical parameter monitoring module collects the three-phase AC input parameters of the power mechanism 3 and transmits them to the control subsystem 4. Using the current-torque mathematical relationship model built into the control subsystem 4, the current load condition and the theoretical torque value of the wind turbine are calculated. Furthermore, the electrical signal can be cross-validated when torque is abnormal. For example, if the torque exceeds the limit but the electrical signal is normal, the control subsystem 4 indicates a mechanical fault, such as bearing damage. If the torque is normal but the electrical signal is abnormal, the control subsystem 4 diagnoses an electrical fault, such as phase loss or winding imbalance. If the torque and electrical signal increase abnormally in sync, the control subsystem 4 indicates an overload fault. The electrical parameter monitoring module can be used to achieve multi-signal redundant comparison and improve the judgment accuracy and anti-interference ability of the control system.

[0031] Furthermore, the electrical parameter monitoring module and the signal measurement module 5 use a unified time scale reference, such as DCS system clock synchronization, to ensure that the current, voltage, and power factor data are aligned with the main shaft torque and speed signals at the millisecond level.

[0032] Furthermore, the control subsystem 4 is also provided with a current-torque mathematical relationship model for comparing and judging whether the real-time torque is reasonable. By analyzing the current signal, the load state of the fan can be reversely deduced, thereby improving the reliability of redundant protection.

[0033] By electrically connecting the control subsystem to the power mechanism, the control subsystem can compare the real-time torque of the fan main shaft collected by the torque measurement component with the rated torque or the theoretical torque calculated based on the speed collected by the speed measurement component. When the real-time torque of the fan main shaft is higher than the rated torque, or the deviation between the real-time torque of the fan main shaft collected by the torque measurement component and the theoretical torque calculated based on the speed collected by the speed measurement component is greater than a threshold, the control subsystem issues a prohibition of raising or lowering or a shutdown command to the power mechanism to ensure the safe operation of the variable frequency high-power fan.

[0034] As an embodiment of the present invention, the speed measurement component 51 further includes a speed sensor 510 and a magnetic wheel 511. The magnetic wheel 511 is fixedly mounted on the outside of the end of the fan main shaft 2 away from the power mechanism 3. The magnetic wheel 511 is fixedly mounted on the outside of the end of the fan main shaft 2 away from the power mechanism 3, so that the fan main shaft 2 rotates and drives the magnetic wheel 511 to rotate. Among them, the speed sensor 510 is used to measure and obtain a speed signal. The speed signal is sent to the control subsystem 4 through a conditioning circuit with EMI (Electromagnetic Interference) filtering. The cables connecting the speed sensor 510 are all shielded wires. The control subsystem 4 is equipped with an electromagnetic compatibility filter to resist electromagnetic interference caused by high-power equipment on site, achieve accurate capture of sub-microsecond pulses under strong interference, and ensure signal accuracy.

[0035] As an embodiment of the present invention, further, a speed sensor 510 is arranged on one side of the magnetic wheel 511, and the speed sensor 510 is electrically connected to the control subsystem 4. Through the setting of the speed sensor 510, the magnetic field change caused by the rotation of the magnetic wheel 511 is facilitated, and the speed sensor 510 generates a speed electrical signal of the fan main shaft 2 according to the magnetic field change.

[0036] As an embodiment of the present invention, a mounting bracket 512 is further provided on the outside of the speed sensor 510. The mounting bracket 512 is fixedly connected to the speed sensor 510. The provision of the mounting bracket 512 facilitates the fixed installation of the speed sensor 510 on the side of the magnetic wheel 511, so that the rotation of the magnetic wheel 511 can cause the speed sensor 510 to generate a speed electrical signal. Furthermore, the speed sensor 510 and the mounting bracket 512 are configured in a redundant configuration with three sets, and are electrically connected to the control subsystem 4. The three generated speed electrical signals are processed in a three-way manner within the control subsystem 4 and then used as the final speed signal.

[0037] As an embodiment of the present invention, the torque measurement assembly 50 further includes a torque sensor 500, which is electrically connected to the control subsystem 4. The provision of the torque sensor 500 facilitates the conversion of the torque output by the power mechanism 3 on the fan main shaft 2 into an electrical signal, which is then transmitted to the control subsystem 4. The torque sensor 500 is used to measure and obtain a torque signal, which is then transmitted to the control subsystem 4 through a conditioning circuit with EMI filtering. The connecting cables of the torque sensor 500 are all shielded, and the control subsystem 4 is equipped with an electromagnetic compatibility filter to resist electromagnetic interference caused by high-power equipment on site, achieve precise capture of sub-microsecond pulses under strong interference, and ensure signal accuracy.

[0038] As an embodiment of the present invention, further, couplings 501 are fixedly installed on the input ends on both sides of the torque sensor 500, and the two couplings 501 are fixedly connected to the output end of the power mechanism 3 and the fan main shaft 2 respectively. Through the setting of the coupling 501, it is convenient to fix the torque sensor 500 with the power mechanism 3 and the fan main shaft 2, thereby facilitating the torque sensor 500 to monitor the torque of the fan main shaft 2.

[0039] As an embodiment of the present invention, the control subsystem 4 further adopts a DCS operating system, and the control subsystem 4 is provided with a control function and an alarm function. By providing the control function and the alarm function within the control subsystem 4, when the control subsystem 4 issues a prohibition of raising or lowering or shutdown instruction to the power mechanism 3, the alarm device is triggered to issue an alarm to remind the operator, which is conducive to improving the response speed of the operator. The control subsystem 4 is also provided with a redundant power switching structure for the main power supply and the UPS backup power supply. When the main power supply is cut off, the system can automatically switch to the backup power supply to ensure the continuous operation of the monitoring system. The use of the DCS operating system facilitates seamless connection of the device with other automation systems of the thermal power plant, centralized control, decentralized layout, and sustainable operation, forming a complete and reliable automation ecosystem.

[0040] As an embodiment of the present invention, further, a rated torque threshold and a rated speed threshold are preset in the control subsystem 4. When the received torque value exceeds the rated torque threshold, or the theoretical torque value calculated according to the speed signal exceeds the set range, the control subsystem 4 sends a prohibition of lifting or lowering or shutdown instruction to the power mechanism 3 and triggers the alarm device.

[0041] As an embodiment of the present invention, further, the control subsystem 4 controls the variable frequency fan power mechanism 3 to perform open-loop control, and the control subsystem 4 controls the fan impeller 1 to perform closed-loop control, maintaining the regulated quantity within a reasonable range under the premise of energy saving. When the control subsystem 4 of the variable frequency high-power fan receives a no-rise, no-lower or shutdown instruction, the power mechanism 3 will maintain the current setting in the open-loop mode, while the fan impeller 1 relies on the angle adjustment of the fan impeller 1 and other means to maintain the stability and efficiency of the system in the closed-loop mode, ensuring that the regulated quantity is within a reasonable range, which helps to improve the adaptability of the variable frequency high-power fan and also ensures the safe operation of the equipment.

[0042] Specifically, the configuration of the power mechanism 3 facilitates the power output of the power mechanism 3 to drive the fan main shaft 2 to rotate. The configuration of the torque measurement component 50 and the speed measurement component 51 facilitates the torque measurement component 50 to detect the torque applied to the fan main shaft 2, and the speed measurement component 51 to monitor the speed of the fan main shaft 2. The control subsystem 4 is electrically connected to the power mechanism 3, so that the control subsystem 4 can compare the real-time torque of the fan main shaft 2 collected by the torque measurement component 50 with the rated torque or the theoretical torque calculated based on the speed collected by the speed measurement component 51. When the real-time torque of the fan main shaft is higher than the rated torque, or the deviation between the real-time torque of the fan main shaft collected by the torque measurement component and the theoretical torque calculated based on the speed collected by the speed measurement component is greater than a threshold, the control subsystem 4 issues a shutdown command to the power mechanism 3 to ensure efficient, energy-saving, safe and stable operation of the variable frequency high-power fan. The configuration of the control module and the alarm module facilitates the triggering of the alarm device to issue an alarm to alert the operator when the control subsystem 4 issues a prohibition of raising or lowering or shutdown command to the power mechanism 3, which is conducive to improving the operator's response speed.

[0043] In the several embodiments provided in this application, it should be understood that the disclosed systems, modules and methods can be implemented in other ways. For example, the module embodiments described above are merely illustrative. For example, the division of units is merely a logical function division. In actual implementation, there may be other division methods, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of modules or units, which can be electrical, mechanical or other forms.

[0044] The above embodiments are intended only to illustrate the technical solutions of the present application and are not intended to limit them. The present application is not limited to the precise structures described above and illustrated in the accompanying drawings, and it cannot be assumed that the specific implementation of the present application is limited to these descriptions. For those skilled in the art of the present application, any changes and modifications made without departing from the concept of the present application should be deemed to fall within the scope of protection of the present application.

Claims

1. A variable frequency high-power wind turbine torque monitoring system, comprising a wind turbine blade (1), a wind turbine main shaft (2), and a power mechanism (3) mounted to the input end of the wind turbine blade (1) through the wind turbine main shaft (2), characterized in that: It also includes a control subsystem (4) and a signal measurement module (5) for measuring the torque value and rotational speed of the fan main shaft (2): The signal measurement module (5) comprises a torque measurement component (50) and a speed measurement component (51), wherein the torque measurement component (50) and the speed measurement component (51) are respectively mounted on both ends of the fan main shaft (2), and the torque measurement component (50) is located between the power mechanism (3) and the fan main shaft (2); wherein the torque measurement component (50) and the speed measurement component (51) respectively send the measured torque signal and speed signal to the control subsystem (4); The control subsystem (4) is electrically connected to the power mechanism (3); wherein the control subsystem (4) is equipped with an electrical parameter monitoring module for real-time acquisition of current, voltage and power factor signals of the power mechanism (3); the control subsystem (4) is also equipped with a current-torque mathematical relationship model for comparison and judgment of whether the real-time torque is reasonable; The torque measuring component (50) and the speed measuring component (51) are used to respectively send the measured torque value signal of the fan main shaft (2) and the speed signal of the fan main shaft (2) to the control subsystem (4), and the control subsystem (4) is electrically connected to the power mechanism (3).

2. The variable frequency high-power wind turbine torque monitoring system according to claim 1, characterized in that: The speed measurement component (51) comprises a speed sensor (510) and a magnetic wheel (511), wherein the magnetic wheel (511) is fixedly mounted on the outside of one end of the fan main shaft (2) away from the power mechanism (3); wherein the speed sensor (510) is used to measure and obtain the speed signal, and the speed signal is sent to the control subsystem (4) through a conditioning circuit with EMI filtering.

3. The variable frequency high power wind turbine torque monitoring system according to claim 2, characterized in that: The rotation speed sensor (510) is arranged on one side of the magnetic wheel (511), and the rotation speed sensor (510) is electrically connected to the control subsystem (4).

4. The variable frequency high power wind turbine torque monitoring system according to claim 3, characterized in that: A mounting bracket (512) is sleeved on the outer side of the rotation speed sensor (510), and the mounting bracket (512) is fixedly connected to the rotation speed sensor (510).

5. The variable frequency high power wind turbine torque monitoring system according to claim 1, characterized in that: The torque measurement component (50) includes a torque sensor (500), and the torque sensor (500) is electrically connected to the control subsystem (4); wherein the torque sensor (500) is used to measure and obtain the torque signal, and the torque signal is sent to the control subsystem (4) through a conditioning circuit with EMI filtering.

6. The variable frequency high power wind turbine torque monitoring system according to claim 5, characterized in that: Couplings (501) are fixedly mounted on both input ends of the torque sensor (500), and the two couplings (501) are fixedly connected to the output end of the power mechanism (3) and the fan main shaft (2), respectively.

7. The variable frequency high power wind turbine torque monitoring system according to claim 1, characterized in that: The control subsystem (4) adopts a DCS operating system; wherein, the control subsystem (4) is internally provided with a control function and an alarm function, and the control subsystem (4) is also internally provided with a redundant power supply switching structure between a main power supply and a UPS backup power supply.

8. The variable frequency high power wind turbine torque monitoring system according to claim 1, characterized in that: The control subsystem (4) is preset with a rated torque threshold and a rated speed threshold. When the received torque value exceeds the rated torque threshold, or the theoretical torque value calculated based on the speed signal exceeds a set range, the control subsystem (4) issues a prohibition of raising or lowering or a shutdown instruction to the power mechanism (3) and triggers an alarm device.

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