Monitoring system and monitoring method for wind power hoisting equipment

Abstract

The invention provides a monitoring system and a monitoring method for wind power hoisting equipment, a plurality of brackets are fixedly arranged at a plurality of preset sites of the wind power hoisting equipment respectively, and the brackets are used for mounting cameras. The sensor array is distributed and integrated on at least one support and a plurality of sites of the wind power hoisting equipment, and the sensor array comprises a stress sensor, a tilt angle sensor and a tension sensor. The analysis processing unit is in communication connection with the sensor array, and is used for evaluating the safety state of the preset site based on the data of the sensor array, and generating early warning information when the safety state is recognized to be abnormal; the analysis processing unit can analyze whether the bracket and the wind power hoisting equipment have risks such as structure instability and load abnormity or not by analyzing data such as stress, inclination angles and tension of sensors at multiple sites of the bracket and the wind power hoisting equipment, and generates early warning information to actively warn when identifying that the safety state is abnormal, so that the accident rate is reduced.

Description

Technical Field

[0001] This disclosure relates to the field of wind power generation technology, and in particular to a monitoring system and method for wind turbine installation equipment. Background Technology

[0002] In the field of wind power installation, with the increasing size of wind turbines, the installation of large components at heights of over 100 meters often faces numerous challenges, including many monitoring blind spots, unclear structural stress states, and dynamic response delays. Currently, wind power installation monitoring mainly relies on fixed-point video surveillance. Not only are the fixed camera installations unable to adapt to the drastic load changes during the installation process, but the limited monitoring data also results in insufficient coverage of blind spots. Summary of the Invention

[0003] Therefore, it is necessary to provide a monitoring system and method for wind power installation equipment to address the problems in the existing technology.

[0004] In a first aspect, this application provides a monitoring system for wind turbine installation equipment, comprising:

[0005] Multiple brackets are fixedly installed at multiple preset positions on the wind power hoisting equipment, and the brackets are used to install cameras;

[0006] A sensor array, distributed and integrated at at least one of the supports and multiple points of the wind power installation equipment, the sensor array including stress sensors, tilt sensors, and tension sensors;

[0007] The analysis and processing unit is communicatively connected to the sensor array and is used to evaluate the security status of preset sites based on the data from the sensor array. When an abnormal security status is detected, an early warning message is generated.

[0008] In one embodiment, the plurality of supports includes a first support mounted at the top of the wind turbine hoisting equipment, a second support mounted on the crane boom, and a third support mounted on the outriggers;

[0009] The first bracket is a dual-axis gimbal hinge bracket, which is located at the top connecting joint of the wind power hoisting equipment; the second bracket is a hydraulic damping bracket, and the position of the camera mounting end of the second bracket is adjustable; the third bracket is a magnetic universal bracket, which is located on the wire rope pulley block of the outrigger.

[0010] In one embodiment, the first bracket integrates a laser positioning device.

[0011] In one embodiment, it further includes:

[0012] The camera module includes a global monitoring camera, a boom monitoring camera, and a foundation monitoring camera, all deployed on the brackets, as well as a cab camera deployed in the cab; wherein the global monitoring camera is mounted on the first bracket, the boom monitoring camera is mounted on the second bracket, and the foundation monitoring camera is mounted on the third bracket.

[0013] The analysis and processing unit is also communicatively connected to the camera module.

[0014] In one embodiment, it further includes:

[0015] A pose sensing module is installed on the wind turbine hoisting equipment to acquire motion state data of the wind turbine hoisting equipment.

[0016] The analysis and processing unit is configured to construct and update a three-dimensional model of the wind power installation equipment based on the data from the pose sensing module, and to calculate the view coverage matrix of the camera module.

[0017] In one embodiment, the analysis and processing unit is further configured to: when the view coverage matrix detects that the view of the first camera is obstructed, schedule the second camera closest to it to compensate for the obstructed view.

[0018] In one embodiment, the analysis and processing unit is further configured to dynamically adjust the focal length of the camera based on the distance between the target object in the 3D model and the camera.

[0019] Secondly, this application provides a monitoring method for wind turbine installation equipment, comprising the following steps:

[0020] Sensor data at preset locations of the wind power hoisting equipment is acquired by a sensor array that is distributed and integrated on at least one support and multiple locations of the wind power hoisting equipment.

[0021] The security status of preset sites is evaluated based on the data from the sensor array, and an early warning message is generated when an abnormal security status is detected.

[0022] In one embodiment, the following steps are also included:

[0023] Based on the data from the pose sensing module of the wind turbine installation equipment, a three-dimensional model of the wind turbine installation equipment is constructed and updated, and the view coverage matrix of the camera module is calculated.

[0024] When the view coverage matrix detects that the view of the first camera is blocked, it schedules the second camera, which is closest to it, to compensate for the blocked view.

[0025] In one embodiment, the following steps are also included:

[0026] Obtain the distance between the target object and the camera;

[0027] The focal length of the camera is dynamically adjusted based on the distance between the target object and the camera.

[0028] This application discloses a monitoring system and method for wind turbine installation equipment. Multiple supports are fixedly installed at multiple preset locations on the wind turbine installation equipment, and these supports are used to mount cameras. A sensor array is distributed and integrated at least one support and multiple locations on the wind turbine installation equipment. The sensor array includes stress sensors, tilt sensors, and tension sensors. An analysis and processing unit is communicatively connected to the sensor array and is used to assess the safety status of the preset locations based on the data from the sensor array. When an abnormal safety status is detected, an early warning message is generated. By analyzing the stress, tilt, and tension data from the sensors at multiple locations on the supports and the wind turbine installation equipment, the analysis and processing unit can analyze whether there are risks such as structural instability or abnormal loads on the supports and the wind turbine installation equipment. When an abnormal safety status is detected, an early warning message is generated to proactively issue a warning, which helps reduce the accident rate. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments or conventional technologies of this disclosure, the accompanying drawings used in the description of the embodiments or conventional technologies will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of a support frame installed on a wind power hoisting device, as provided in one embodiment.

[0031] Figure 2 This is a schematic diagram of multiple cameras of a camera module provided in one embodiment being installed on a wind power hoisting device;

[0032] Figure 3 This is a schematic diagram of the structure of the second support provided in one embodiment;

[0033] Figure 4 This is a block diagram of a monitoring system for wind turbine installation equipment provided in one embodiment;

[0034] Figure 5 A flowchart of a monitoring method for wind turbine installation equipment provided in one embodiment;

[0035] Figure 6 A flowchart of a monitoring method for wind turbine hoisting equipment provided in another embodiment;

[0036] Figure 7 This is a flowchart of a monitoring method for wind turbine installation equipment provided in another embodiment.

[0037] Explanation of reference numerals in the attached figures:

[0038] 1. Wind power hoisting equipment; 101. Global monitoring camera; 102. Boom monitoring camera; 103. Cab camera; 104. Foundation monitoring camera; 10. Bracket; 210. Second bracket; 11. Main body; 111. Mounting hole; 112. Locking device; 12. Extension; 121. Connection hole; 122. Quick release structure; 13. Fixing structure; 20. Sensor array; 30. Analysis and processing unit; 40. Pose sensing module; 41. Positioning receiving unit; 42. Inertial measurement unit. Detailed Implementation

[0039] To facilitate understanding of this disclosure, a more complete description will now be given with reference to the accompanying drawings, in which preferred embodiments of the present disclosure are shown. However, this disclosure may be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.

[0040] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of this disclosure.

[0041] Wind power hoisting equipment (refer to) Figure 1 Such as large tower cranes or crawler cranes, including mast pulley assemblies, luffing drum support seats, turntable pulley blocks, crawler track connecting pins, slewing ball speed machine tooth surfaces, slewing bearings, main boom lower section boom connecting pins, main luffing mast connecting pins, main and auxiliary lifting drum support seats, hook pulleys and bearings, guide pulleys, crane boom, boom head pulleys, extended boom pulleys, hook pulleys and bearings, and other components.

[0042] Current wind turbine installation monitoring typically involves independently deploying fixed-point cameras on the installation equipment, using closed-circuit television for localized observation. Camera brackets are mostly rigidly fixed, unable to adapt to the dynamic swinging trajectory of the target during installation, resulting in blind spots in critical areas such as the hook-tower docking zone, making it difficult to track the millimeter-precision docking process in real time. Traditional bracket structures lack effective vibration reduction and protection designs, making it difficult to guarantee the stability and clarity of image acquisition under the continuous vibrations generated during installation and the complex environmental interference of wind loads and temperature changes. Existing monitoring systems mainly rely on visual monitoring, lacking synchronous monitoring of the stress state, spatial posture, and wire rope tension of key structures of the installation equipment, making it impossible to comprehensively assess the overall safety status of the installation process. Once the cameras are installed, adjusting the viewing angle or performing maintenance requires professionals to climb hundreds of meters into the air, which is not only extremely risky but also leads to prolonged idleness of the crane equipment, severely impacting installation efficiency.

[0043] According to an exemplary embodiment, this embodiment provides a monitoring system for wind turbine installation equipment, referring to... Figures 1-4 As shown, the monitoring system for wind turbine installation equipment includes multiple supports 10, a sensor array 20, and an analysis and processing unit 30. The supports 10 are fixedly installed at multiple preset locations on the wind turbine installation equipment 1, and are used to mount cameras. The sensor array 20 is distributed and integrated at least one support 10 and multiple locations on the wind turbine installation equipment 1. The sensor array 20 includes stress sensors, tilt sensors, and tension sensors. The analysis and processing unit 30 is communicatively connected to the sensor array 20 and is used to assess the safety status of the preset locations based on the data from the sensor array 20. When an abnormal safety status is detected, it generates an early warning message.

[0044] Sensor array 20 is integrated into the support frame 10 and the wind turbine hoisting equipment 1 to sense changes in the physical state of the support frame 10 and the wind turbine hoisting equipment 1, such as stress. Sensor array 20 includes multiple stress sensors, which can be distributed and attached to the surface of the support frame 10, near the welds of the boom, and in stress concentration areas such as connecting flanges, for real-time monitoring of the structural stress state. Sensor array 20 includes multiple tilt sensors, integrated into the surface of each support frame 10 and the wind turbine hoisting equipment 1, for monitoring changes in the boom's attitude angle. Sensor array 20 includes multiple tension sensors, which are embedded in the bearing seats of the wire rope pulley blocks of the support frame 10 or the wind turbine hoisting equipment 1, directly measuring real-time tension changes in the wire rope.

[0045] It is understood that the analysis and processing unit 30 can be deployed on a cloud server and interact with the sensor array 20 deployed on the wind power installation equipment 1 via a 5G network to achieve remote monitoring. This architecture can reduce the computing load of on-site equipment and facilitate centralized management.

[0046] In this embodiment, refer to Figure 4 The analysis and processing unit 30 is communicatively connected to the sensor array 20, continuously receiving data from the distributed sensor array 20. The analysis and processing unit 30 assigns a unified timestamp to all data, ensuring that data from different sensors at the same time can be correlated and analyzed. The analysis and processing unit 30 performs safety status assessment based on multi-sensor data. The analysis and processing unit 30 has a pre-stored safety threshold library for different operating conditions. It compares the data from the sensor array 20 with the corresponding safety thresholds. If the data from the sensor array 20 exceeds the safety threshold, it identifies an abnormal safety status and generates a warning message. The warning message includes at least the risk location, risk type, risk level, and recommended measures. The analysis and processing unit 30 outputs the warning message to the driver's cab human-machine interface and the remote monitoring center.

[0047] For example, the analysis and processing unit 30 sets three thresholds for the stress points of the support 10: a warning threshold, an alarm threshold, and a danger threshold. When the stress sensor data reaches 60% of the yield limit, the point is marked as "attention"; when the stress data reaches 80% of the material's yield limit, the point is marked as "abnormal"; and when the stress data reaches 95% of the material's yield limit, the point is marked as "dangerous".

[0048] In this embodiment, a monitoring system for wind turbine installation equipment includes multiple supports 10 fixedly installed at multiple preset locations on the wind turbine installation equipment 1. Each support 10 is used to mount cameras. A sensor array 20 is distributed and integrated at least one support 10 and multiple locations on the wind turbine installation equipment 1. The sensor array 20 includes stress sensors, tilt sensors, and tension sensors. An analysis and processing unit 30 is communicatively connected to the sensor array 20 and is used to assess the safety status of the preset locations based on the data from the sensor array 20. When an abnormal safety status is detected, an early warning message is generated. By analyzing the stress, tilt, and tension data from the sensors at multiple locations on the support 10 and the wind turbine installation equipment 1, the analysis and processing unit 30 can analyze whether there are risks such as structural instability or abnormal loads on the support 10 and the wind turbine installation equipment 1. When an abnormal safety status is detected, an early warning message is generated to proactively issue a warning, which helps reduce the accident rate.

[0049] In some embodiments, refer to Figure 4 The analysis and processing unit 30 receives data from the sensor array 20 and predicts the trend of state changes in the near future (3s-5s) based on the historical data of the sensor array 20. For example, the analysis and processing unit 30 receives tilt sensor data and analyzes it. If it finds that the tilt angle of the boom is continuously and rapidly deviating from the safe working range, even if the current value does not exceed the threshold, the analysis and processing unit 30 will issue an early warning message to achieve predictive maintenance.

[0050] In one example, when the tension sensor detects a sudden and sharp decrease in the tension of the wire rope (suspected breakage), and at the same time the tilt sensor detects a drastic change in the boom posture, the analysis and processing unit 30 can cross-verify and confirm that a serious accident of loss of load has occurred, and issue an early warning message.

[0051] In another example, when the stress sensor shows a significant increase in outrigger pressure and the tilt sensor shows that the vehicle is tilting, the analysis and processing unit 30 can comprehensively determine that it is due to foundation settlement or instability, rather than simply an increase in load, and issue a warning message.

[0052] In one embodiment, reference Figure 1 , Figure 3 The multiple supports 10 include a first support (not shown in the figure) installed at the top of the wind power hoisting equipment 1, a second support 210 installed on the crane boom, and a third support (not shown in the figure) installed on the outriggers.

[0053] The first support is a dual-axis gimbal hinge support, located at the top connecting joint of the wind turbine installation equipment 1. The first support is fixedly installed at the top connecting joint of the wind turbine tower or nacelle. The main body of the first support is made of stainless steel and has a load-bearing capacity of more than 2.5 kg to adapt to high-altitude strong wind environments. The end of the first support integrates a dual-axis gimbal, which can provide ±45° pitch and horizontal adjustment.

[0054] The second bracket 210 is a hydraulically damped bracket, and the position of the camera mounting end of the second bracket 210 is adjustable. The second bracket 210 is installed on the crane boom via a ring clamp. The second bracket 210 has a built-in hydraulic damping mechanism, which can effectively filter the high-frequency vibrations generated by boom swing and winch start-stop, ensuring image stability. The position of the camera mounting end of the second bracket 210 is adjustable.

[0055] The third support is a magnetic universal support, installed on the wire rope pulley block of the outrigger. The base of the third support uses a high-strength magnet, allowing it to firmly attach to metal surfaces such as the pulley block bearing housing. The third support employs a universal ball joint structure, allowing for ±15° angle adjustments after attachment. Specifically, the third support is designed to embed ±2 cm into the pulley groove, enabling embedded, close-range monitoring of the wire rope tension, wear, and rope arrangement.

[0056] In one example, refer to Figure 3The second support 210 includes a main body 11, an extension 12, a first drive mechanism (not shown in the figure), a longitudinal slide rail (not shown in the figure), and a second drive mechanism (not shown in the figure). The main body 11 is provided with an adjustable mounting hole 111 and a locking device 112. It is mounted on the wind power hoisting equipment 1 through the mounting hole 111 and locked by the locking device 112. The extension 12 is movably connected to the main body 11. The first drive mechanism is used to drive the extension 12 to move horizontally along its length direction to adjust the extension length of the extension 12. The longitudinal slide rail is movably disposed on the main body 11 through the second drive mechanism. The second drive mechanism can drive the longitudinal slide rail to move up and down in the vertical direction. The extension 12 is installed on the longitudinal slide rail and moves with it. The end of the extension 12 away from the main body 11 is provided with a connecting hole 121. The inner wall of the connecting hole 121 is provided with a quick-release structure 122. The pan-tilt mechanism is installed at the end of the extension 12 away from the main body 11, specifically at the connecting hole 121, and is used to support the boom monitoring camera 102. The pan-tilt mechanism includes at least one angle fine-tuning component. The angle fine-tuning component is a universal joint structure driven by a gear set, which can drive the boom monitoring camera 102 to achieve pitch, rotation and angle adjustment.

[0057] Reference Figure 4 The second support 210 also includes a fixing structure 13, which is sleeved on the outside of the extension 12. The inner wall of the fixing structure 13 and the outer surface of the extension 12 maintain a small and uniform gap. When the first drive mechanism drives the extension 12 to move, the fixing structure 13 can effectively constrain the extension 12 and prevent the extension 12 from generating unexpected radial jumps or swaying during the movement.

[0058] Thus, the extension section is driven to extend and retract horizontally via the first drive mechanism (adjustment range 0.5-1.5 meters); the entire extension section 12 is driven to make fine adjustments in the vertical direction by ±0.3 meters via the second drive mechanism. This design enables the boom monitoring camera 102 to continuously track the swing of the suspended object and adapt to the changes in viewing angle caused by boom luffing and extension.

[0059] In some embodiments, the first support integrates a laser positioning device (not shown in the figure). The laser positioning device is used to project a visible light spot during the installation phase to assist the operator in remotely connecting the hook and the tower, and to provide a spectral reference for observing the alignment of bolt holes down to the millimeter level.

[0060] In some embodiments, the bracket 10 (first bracket, second bracket 210, and third bracket) is made of stainless steel. Stainless steel has good corrosion resistance and is less affected by high-salt, high-humidity air, strong winds, sandstorms, rain, and snow, which can extend the service life of the bracket 10 in outdoor working conditions.

[0061] In some embodiments, the support 10 (first support, second support 210, third support) has a load-bearing capacity greater than 2.5 kg, ensuring that the support 10 can stably support all end loads composed of gimbal, camera, etc., and can maintain structural stability and not deform or shake when subjected to dynamic interference such as high-altitude wind load and equipment vibration, thereby ensuring the stability of the camera's captured image.

[0062] In some embodiments, refer to Figure 2 , Figure 4 The monitoring system for wind power hoisting equipment also includes a camera module 100, which includes a global monitoring camera 101, a boom monitoring camera 102, a foundation monitoring camera 104, and a cab camera 103, all of which are deployed on the support 10.

[0063] The global monitoring camera 101 is mounted on the first support. It is a long-range zoom camera with a monitoring distance greater than 200 meters, a focal length range of 6.8-110mm, and a pointing accuracy of ±0.1°. The global monitoring camera 101 monitors the macroscopic scene of the entire hoisting process and is specifically used to acquire high-definition panoramic images of the hoisting docking area. During the bolting connection between the impeller and the nacelle, the global monitoring camera 101 provides a clear image sufficient to observe alignment details.

[0064] The boom monitoring camera 102 is mounted on the second bracket 210. The boom monitoring camera 102 is a wide-angle camera with a horizontal viewing angle greater than 120°. Through the hydraulic damping mechanism and anti-vibration gimbal built into the second bracket 210, it effectively suppresses vibrations caused by boom movement, ensuring image stability. The boom monitoring camera 102 moves with the boom to acquire real-time dynamic images of the boom's swing area and continuously track the movement trajectory of the hook and the hoisted object.

[0065] The foundation monitoring camera 104 is installed on the third bracket. The foundation monitoring camera 104 integrates an infrared thermal imaging module and a laser ranging module. The infrared thermal imaging is used to detect potential hazards by monitoring the abnormal temperature field of the foundation at night or in the absence of light. The laser ranging is used to monitor the minute changes in the distance between the outrigger and the ground, and to monitor the settlement and cracks in the load-bearing area of ​​the outrigger in all weather and in multiple modes.

[0066] The cab camera 103 is deployed in front of the cab of the wind turbine hoisting equipment 12, or it may be deployed on the top of the cab. The cab camera 103 is used to capture images inside the cab and monitor the operator's status. The cab camera 103 is used to identify the operator's working status inside the cab. In some embodiments, the cab camera 103 can also provide wide-angle coverage of the intrusion warning zone in front of the cab, covering blind spots in the operator's field of vision.

[0067] The analysis and processing unit 30 is also communicatively connected to the camera module 100. The analysis and processing unit 30 synchronously receives data (stress, tilt angle, tension) from the sensor array 20 and various video streams from the camera module. The analysis and processing unit 30 can perform image analysis on the video streams. For example, when the stress sensor indicates that the stress at the base of the boom is close to a threshold, the analysis and processing unit 30 can automatically access the image from the boom monitoring camera 102 to assist in verifying whether there is structural deformation or abnormal swaying through visual imagery, thus reducing the probability of false alarms from a single sensor.

[0068] It is understood that although each camera in this embodiment is assigned a primary monitoring area, this does not mean that each camera only monitors its assigned area, and the viewing angle of each camera is not limited to its primary area of ​​responsibility. For example, the monitoring area also includes the environmental intrusion warning zone, which can be monitored by the global monitoring camera 101, the boom monitoring camera 102, the cab camera 103, and the foundation monitoring camera 104. Furthermore, the global monitoring camera 101 can monitor almost every area of ​​responsibility, including the hoisting docking area, the boom swing area, the environmental intrusion warning zone, and the outrigger load-bearing area. This improves monitoring coverage, and even if a camera module 100 is damaged or its viewing angle is obstructed, the missing monitoring from the damaged or obstructed camera can be compensated for by other cameras.

[0069] In some embodiments, refer to Figure 4 The monitoring system for wind turbine installation equipment also includes a pose sensing module 40, which is installed on the wind turbine installation equipment 1. The pose sensing module 40 is used to acquire motion state data of the wind turbine installation equipment 1. The analysis and processing unit 30 is configured to construct and update a three-dimensional model of the wind turbine installation equipment 1 based on the data from the pose sensing module 40, and to calculate the view coverage matrix of the camera module 100.

[0070] Among them, reference Figure 2 , Figure 4 The pose sensing module 40 includes a positioning receiving unit 41 and an inertial measurement unit 42. The positioning receiving unit 41 is deployed at the crane's rotation center or the base of the boom, and is used to determine the position (latitude, longitude, and altitude) of the wind power installation equipment 1. The inertial measurement unit 42 is deployed on moving parts that require precise attitude sensing, such as the boom head and the top of the tower. The inertial measurement unit 42 is used to measure the angular velocity and linear acceleration of the equipment in three-dimensional space, and then calculate the real-time motion attitude of the equipment (such as pitch angle, roll angle, and yaw angle).

[0071] The analysis and processing unit 30 is equipped with a pose calculation engine. This engine uses a sensor fusion algorithm to deeply fuse the position data provided by the positioning receiving unit 41 with the motion state data provided by the inertial measurement unit 42. A 1:1 corresponding 3D model of the wind turbine installation equipment 1 is constructed in digital space. This 3D model not only includes static structures such as the tower, boom, and outriggers, but also allows for real-time driving of the virtual boom to perform rotation, luffing, and telescopic movements, ensuring its pose is synchronized with the actual equipment.

[0072] In the 3D model, the analysis and processing unit 30 calculates the viewing frustum of each camera in real time based on the pre-calibrated intrinsic parameters (focal length, sensor size) and extrinsic parameters (fixed coordinate transformation based on the mounting position of its bracket 10). The set of viewing frustums of the cameras constitutes the view coverage matrix. The view coverage matrix represents the range of 3D space that each camera can see at any given time, as well as the overlapping area between the fields of view of different cameras.

[0073] In some embodiments, the analysis and processing unit 30 is further configured to, when the view coverage matrix detects that the view of the first camera (any camera in the camera module 100) is obstructed, schedule the nearest second camera (another camera in the camera module 100, such as the camera closest to the first camera) to compensate for the obstructed view.

[0074] The analysis and processing unit 30 predicts visual blind spots that will be generated due to equipment movement based on the view coverage matrix. For example, when the 3D model shows that the rotation of the boom will obstruct the view of the outriggers in 3 seconds, the analysis and processing unit 30 can pre-arrange the ground monitoring camera 104 to adjust its angle or instruct the global monitoring camera 101 to zoom and lock onto the area in advance, achieving seamless view switching and reducing the time of loss of view due to obstruction to less than 200 milliseconds.

[0075] In some embodiments, the analysis and processing unit 30 is further configured to dynamically adjust the focal length of the camera based on the distance between the target object in the 3D model and the camera.

[0076] For example, when continuous tracking of a target object (such as a swinging blade, hook, or bolt hole) is required, the analysis and processing unit 30 can calculate the optimal camera pose parameters based on the real-time coordinates of the target object in the 3D model, and automatically drive the corresponding support 10, gimbal, and zoom lens to achieve automatic focus and ensure that the target object is always in the best position in the image. For example, switching the camera to 4K super macro mode.

[0077] Alternatively, the analysis and processing unit 30 can spatially locate the abnormal data (such as a sudden increase in stress at a certain point) reported by the sensor array 20 in the three-dimensional model, and call the camera closest to that point to view it, realizing the second-level linkage between physical anomalies and visual verification, which greatly improves the efficiency of safety hazard investigation.

[0078] According to an exemplary embodiment, this embodiment provides a monitoring method for wind turbine installation equipment, referring to... Figure 5 As shown, the monitoring method for wind turbine installation equipment includes the following steps:

[0079] Step S501: Obtain sensor data at preset locations of the wind power installation equipment by using a sensor array that is distributed and integrated on at least one support and multiple locations of the wind power installation equipment.

[0080] In this embodiment, the sensor array 20 includes stress sensors, tilt sensors, and tension sensors. Stress sensors can be distributed and attached to the surface of the support 10, near the welds of the boom, and in stress concentration areas such as connecting flanges, for real-time monitoring of the structural stress state. Tilt sensors are integrated into the surfaces of each support 10 and the wind turbine hoisting equipment 1 to monitor changes in the attitude angle of the tower and boom. Tension sensors are embedded in the bearing seats of the wire rope pulley blocks of the support 10 or the wind turbine hoisting equipment 1 to directly measure the real-time tension changes of the wire rope. The analysis and processing unit 30 receives data collected by the sensors in the sensor array 20.

[0081] Step S502: Evaluate the safety status of preset sites based on data from the sensor array, and generate early warning information when an abnormal safety status is detected.

[0082] The analysis and processing unit 30 has a pre-stored safety threshold library for different operating conditions. The unit compares the data from the sensor array 20 with the corresponding safety thresholds. If the data from the sensor array 20 exceeds the safety threshold, an abnormal safety condition is identified, and a warning message is generated. The warning message includes at least the location of the risk, the type of risk, the risk level, and recommended measures. The analysis and processing unit 30 outputs the warning message to the driver's cab human-machine interface and the remote monitoring center.

[0083] For example, the analysis and processing unit 30 sets three thresholds for the stress points of the support 10: a warning threshold, an alarm threshold, and a danger threshold. When the stress sensor data reaches 60% of the yield limit, the point is marked as "attention"; when the stress data reaches 80% of the material's yield limit, the point is marked as "abnormal"; and when the stress data reaches 95% of the material's yield limit, the point is marked as "dangerous".

[0084] The detection method in this embodiment analyzes the stress, tilt angle, tension and other data of sensors at multiple locations of the support 10 and the wind power hoisting equipment 1. This analysis can determine whether there are risks such as structural instability or abnormal loads in the support 10 and the wind power hoisting equipment 1. When an abnormal safety condition is detected, an early warning message is generated to proactively warn the user, which helps to reduce the accident rate.

[0085] In some embodiments, the monitoring method for wind turbine installation equipment refers to Figure 6 As shown, steps S503-S504 were also executed. It can be understood that steps S503-S504 are executed throughout the entire operation of the monitoring method, and the execution order of steps S503-S504 is not important compared to steps S501-S502.

[0086] Step S503: Based on the data from the pose sensing module of the wind turbine installation equipment, construct and update the 3D model of the wind turbine installation equipment, and calculate the view coverage matrix of the camera module.

[0087] In this embodiment, the analysis and processing unit 30 acquires the position and motion status data of the wind turbine hoisting equipment 1 through the pose sensing module 40 installed on the wind turbine hoisting equipment 1. A 1:1 corresponding three-dimensional model of the wind turbine hoisting equipment 1 is constructed in digital space. The three-dimensional model not only includes static structures such as the tower, boom, and outriggers, but also allows for real-time driving of the virtual boom to perform rotation, luffing, and telescopic movements, ensuring its pose is synchronized with the actual equipment.

[0088] In the 3D model, the analysis and processing unit 30 calculates the viewing frustum of each camera in real time based on the pre-calibrated intrinsic parameters (focal length, sensor size) and extrinsic parameters (fixed coordinate transformation based on the mounting position of its bracket 10). The set of viewing frustums of the cameras constitutes the view coverage matrix. The view coverage matrix represents the range of 3D space that each camera can see at any given time, as well as the overlapping area between the fields of view of different cameras.

[0089] Step S504: When the view coverage matrix detects that the view of the first camera is blocked, it schedules the second camera, which is closest to it, to compensate for the blocked view.

[0090] In this embodiment, the analysis and processing unit 30 predicts visual blind spots that will be generated due to equipment movement based on the view coverage matrix. For example, when the 3D model shows that the rotation of the boom will obstruct the view of the outriggers after 3 seconds, the analysis and processing unit 30 can pre-arrange the ground monitoring camera 104 to adjust its angle, or instruct the global monitoring camera 101 to pre-focus and lock onto the area, thereby achieving seamless view switching and reducing the time of loss of view due to obstruction to less than 200 milliseconds.

[0091] In some embodiments, refer to Figure 7As shown, the monitoring method for wind power hoisting equipment also executes steps S505-S506. It can be understood that steps S505-S506 are executed throughout the entire operation of the monitoring method, and the execution order of steps S505-S506 is not important compared to steps S501-S502.

[0092] Step S505: Obtain the distance between the target object and the camera.

[0093] Step S506: Dynamically adjust the camera's focal length based on the distance between the target object and the camera.

[0094] In this embodiment, the analysis and processing unit 30 dynamically adjusts the focal length of the camera based on the distance between the target object (such as a swinging blade, hook, or bolt hole) in the three-dimensional model and the camera.

[0095] For example, when it is necessary to align and examine a target object, the analysis and processing unit 30 calls the camera closest to that point to align and examine it, and automatically switches the camera to 4K super macro mode to capture a clear image of millimeter-level defects.

[0096] The monitoring system and method for wind turbine installation equipment disclosed in this application, through data analysis and verification from multiple sensors, can identify safety hazards in the support structure and wind turbine installation equipment. When an abnormal safety condition is detected, it generates early warning information, reducing the false alarm rate from over 30% to less than 5%, achieving early and accurate diagnosis of structural safety hazards. It identifies potential risks 3-5 seconds in advance, providing operators with a valuable intervention window and enabling predictive safety control. Simultaneously, by adjusting the camera's viewing angle, the monitoring coverage is increased from less than 40% to over 99.5%, eliminating blind spots. This application also improves camera installation reliability by optimizing the structure and setup of the support structure and cameras, ensuring stable system operation under harsh conditions and enhancing maintenance efficiency and safety.

[0097] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features of the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0098] The embodiments described above are merely illustrative of several implementations of this disclosure, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this disclosure, and these all fall within the scope of protection of this disclosure. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A monitoring system for wind turbine installation equipment, characterized in that, include: Multiple brackets are fixedly installed at multiple preset positions on the wind power hoisting equipment, and the brackets are used to install cameras; A sensor array, distributed and integrated at at least one of the supports and multiple points of the wind power installation equipment, the sensor array including stress sensors, tilt sensors, and tension sensors; The analysis and processing unit is communicatively connected to the sensor array and is used to evaluate the security status of preset sites based on the data from the sensor array. When an abnormal security status is detected, an early warning message is generated.

2. The monitoring system for wind turbine installation equipment according to claim 1, characterized in that, The plurality of supports includes a first support installed at the top of the wind turbine hoisting equipment, a second support installed on the crane boom, and a third support installed on the outriggers; The first bracket is a dual-axis gimbal hinge bracket, which is located at the top connecting joint of the wind power hoisting equipment; the second bracket is a hydraulic damping bracket, and the position of the camera mounting end of the second bracket is adjustable; the third bracket is a magnetic universal bracket, which is located on the wire rope pulley block of the outrigger.

3. The monitoring system for wind turbine installation equipment according to claim 2, characterized in that, The first bracket integrates a laser positioning device.

4. The monitoring system for wind turbine hoisting equipment according to any one of claims 1-3, characterized in that, Also includes: The camera module includes a global monitoring camera, a boom monitoring camera, and a foundation monitoring camera, all deployed on the brackets, as well as a cab camera deployed in the cab; wherein the global monitoring camera is mounted on the first bracket, the boom monitoring camera is mounted on the second bracket, and the foundation monitoring camera is mounted on the third bracket. The analysis and processing unit is also communicatively connected to the camera module.

5. The monitoring system for wind turbine installation equipment according to claim 4, characterized in that, Also includes: A pose sensing module is installed on the wind turbine hoisting equipment to acquire motion state data of the wind turbine hoisting equipment. The analysis and processing unit is configured to construct and update a three-dimensional model of the wind power installation equipment based on the data from the pose sensing module, and to calculate the view coverage matrix of the camera module.

6. The monitoring system for wind turbine installation equipment according to claim 5, characterized in that, The analysis and processing unit is further configured to: when the view coverage matrix detects that the view of the first camera is blocked, schedule the second camera closest to it to compensate for the blocked view.

7. The monitoring system for wind turbine installation equipment according to claim 5, characterized in that, The analysis and processing unit is further configured to dynamically adjust the focal length of the camera based on the distance between the target object in the 3D model and the camera.

8. A monitoring method for wind turbine installation equipment, characterized in that, Includes the following steps: Sensor data at preset locations of the wind power hoisting equipment is acquired by a sensor array that is distributed and integrated on at least one support and multiple locations of the wind power hoisting equipment. The security status of preset sites is evaluated based on the data from the sensor array, and an early warning message is generated when an abnormal security status is detected.

9. The monitoring method for wind turbine installation equipment according to claim 8, characterized in that, It also includes the following steps: Based on the data from the pose sensing module of the wind turbine installation equipment, a three-dimensional model of the wind turbine installation equipment is constructed and updated, and the view coverage matrix of the camera module is calculated. When the view coverage matrix detects that the view of the first camera is blocked, it schedules the second camera, which is closest to it, to compensate for the blocked view.

10. The monitoring method for wind turbine installation equipment according to claim 8, characterized in that, It also includes the following steps: Obtain the distance between the target object and the camera; The focal length of the camera is dynamically adjusted based on the distance between the target object and the camera.

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