Generator collector ring dynamic grinding surface roughness monitoring system and method

Abstract

The invention provides a dynamic grinding surface roughness monitoring system and method for a collector ring of a generator, and the system comprises a temperature detection module, the detection end of the temperature detection module is opposite to the surface of the collector ring, and the temperature detection module is used for detecting the temperature distribution of the surface of the collector ring; and the control module is used for obtaining the temperature difference between a smooth area and a rough area in the surface of the collecting ring according to the temperature distribution of the surface of the collecting ring, obtaining the roughness grade of the rough area based on the temperature difference and a roughness corresponding model, and adjusting the grinding pressure and the grinding rotating speed of the grinding equipment according to the roughness grade of the rough area. Therefore, the roughness of the surface of the collecting ring is in a preset roughness range. According to the dynamic grinding surface roughness monitoring system and method for the collector ring of the generator, closed-loop control over surface grinding of the collector ring is achieved, and therefore the grinding precision is effectively improved.

Description

Technical Field

[0001] The present disclosure relates to the technical field of roughness monitoring, and in particular to a system and method for monitoring the roughness of a dynamic grinding surface of a generator slip ring. Background Art

[0002] The collector ring of a hydro-turbine generator is a key connecting component between the rotor excitation system and the external circuit. It is responsible for transmitting DC current to the rotor winding. Its surface roughness directly affects the contact stability and wear rate of the carbon brush and the operating efficiency of the generator.

[0003] After running for a long time, the collector ring will have problems such as surface oxidation, surface electrical corrosion points, and surface high and low points. The current solution is to grind the collector ring. However, during the grinding process, the grinding equipment only operates according to the preset grinding pressure and grinding speed. It cannot monitor the roughness of the collector ring surface in real time and cannot achieve closed-loop control, resulting in low grinding accuracy, which seriously affects the maintenance quality and efficiency of the collector ring. Summary of the Invention

[0004] The present disclosure aims to solve one of the technical problems in the related art at least to a certain extent.

[0005] To this end, the object of the present disclosure is to provide a system and method for monitoring the roughness of the dynamic grinding surface of a generator slip ring.

[0006] To achieve the above-mentioned purpose, the first aspect of the present disclosure provides a dynamic grinding surface roughness monitoring system for a generator collector ring, comprising: a temperature detection module, the detection end of the temperature detection module and the surface of the collector ring are arranged relative to each other, and the temperature detection module is used to detect the temperature distribution of the collector ring surface; a control module, the signal input end of the control module is connected to the signal output end of the temperature detection module, and the signal output end of the control module is connected to the signal input end of the grinding equipment, the control module is used to obtain the temperature difference between the smooth area and the rough area on the collector ring surface according to the temperature distribution of the collector ring surface, and obtain the roughness level of the rough area based on the temperature difference and roughness correspondence model, and adjust the grinding pressure and grinding speed of the grinding equipment according to the roughness level of the rough area, so that the roughness of the collector ring surface is within a preset roughness range.

[0007] Optionally, the temperature detection module includes: an infrared imaging unit, the detection end of the infrared imaging unit and the surface of the slip ring are arranged relative to each other, and the infrared imaging unit is used to detect the thermal radiation image of the slip ring surface; wherein, the signal input end of the control module and the signal output end of the infrared imaging unit are connected, and the control module is used to obtain the temperature distribution of the slip ring surface according to the thermal radiation image of the slip ring surface, and obtain the temperature difference between the smooth area and the rough area according to the temperature distribution of the slip ring surface.

[0008] Optionally, the temperature detection module also includes: a displacement detection unit, which is arranged on the infrared imaging unit, and the detection end of the displacement detection unit and the surface of the slip ring are arranged relative to each other, and the displacement detection unit is used to detect the relative displacement of the detection end of the infrared imaging unit and the surface of the slip ring; wherein the signal input end of the control module is connected to the signal output end of the displacement detection unit, and the control module is used to adjust the focal length of the detection end of the infrared imaging unit according to the relative displacement between the detection end of the infrared imaging unit and the surface of the slip ring.

[0009] Optionally, the temperature detection module also includes: a temperature sensing unit, which is arranged on the infrared imaging unit and is used to detect the temperature at the infrared imaging unit; wherein the signal input end of the control module is connected to the signal output end of the temperature sensing unit, and the control module is used to compensate for the temperature distribution on the surface of the collector ring according to the temperature at the infrared imaging unit.

[0010] Optionally, the system also includes: a non-contact optical morphology measurement module, the detection end of the non-contact optical morphology measurement module and the surface of the collector ring are arranged relative to each other, and the non-contact optical morphology measurement module is used to detect the morphology of the collector ring surface; wherein the signal input end of the control module is connected to the signal output end of the non-contact optical morphology measurement module, and the control module is used to align the temperature difference between the smooth area and the rough area with the morphology of the collector ring surface in time and space, and obtain the roughness level of the rough area based on the dynamic fusion model, and adjust the grinding pressure and grinding speed of the grinding equipment according to the roughness level of the rough area.

[0011] Optionally, the control module is used to obtain a first roughness level of the rough area based on the temperature difference between the smooth area and the rough area, and to obtain a second roughness level of the rough area based on the morphology of the surface of the collector ring, and when the difference between the first roughness level and the second roughness level does not exceed a preset difference, to obtain a corrected roughness level of the rough area based on the first roughness level and the second roughness level, and to adjust the grinding pressure and grinding speed of the grinding equipment based on the corrected roughness level of the rough area.

[0012] Optionally, the system also includes: an alarm module, the signal output end of the control module is connected to the signal input end of the alarm module, and the control module is used to control the alarm module to issue a prompt message when the difference between the first roughness level and the second roughness level exceeds a preset difference.

[0013] Optionally, the non-contact optical morphology measurement module includes: a laser triangulation displacement sensing unit, the detection end of the laser triangulation displacement sensing unit and the surface of the slip ring are arranged relative to each other, and the signal output end of the laser triangulation displacement sensing unit is connected to the signal input end of the control module, and the laser triangulation displacement sensing unit is used to detect the morphology of the slip ring surface; and / or a white light interference unit, the detection end of the white light interference unit and the surface of the slip ring are arranged relative to each other, and the signal output end of the white light interference unit is connected to the signal input end of the control module, and the white light interference unit is used to detect the morphology of the slip ring surface.

[0014] Optionally, the control module is used to obtain a local hot spot on the surface of the slip ring according to the temperature distribution on the surface of the slip ring, and to obtain a defect type and defect position on the surface of the slip ring based on the hot spot temperature and a defect correspondence model.

[0015] A second aspect of the present disclosure provides a method for monitoring the roughness of a generator collector ring during dynamic grinding, comprising: detecting the temperature distribution of the collector ring surface; obtaining the temperature difference between a smooth area and a rough area on the collector ring surface according to the temperature distribution of the collector ring surface; obtaining the roughness level of the rough area based on a temperature difference and roughness correspondence model; and adjusting the grinding pressure and grinding speed of a grinding device according to the roughness level of the rough area so that the roughness of the collector ring surface is within a preset roughness range.

[0016] The technical solution provided by the present disclosure may have the following beneficial effects:

[0017] The control module obtains the temperature difference between the smooth area and the rough area on the surface of the collector ring according to the temperature distribution on the surface of the collector ring, obtains the roughness level of the rough area based on the temperature difference and roughness correspondence model, and adjusts the grinding pressure and grinding speed of the grinding equipment according to the roughness level of the rough area, thereby realizing closed-loop control of the collector ring surface grinding, thereby effectively improving the grinding accuracy, and thus ensuring higher maintenance quality and maintenance efficiency of the collector ring.

[0018] Additional aspects and advantages of the present disclosure will be given in part in the description below and in part will be obvious from the description below, or will be learned through practice of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The above and / or additional aspects and advantages of the present disclosure will become apparent and readily understood from the following description of the embodiments in conjunction with the accompanying drawings, in which:

[0020] Figure 1 1 is a schematic structural diagram of a system for monitoring the surface roughness of a generator collector ring dynamically ground, according to an embodiment of the present disclosure;

[0021] Figure 2 1 is a flow chart of a method for monitoring the surface roughness of a generator slip ring during dynamic grinding, according to an embodiment of the present disclosure;

[0022] As shown in the figure: 1. Control module;

[0023] 2. Temperature detection module, 21. Infrared imaging unit, 22. Displacement detection unit, 23. Temperature sensing unit;

[0024] 3. Non-contact optical profile measurement module, 4. Alarm module, 5. Grinding equipment. DETAILED DESCRIPTION

[0025] The following describes in detail embodiments of the present disclosure, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended only to explain the present disclosure and are not to be construed as limiting the present disclosure. On the contrary, the embodiments of the present disclosure include all variations, modifications, and equivalents that fall within the spirit and scope of the appended claims.

[0026] like Figure 1As shown, the embodiment of the present disclosure proposes a dynamic grinding surface roughness monitoring system for a generator collector ring, comprising: a temperature detection module 2 and a control module 1, the detection end of the temperature detection module 2 and the surface of the collector ring are arranged relative to each other, and the temperature detection module 2 is used to detect the temperature distribution on the surface of the collector ring, the signal input end of the control module 1 is connected to the signal output end of the temperature detection module 2, and the signal output end of the control module 1 is connected to the signal input end of the grinding equipment 5, the control module 1 is used to obtain the temperature difference between the smooth area and the rough area on the collector ring surface according to the temperature distribution on the collector ring surface, and obtain the roughness level of the rough area based on the temperature difference and roughness corresponding model, and adjust the grinding pressure and grinding speed of the grinding equipment 5 according to the roughness level of the rough area, so that the roughness of the collector ring surface is within a preset roughness range.

[0027] It can be understood that since the detection end of the temperature detection module 2 and the surface of the collector ring are arranged relative to each other, and the signal input end of the control module 1 is connected to the signal output end of the temperature detection module 2, and the signal output end of the control module 1 is connected to the signal input end of the grinding equipment 5, the control module 1 can use the temperature detection module 2 to obtain the temperature distribution of the collector ring surface, thereby controlling the grinding equipment 5 according to the temperature distribution of the collector ring surface. Specifically, the control module 1 obtains the temperature difference between the smooth area and the rough area on the collector ring surface according to the temperature distribution of the collector ring surface, and obtains the roughness level of the rough area based on the temperature difference and roughness correspondence model, and adjusts the grinding pressure and grinding speed of the grinding equipment 5 according to the roughness level of the rough area, thereby realizing closed-loop control of the collector ring surface grinding, thereby effectively improving the grinding accuracy, and thus ensuring higher maintenance quality and maintenance efficiency of the collector ring.

[0028] It should be noted that the collector ring of the generator is used to transmit DC current to the rotor winding. During the grinding stage, the collector ring has a smooth area with low surface roughness and a rough area with high surface roughness. The rough surface will cause a significant local temperature rise due to the increase in the friction coefficient. Therefore, the temperature difference-roughness model can be established through the strong correlation between the friction heat effect and the surface roughness, and then the roughness level of the rough area can be accurately obtained according to the temperature difference and roughness correspondence model. For example, the surface of the rough area (Ra>3.2μm) has an increased friction coefficient, and the local temperature is about 8℃-15℃ higher than that of the smooth area. The roughness level of the rough area can be determined through this temperature difference.

[0029] Different temperature ranges correspond to different roughness ranges (roughness levels), and the higher the temperature difference, the higher the corresponding roughness level.

[0030] The temperature detection module 2 is used to detect the temperature distribution on the surface of the slip ring. The specific type of the temperature detection module 2 can be set according to actual needs and is not limited to this.

[0031] Control module 1 is used to control grinding equipment 5 based on the temperature distribution on the slip ring surface detected by temperature detection module 2. The specific type of control module 1 can be set according to actual needs and is not limited to this. For example, control module 1 can be an embedded controller, an edge computing terminal based on RAEM2, supporting multi-channel signal synchronous acquisition and real-time data processing delay ≤ 10ms. In addition, it has a built-in nanometer-level standard roughness reference block, regular self-calibration, a calibration period of ≤ 15 minutes, and an accuracy of ± 8nm.

[0032] Specifically, the embedded controller is integrated on a 1.8cm×1.2cm micro-printed circuit board (PCB), supports Bluetooth communication and multi-sensor data fusion; is equipped with a low-power processor to achieve real-time grinding parameter monitoring and surface condition analysis; adopts an on-chip optoelectronic information system design paradigm, combined with reconfigurable multi-dimensional spectral shaping technology, to dynamically optimize control instructions; through sensor array redundant measurement and machine learning algorithms, it achieves real-time calibration of multiple parameters during the grinding process; adaptively matches environmental variables (such as temperature and vibration) to ensure long-term operational stability; supports visual monitoring on smartphones, and transmits calibration logs and abnormal alarms via Bluetooth.

[0033] The system of this embodiment utilizes real-time feedback to improve grinding efficiency by 25%-30% and extend the life of the carbon brush by approximately 20%.

[0034] like Figure 1 As shown, in some embodiments, the temperature detection module 2 includes an infrared imaging unit 21, wherein the detection end of the infrared imaging unit 21 is arranged opposite to the surface of the slip ring, and the infrared imaging unit 21 is used to detect the thermal radiation image of the slip ring surface. The signal input end of the control module 1 is connected to the signal output end of the infrared imaging unit 21, and the control module 1 is used to obtain the temperature distribution of the slip ring surface based on the thermal radiation image of the slip ring surface, and obtain the temperature difference between the smooth area and the rough area based on the temperature distribution of the slip ring surface.

[0035] It can be understood that since the detection end of the infrared imaging unit 21 and the surface of the slip ring are arranged relative to each other, and the signal input end of the control module 1 is connected to the signal output end of the infrared imaging unit 21, the control module 1 can obtain the thermal radiation image of the slip ring surface by using the detection of the infrared imaging unit 21, and obtain the temperature distribution of the slip ring surface based on the thermal radiation image of the slip ring surface, thereby obtaining the temperature difference between the smooth area and the rough area based on the temperature distribution of the slip ring surface, thereby realizing the determination of the roughness level and the closed-loop control of the grinding equipment 5.

[0036] It should be noted that the infrared imaging unit 21 is used to detect the thermal radiation image of the slip ring surface. The specific type of the infrared imaging unit 21 can be set according to actual needs and is not limited to this. For example, the infrared imaging unit 21 can use a FLIRA655SC infrared thermal imager with a resolution of 640×480 and a thermal sensitivity of ≤0.03°C.

[0037] The infrared imaging unit 21 can be equipped with a high-resolution infrared camera, using a narrowband filter to optimize the infrared spectral response range and focus on the characteristic thermal radiation band of the collector ring surface. Furthermore, a built-in dynamic focus module, combined with feedback from the displacement detection unit 22, adjusts the focal length in real time to adapt to surface deformation during the grinding process. Furthermore, a supporting heat dissipation structure (such as a micro fan, heat sink, etc.) is provided to ensure imaging stability under high-temperature conditions. Accordingly, the control module 1 can extract surface texture features based on the gray-level co-occurrence matrix (GLCM) and quantify the roughness parameters.

[0038] like Figure 1 As shown, in some embodiments, the temperature detection module 2 further includes a displacement detection unit 22, which is disposed on the infrared imaging unit 21, with a detection end of the displacement detection unit 22 disposed opposite to the surface of the slip ring, and is configured to detect the relative displacement between the detection end of the infrared imaging unit 21 and the surface of the slip ring. The signal input end of the control module 1 is connected to the signal output end of the displacement detection unit 22, and the control module 1 is configured to adjust the focal length of the detection end of the infrared imaging unit 21 based on the relative displacement between the detection end of the infrared imaging unit 21 and the surface of the slip ring.

[0039] It can be understood that since the detection end of the displacement detection unit 22 and the surface of the slip ring are arranged relative to each other, and the signal input end of the control module 1 is connected to the signal output end of the displacement detection unit 22, the control module 1 can use the detection of the displacement detection unit 22 to obtain the relative displacement of the detection end of the infrared imaging unit 21 and the surface of the slip ring, and adjust the focal length of the detection end of the infrared imaging unit 21 according to the relative displacement of the detection end of the infrared imaging unit 21 and the surface of the slip ring, thereby ensuring that the focal length of the detection end of the infrared imaging unit 21 is adapted to the displacement and deformation of the slip ring, thereby ensuring the precise grinding of the slip ring surface.

[0040] It should be noted that the displacement detection unit 22 is used to detect the relative displacement between the detection end of the infrared imaging unit 21 and the surface of the slip ring. The specific type of the displacement detection unit 22 can be set according to actual needs and is not limited to this.

[0041] like Figure 1As shown, in some embodiments, the temperature detection module 2 further includes a temperature sensing unit 23, which is disposed on the infrared imaging unit 21 and is used to detect the temperature at the infrared imaging unit 21. The signal input end of the control module 1 is connected to the signal output end of the temperature sensing unit 23, and the control module 1 is used to compensate for the temperature distribution on the slip ring surface according to the temperature at the infrared imaging unit 21.

[0042] It can be understood that since the temperature sensing unit 23 is arranged on the infrared imaging unit 21, and the signal input end of the control module 1 is connected to the signal output end of the temperature sensing unit 23, the control module 1 can use the detection of the temperature sensing unit 23 to obtain the temperature at the infrared imaging unit 21, and compensate the temperature distribution on the surface of the collector ring according to the temperature at the infrared imaging unit 21, thereby effectively eliminating the imaging influence of the external ambient temperature on the infrared imaging unit 21, thereby ensuring the precise grinding of the collector ring surface.

[0043] It should be noted that the temperature sensing unit 23 is used to detect the temperature at the infrared imaging unit 21 . The specific type of the temperature sensing unit 23 can be set according to actual needs and is not limited thereto.

[0044] For the expansion of temperature detection module 2, near-infrared spectral domain microscopic interference technology can also be used to realize surface roughness detection based on high-precision spectral analysis. At the same time, PAN / BaTiO3 / MXene nanofiber membrane is integrated to enhance the photothermal conversion efficiency and piezoelectric performance, improve the infrared signal sensitivity, and suppress visible light crosstalk through short-wave cutoff filter to ensure the purity of near-infrared band signal. Solid-state silicon sensor (Si-HR) technology is used to achieve sub-nanometer stability and reduce the influence of air pressure and temperature changes on measurement.

[0045] like Figure 1 As shown, in some embodiments, the system further includes: a non-contact optical profile measurement module 3, the detection end of the non-contact optical profile measurement module 3 is arranged relative to the surface of the slip ring, and the non-contact optical profile measurement module 3 is used to detect the profile of the slip ring surface. Among them, the signal input end of the control module 1 is connected to the signal output end of the non-contact optical profile measurement module 3, and the control module 1 is used to align the temperature difference between the smooth area and the rough area with the profile of the slip ring surface in time and space, and obtain the roughness level of the rough area based on the dynamic fusion model, and adjust the grinding pressure and grinding speed of the grinding device 5 according to the roughness level of the rough area.

[0046] It can be understood that since the detection end of the non-contact optical profile measurement module 3 and the surface of the collector ring are arranged relative to each other, and the signal input end of the control module 1 is connected to the signal output end of the non-contact optical profile measurement module 3, the control module 1 can use the non-contact optical profile measurement module 3 to obtain the morphology of the collector ring surface. In addition, the control module 1 aligns the temperature difference between the smooth area and the rough area with the morphology of the collector ring surface in time and space, and obtains the roughness level of the rough area based on the dynamic fusion model. Therefore, the surface morphology of the collector ring obtained by the non-contact optical profile measurement module 3 and the temperature distribution of the collector ring surface obtained by the temperature detection module 2 realize the multi-dimensional acquisition of the roughness of the rough area, thereby ensuring the precise grinding of the collector ring surface.

[0047] It should be noted that the dynamic fusion model is used to fuse the surface morphology of the collector ring obtained by the non-contact optical morphology measurement module 3 and the temperature distribution of the collector ring surface obtained by the temperature detection module 2, thereby correcting each other and achieving accurate acquisition of the roughness of the rough area.

[0048] Among them, the dynamic fusion model can use the random forest algorithm to optimize the roughness inversion accuracy, and realize signal noise reduction, feature extraction and multimodal data fusion based on the RAEM2 edge computing platform (delay ≤ 10ms).

[0049] The non-contact optical profile measurement module 3 is used to detect the profile of the slip ring surface while avoiding damage to the slip ring. The specific type of the non-contact optical profile measurement module 3 can be set according to actual needs and is not limited to this.

[0050] The topography may be parameters such as the concave depth, convex height, and flatness of the collector ring surface, and there is no limitation on this.

[0051] In some embodiments, the control module 1 is used to obtain a first roughness level of the rough area based on the temperature difference between the smooth area and the rough area, and to obtain a second roughness level of the rough area based on the morphology of the surface of the collector ring, and when the difference between the first roughness level and the second roughness level does not exceed a preset difference, to obtain a corrected roughness level of the rough area based on the first roughness level and the second roughness level, and to adjust the grinding pressure and grinding speed of the grinding equipment 5 based on the corrected roughness level of the rough area.

[0052] It can be understood that the first roughness level of the rough area is obtained by the temperature difference between the smooth area and the rough area, and the second roughness level of the rough area is obtained by the morphology of the collector ring surface. Moreover, when the difference between the first roughness level and the second roughness level does not exceed the preset difference, the corrected roughness level of the rough area is obtained according to the first roughness level and the second roughness level. Thus, the dynamic fusion between the temperature difference data of the smooth area and the rough area and the collector ring surface morphology data is realized, and the grinding pressure and grinding speed of the grinding equipment 5 are adjusted using the corrected roughness level to ensure the precise grinding of the collector ring surface.

[0053] It should be noted that the preset difference between the first roughness level and the second roughness level can be expressed as the first roughness level and the second roughness level differing by one level, or can be expressed as the first roughness level and the second roughness level being at the same level, and there is no limitation on this.

[0054] The corrected roughness level may be an average level of the first roughness level and the second roughness level, a maximum level therebetween, a minimum level therebetween, etc., without limitation.

[0055] like Figure 1 As shown, in some embodiments, the system also includes: an alarm module 4, the signal output end of the control module 1 is connected to the signal input end of the alarm module 4, and the control module 1 is used to control the alarm module 4 to issue a prompt message when the difference between the first roughness level and the second roughness level exceeds a preset difference.

[0056] It can be understood that since the signal output end of the control module 1 is connected to the signal input end of the alarm module 4, when the difference between the first roughness level and the second roughness level exceeds the preset difference, the control module 1 can control the alarm module 4 to issue a prompt message, thereby adjusting the system in time to ensure efficient grinding of the collector ring surface.

[0057] It should be noted that when the difference between the first roughness level and the second roughness level exceeds the preset difference, it indicates that there is a problem with the system detection. For example, the temperature detection module 2 detects that the temperature in a certain area suddenly rises by 10°C, but the non-contact optical morphology measurement module 3 shows that Ra is only 2.1μm. The control module 1 can determine that the abrasive adhesion causes abnormal friction and trigger a cleaning alarm.

[0058] The alarm module 4 is used to issue prompt information. The specific type of the alarm module 4 can be set according to actual needs and is not limited to this. For example, the alarm module 4 can be an audible and visual alarm.

[0059] In some embodiments, the non-contact optical morphology measurement module 3 includes: a laser triangulation displacement sensing unit, the detection end of the laser triangulation displacement sensing unit and the surface of the collector ring are arranged relative to each other, and the signal output end of the laser triangulation displacement sensing unit is connected to the signal input end of the control module 1, and the laser triangulation displacement sensing unit is used to detect the morphology of the collector ring surface.

[0060] It can be understood that since the detection end of the laser triangulation displacement sensing unit and the surface of the collector ring are arranged relative to each other, and the signal output end of the laser triangulation displacement sensing unit is connected to the signal input end of the control module 1, the control module 1 can use the laser triangulation displacement sensing unit to obtain the morphology of the collector ring surface, thereby facilitating the accurate acquisition of the roughness level of the rough area, thereby ensuring the precise grinding of the collector ring surface.

[0061] It should be noted that the specific type of the laser triangulation displacement sensing unit can be set according to actual needs and is not limited to this. For example, the laser triangulation displacement sensing unit can be a laser triangulation displacement sensor with a sampling frequency of 50kHz and an accuracy of ±0.1μm.

[0062] Microwave-band artificial surface plasmon resonators can be utilized to enhance displacement sensing sensitivity and resonance strength. Furthermore, a dual-axis sensor array design can be used to compensate for material thermal expansion errors in real time, with an accuracy better than 0.02μm. The control component can implement a software-based adaptive detection solution, optimizing the displacement signal-to-noise ratio (SNR) (up to 69dB) through dual-mode switching between frequency scanning and resonance tracking.

[0063] In some embodiments, the non-contact optical profile measurement module 3 includes: a white light interference unit, the detection end of the white light interference unit and the surface of the slip ring are arranged relative to each other, and the signal output end of the white light interference unit is connected to the signal input end of the control module 1, and the white light interference unit is used to detect the profile of the slip ring surface.

[0064] It can be understood that since the detection end of the white light interference unit and the surface of the slip ring are arranged relative to each other, and the signal output end of the white light interference unit is connected to the signal input end of the control module 1, the control module 1 can use the white light interference unit to obtain the morphology of the slip ring surface, thereby facilitating the accurate acquisition of the roughness level of the rough area, thereby ensuring the precise grinding of the slip ring surface.

[0065] It should be noted that the specific type of the white light interference unit can be set according to actual needs and is not limited thereto. For example, the white light interference unit can be a white light interferometer with a vertical resolution of 0.1 nm.

[0066] In some embodiments, the control module 1 is used to obtain a local hot spot on the slip ring surface according to the temperature distribution on the slip ring surface, and to obtain a defect type and defect location on the slip ring surface based on the hot spot temperature and the defect correspondence model.

[0067] It can be understood that the local hot spots on the surface of the collector ring are obtained based on the temperature distribution on the surface of the collector ring, and the defect type and defect position on the surface of the collector ring are obtained based on the hot spot temperature and defect correspondence model. Therefore, while realizing closed-loop control of the grinding equipment 5, the temperature distribution on the surface of the collector ring monitored by the temperature detection module 2 can be reused to realize defect detection, thereby further improving the maintenance quality and efficiency of the collector ring.

[0068] It should be noted that surface defects can be identified simultaneously through temperature anomalies. For example, if the local hot spot is greater than 150°C, the defect type can be determined to be a composite defect such as burns or cracks, and the hot spot location is the defect location.

[0069] For the system of this embodiment, the following operations can be performed during implementation:

[0070] Surface pretreatment: A titanium dioxide reflective coating is sprayed on the surface of the low-reflectivity collector ring to improve the signal-to-noise ratio of the optical signal. Environmental compensation: An integrated thermocouple module monitors the ambient temperature in real time, and an algorithm is used to eliminate the interference of temperature drift on the infrared data. Operation and maintenance strategy: Reference block calibration is automatically performed every 8 hours to ensure long-term measurement stability.

[0071] The system of this embodiment has at least the following advantages:

[0072] Non-contact online monitoring is suitable for rotating collector rings with a speed of ≥3000rpm, avoiding the interference of contact measurement on the grinding process; composite defect diagnosis simultaneously identifies surface burns, cracks and other defects through temperature field anomalies (such as local hot spots), improving the level of equipment health management; process optimization benefits, real-time roughness feedback can increase grinding efficiency by 25%-35%, and reduce excessive material loss (carbon brush wear rate is reduced by 18% in typical scenarios).

[0073] like Figure 2 As shown, the embodiment of the present disclosure also provides a method for monitoring the surface roughness of a generator slip ring during dynamic grinding, comprising:

[0074] S1: Detect the temperature distribution on the surface of the collector ring;

[0075] S2: Obtain the temperature difference between the smooth area and the rough area on the slip ring surface according to the temperature distribution on the slip ring surface;

[0076] S3: Obtain the roughness level of the rough area based on the temperature difference and roughness correspondence model;

[0077] S4: adjusting the grinding pressure and grinding speed of the grinding device 5 according to the roughness level of the rough area, so that the roughness of the slip ring surface is within a preset roughness range.

[0078] It can be understood that the temperature difference between the smooth area and the rough area on the surface of the collector ring is obtained according to the temperature distribution on the surface of the collector ring, and the roughness level of the rough area is obtained based on the temperature difference and roughness correspondence model, and the grinding pressure and grinding speed of the grinding equipment 5 are adjusted according to the roughness level of the rough area, thereby realizing closed-loop control of the collector ring surface grinding, thereby effectively improving the grinding accuracy, and further ensuring higher maintenance quality and maintenance efficiency of the collector ring.

[0079] It should be noted that, in the description of this disclosure, the terms "first", "second", etc. are used for descriptive purposes only and should not be understood as indicating or implying relative importance. In addition, in the description of this disclosure, unless otherwise specified, the meaning of "plurality" is two or more.

[0080] Any process or method description in a flowchart or otherwise described herein may be understood to represent a module, segment or portion of code that includes one or more executable instructions for implementing the steps of a specific logical function or process, and the scope of the preferred embodiments of the present disclosure includes additional implementations in which functions may be performed out of the order shown or discussed, including performing functions in a substantially simultaneous manner or in the reverse order depending on the functions involved, which should be understood by those skilled in the art to which the embodiments of the present disclosure belong.

[0081] Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "examples," "specific examples," or "some examples" means that a specific feature, structure, material, or characteristic described in conjunction with that embodiment or example is included in at least one embodiment or example of the present disclosure. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0082] Although the embodiments of the present disclosure have been shown and described above, it is understood that the above embodiments are illustrative and are not to be construed as limitations on the present disclosure. A person skilled in the art may change, modify, replace and vary the above embodiments within the scope of the present disclosure.

Claims

1. A generator collector ring dynamic grinding surface roughness monitoring system, characterized in that: include: a temperature detection module, wherein a detection end of the temperature detection module is arranged opposite to the surface of the slip ring, and the temperature detection module is used to detect the temperature distribution on the surface of the slip ring; A control module, wherein the signal input end of the control module is connected to the signal output end of the temperature detection module, and the signal output end of the control module is connected to the signal input end of the grinding equipment, the control module is used to obtain the temperature difference between the smooth area and the rough area on the surface of the collector ring according to the temperature distribution of the collector ring surface, and obtain the roughness level of the rough area based on the temperature difference and roughness correspondence model, and adjust the grinding pressure and grinding speed of the grinding equipment according to the roughness level of the rough area, so that the roughness of the collector ring surface is within a preset roughness range.

2. The generator slip ring dynamic grinding surface roughness monitoring system according to claim 1 is characterized in that: The temperature detection module includes: an infrared imaging unit, wherein a detection end of the infrared imaging unit is arranged opposite to the surface of the slip ring, and the infrared imaging unit is used to detect a thermal radiation image of the surface of the slip ring; In which, the signal input end of the control module is connected to the signal output end of the infrared imaging unit, and the control module is used to obtain the temperature distribution of the surface of the slip ring based on the thermal radiation image of the surface of the slip ring, and obtain the temperature difference between the smooth area and the rough area based on the temperature distribution of the surface of the slip ring.

3. The generator slip ring dynamic grinding surface roughness monitoring system according to claim 2, characterized in that: The temperature detection module also includes: a displacement detection unit, the displacement detection unit being arranged on the infrared imaging unit, with a detection end of the displacement detection unit and a surface of the slip ring being arranged opposite to each other, and the displacement detection unit being used to detect a relative displacement between the detection end of the infrared imaging unit and the surface of the slip ring; The signal input end of the control module is connected to the signal output end of the displacement detection unit, and the control module is used to adjust the focal length of the infrared imaging unit detection end according to the relative displacement between the infrared imaging unit detection end and the slip ring surface.

4. The generator slip ring dynamic grinding surface roughness monitoring system according to claim 2, characterized in that: The temperature detection module also includes: a temperature sensing unit, the temperature sensing unit being disposed on the infrared imaging unit and being used to detect the temperature at the infrared imaging unit; The signal input end of the control module is connected to the signal output end of the temperature sensing unit, and the control module is used to compensate for the temperature distribution on the surface of the slip ring according to the temperature at the infrared imaging unit.

5. The generator slip ring dynamic grinding surface roughness monitoring system according to claim 1, characterized in that: The system further comprises: A non-contact optical profile measurement module, wherein a detection end of the non-contact optical profile measurement module is arranged opposite to the surface of the slip ring, and the non-contact optical profile measurement module is used to detect the profile of the slip ring surface; Among them, the signal input end of the control module is connected to the signal output end of the non-contact optical morphology measurement module, and the control module is used to align the temperature difference between the smooth area and the rough area with the morphology of the surface of the collector ring in time and space, and obtain the roughness level of the rough area based on the dynamic fusion model, and adjust the grinding pressure and grinding speed of the grinding equipment according to the roughness level of the rough area.

6. The generator slip ring dynamic grinding surface roughness monitoring system according to claim 5, characterized in that: The control module is used to obtain a first roughness level of the rough area based on the temperature difference between the smooth area and the rough area, and to obtain a second roughness level of the rough area based on the morphology of the surface of the collector ring, and when the difference between the first roughness level and the second roughness level does not exceed a preset difference, to obtain a corrected roughness level of the rough area based on the first roughness level and the second roughness level, and to adjust the grinding pressure and grinding speed of the grinding equipment based on the corrected roughness level of the rough area.

7. The generator slip ring dynamic grinding surface roughness monitoring system according to claim 6, characterized in that: The system further comprises: An alarm module, wherein the signal output end of the control module is connected to the signal input end of the alarm module, and the control module is used to control the alarm module to issue a prompt message when the difference between the first roughness level and the second roughness level exceeds a preset difference.

8. The generator slip ring dynamic grinding surface roughness monitoring system according to claim 5, characterized in that: The non-contact optical profile measurement module includes: a laser triangulation displacement sensing unit, wherein a detection end of the laser triangulation displacement sensing unit is arranged opposite to the surface of the slip ring, and a signal output end of the laser triangulation displacement sensing unit is connected to a signal input end of the control module, and the laser triangulation displacement sensing unit is used to detect the topography of the slip ring surface; and / or, A white light interference unit, wherein the detection end of the white light interference unit is arranged opposite to the surface of the slip ring, and the signal output end of the white light interference unit is connected to the signal input end of the control module, and the white light interference unit is used to detect the morphology of the slip ring surface.

9. The generator slip ring dynamic grinding surface roughness monitoring system according to claim 1, characterized in that: The control module is used to obtain the local hot spot on the surface of the slip ring according to the temperature distribution on the surface of the slip ring, and to obtain the defect type and defect position on the surface of the slip ring based on the hot spot temperature and the defect corresponding model.

10. A method for monitoring the surface roughness of a generator collector ring by dynamic grinding, characterized in that: include: detecting the temperature distribution on the surface of the slip ring; Obtaining a temperature difference between a smooth area and a rough area on the slip ring surface according to the temperature distribution on the slip ring surface; Obtaining a roughness level of the rough area based on a temperature difference and a roughness correspondence model; The grinding pressure and the grinding speed of the grinding equipment are adjusted according to the roughness level of the rough area, so that the roughness of the surface of the slip ring is within a preset roughness range.

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