An on-line monitoring device for lubricating oil of a wind power generator

Abstract

The application discloses a kind of wind-driven generator lubricating oil on-line monitoring device, belong to lubricating oil detection technical field, including on-line monitor, on-line monitor includes monitoring shell, monitoring shell is set with multiple detection stations according to detection cavity mouth position, multiple on-line monitoring sensors for detecting the lubricating oil in detection cavity mouth are set on the monitoring shell at detection station position.The application obtains the lubricating oil circulating in system by directly, regularly sampling from main circulating pipeline, guarantees that sample can truly reflect the oil state of entire lubricating system, by built-in resistance type heating layer, can preheat lubricating oil sample to standard detection temperature, effectively eliminates the interference of oil temperature change to detection result caused by the harsh environment of fan, and using ultrasonic vibration source, oil sample is mixed, prevent particle deposition, ensure oil sample uniform, to improve the accuracy of each sensor detection data.

Description

Technical Field

[0001] This invention relates to the field of lubricating oil testing technology, and in particular to an online monitoring device for lubricating oil in wind turbine generators. Background Technology

[0002] As a core component of the transmission system, the gearbox of a wind turbine directly affects the operational safety and lifespan of the entire unit. Continuous monitoring of the gearbox lubricating oil, known as "oil analysis," is akin to "drawing blood" from the turbine. By analyzing the physicochemical properties of the oil and the wear particles it carries, the operating status of the gearbox can be effectively assessed. This is a key means of achieving predictive maintenance and avoiding catastrophic failures.

[0003] However, wind turbines are typically located in remote, harsh environments (such as high altitude and high humidity), which poses a significant challenge to traditional manual oil sampling and testing. This method is not only costly but also lacks timeliness, making it difficult to meet the needs of real-time early warning. Therefore, online oil monitoring technology has become the mainstream approach.

[0004] However, existing online monitoring solutions still have significant shortcomings:

[0005] The accuracy of detection is limited by the environment: most existing sensors are directly installed on the circulation pipeline, and their detection performance is severely restricted by the ambient temperature. The temperature of lubricating oil often cannot reach the detection temperature conditions of a standard laboratory, resulting in distorted measurement results of key parameters such as viscosity and moisture, which cannot truly reflect the state of the oil.

[0006] Lack of effective real-time intervention capabilities: Even if the monitoring system detects oil deterioration, the maintenance team struggles to arrive on-site quickly to address the issue. Wind turbines often face a dilemma: either operate at risk under deteriorated lubrication conditions, exacerbating equipment wear, or immediately shut down for maintenance, resulting in significant power generation losses. This passive "monitoring only, difficult to intervene" approach fails to fundamentally solve the problem. Summary of the Invention

[0007] The purpose of this invention is to solve the problems existing in the prior art by proposing an online monitoring device for lubricating oil of wind turbine generators.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] An online monitoring device for lubricating oil in a wind turbine generator includes a circulating sampling pipe installed on the pipeline of the wind turbine generator lubrication system. An online monitor is installed on one side of the circulating sampling pipe. The online monitor includes a monitoring housing. A sampling chamber is opened inside the monitoring housing. A sampling port penetrating the side wall is opened on one side of the sampling chamber. A sampling inner cylinder is arranged inside the monitoring housing. Multiple detection ports are opened on the outer wall of the sampling inner cylinder. Multiple detection stations are arranged on the monitoring housing corresponding to the detection ports. Multiple online monitoring sensors for detecting the lubricating oil in the detection ports are arranged on the monitoring housing at the detection stations.

[0010] Both ends of the monitoring housing are provided with mounting end caps, and the inner wall of the mounting end cap at the corresponding detection station is provided with a standardized detection scenario component for pre-processing lubricating oil detection.

[0011] The monitoring housing is equipped with a lubricating oil emergency treatment device, which includes a lubricating oil drive assembly mounted on the mounting end cover, and a lubricating oil replacement pipeline system mounted on the mounting end cover.

[0012] As a preferred embodiment, the online monitoring sensors include an online oil quality sensor, an online viscometer, an online particle sensor, and an online moisture sensor, and the detection ends of the online monitoring sensors are all located inside the monitoring housing at the detection station.

[0013] As a preferred embodiment, the standardized testing scenario component includes two sets of ultrasonic vibration sources mounted on the mounting end cap. The ultrasonic vibration sources are located at the testing station and are used to uniformly mix the lubricating oil during the lubricating oil testing process.

[0014] As a preferred embodiment, the inner wall of the sampling chamber located at the testing station is provided with a resistance heating layer, which is used to heat the lubricating oil in the testing chamber.

[0015] As a preferred embodiment, the lubricating oil drive assembly includes piston storage grooves formed in both ends of the mounting end cap. The piston storage grooves are adapted to the detection chamber openings. A replacement piston is provided in the piston storage grooves. When the lubricating oil is being replaced, the replacement piston can move between the piston storage grooves and the detection chamber openings.

[0016] As a preferred embodiment, the lubricating oil replacement pipeline system includes an electromagnetic control valve located at the bottom of the monitoring housing, and a recovery pipeline and an injection pipeline connected to the electromagnetic control valve are provided on the piston receiving groove. The electromagnetic control valve is connected to the recovery pipeline and the injection pipeline.

[0017] As a preferred embodiment, an online control motor is provided at one end of the monitoring housing, and the output end of the online control motor extends into the sampling chamber and is connected to the sampling inner cylinder.

[0018] As a preferred embodiment, the circulating sampling tube has a snap-fit ​​opening on one side that communicates with the sampling port, and the sampling inner cylinder is located inside the circulating sampling tube.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0020] 1. The monitoring device designed in this invention directly and periodically samples the lubricating oil circulating in the system, ensuring that the sample accurately reflects the oil condition of the entire lubrication system. Through the built-in resistance heating layer, the lubricating oil sample can be preheated to the standard detection temperature, effectively eliminating the interference of oil temperature changes caused by the harsh environment of the fan on the detection results. Furthermore, the oil sample is shaken and mixed using an ultrasonic vibration source to prevent particulate matter from settling and ensure that the oil sample is uniform, thereby improving the accuracy of the detection data of various sensors.

[0021] 2. When the lubricating oil deterioration is detected, the device can automatically start the emergency program without waiting for manual intervention. Through the built-in piston and pipeline system, the deteriorated lubricating oil can be gradually replaced. The integrated "online partial oil change" emergency mode can effectively improve the lubrication condition before maintenance personnel arrive, avoid the fan from shutting down immediately due to lubricating oil problems, or minimize the risk of catastrophic failure, significantly improving the availability and operational safety of the fan. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the main structure of an online monitoring device for lubricating oil of a wind turbine generator proposed in this invention;

[0023] Figure 2 This is a structural assembly diagram of the online monitor in the online monitoring device for wind turbine lubricating oil proposed in this invention;

[0024] Figure 3 This is a schematic diagram of the online monitor in the online monitoring device for lubricating oil of a wind turbine generator proposed in this invention;

[0025] Figure 4 This is a cross-sectional schematic diagram of the online monitor in the wind turbine lubricating oil online monitoring device proposed in this invention;

[0026] Figure 5 This is a diagram showing the installation distribution of components on the mounting end cover in an online monitoring device for lubricating oil of a wind turbine generator proposed in this invention.

[0027] Figure 6This is a schematic diagram of the circulating sampling tube in an online monitoring device for lubricating oil of a wind turbine generator proposed in this invention.

[0028] In the diagram: 1. Circulating sampling tube; 2. Monitoring shell; 3. Sampling chamber; 4. Sampling inner cylinder; 5. Detection port; 6. Online oil quality sensor; 7. Online viscometer; 8. Online particle sensor; 9. Online moisture sensor; 10. Mounting end cap; 11. Ultrasonic vibration source; 12. Resistance heating layer; 13. Piston receiving groove; 14. Replacement piston; 15. Electromagnetic control valve; 16. Recovery pipeline; 17. Injection pipeline; 18. Online control motor. Detailed Implementation

[0029] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0030] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0031] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0032] Example, refer to Figures 1 to 6 An online monitoring device for lubricating oil of a wind turbine includes a circulating sampling pipe 1 installed on the pipeline of the wind turbine lubrication system. The flow diameter of the circulating sampling pipe 1 needs to be larger than that of the pipe on the wind turbine lubrication system to ensure that the online monitor can meet the normal operation of the wind turbine lubrication system even when sampling.

[0033] An online monitor is installed on one side of the circulating sampling tube body 1. The online monitor includes a monitoring housing 2. The monitoring housing 2 is supported and installed on the circulating sampling tube body 1 by a support member. A sampling chamber 3 is opened inside the monitoring housing 2. A sampling port penetrating the side wall is opened on one side of the sampling chamber 3. A sampling inner cylinder 4 is set inside the monitoring housing 2.

[0034] Furthermore, a snap-fit ​​opening connected to the sampling port is provided on one side of the circulating sampling tube body 1. The sampling inner cylinder 4 is located inside the circulating sampling tube body 1. When the detection cavity 5 opened on the outer wall of the sampling inner cylinder 4 moves to the circulating sampling tube body 1, it will realize sampling inside the circulating sampling tube body 1, thereby sampling the lubricating oil inside the circulating sampling tube body 1. By periodically controlling the online control motor 18 to rotate, automatic sampling can be achieved. Moreover, the extracted lubricating oil sample belongs to the lubricating oil that is continuously circulating inside the circulating sampling tube body 1, thus ensuring that the lubricating oil sampling is more representative.

[0035] Furthermore, an online control motor 18 is provided at one end of the monitoring housing 2. The output end of the online control motor 18 extends into the sampling chamber 3 and is connected to the sampling inner cylinder 4. The online control motor 18 can be programmed to achieve periodic control, thereby driving the sampling inner cylinder 4 to perform timed sampling.

[0036] Multiple detection ports 5 are provided on the outer wall of the sampling inner cylinder 4. Multiple detection stations are set on the monitoring housing 2 corresponding to the detection ports 5. The detection stations are adjusted according to the number of detection ports 5 on the sampling inner cylinder 4. Multiple online monitoring sensors for detecting the lubricating oil in the detection ports 5 are set on the monitoring housing 2 located at the detection stations. Furthermore, the online monitoring sensors include an online oil quality sensor 6, an online viscometer 7, an online particle sensor 8, and an online moisture sensor 9. The detection ends of the online monitoring sensors are all located inside the monitoring housing 2 located at the detection stations.

[0037] Among them, the online moisture sensor 9 is used to monitor the moisture content in the oil in real time; the online particle sensor 8 is used to monitor the cleanliness level of the oil in real time; the online viscometer 7 is used to monitor the viscosity change of the oil in real time; and the online oil quality sensor 6 is used to comprehensively judge the overall aging state of the oil by parameters such as dielectric constant.

[0038] Since different online monitoring sensors require different temperature ranges when detecting lubricating oil, the resistance heating layer 12 in the two detection stations can be set in different temperature ranges, and the online oil quality sensor 6, online viscometer 7, online particle sensor 8 and online moisture sensor 9 can be set in different detection stations according to the same temperature range.

[0039] Both ends of the monitoring housing 2 are provided with mounting end caps 10, and the inner wall of the mounting end caps 10 at the corresponding detection station is provided with a standardized detection scenario component for pre-processing the lubricating oil detection.

[0040] Furthermore, the standardized testing scenario components include two sets of ultrasonic vibration sources 11 set on the mounting end cap 10. The ultrasonic vibration sources 11 are located at the testing station and are used to uniformly mix the lubricating oil during the lubricating oil testing process.

[0041] The inner wall of the sampling chamber 3 located at the testing station is provided with a resistance heating layer 12. The resistance heating layer 12 is used to heat the lubricating oil in the testing chamber 5. By preheating the lubricating oil to the standard testing temperature before the testing sensor detects the lubricating oil, it is ensured that the state of the lubricating oil at this time is consistent with the testing requirements. This avoids the influence of external environmental factors on the state of the lubricating oil (the altitude and environment of the wind turbine will cause the temperature of the lubricating oil after sampling to change greatly), thereby ensuring the accuracy of the test results.

[0042] The monitoring housing 2 is equipped with a lubricating oil emergency treatment device, which includes a lubricating oil drive assembly installed on the mounting end cover 10, and a lubricating oil replacement pipeline system installed on the mounting end cover 10.

[0043] Furthermore, the lubricating oil drive assembly includes piston receiving grooves 13 formed in both ends of the mounting end cap 10. The piston receiving grooves 13 are adapted to the detection chamber 5. A replacement piston 14 is provided in the piston receiving grooves 13. When the lubricating oil is being replaced, the replacement piston 14 can move within the piston receiving grooves 13 and the detection chamber 5.

[0044] In the detection state, the detection chamber 5 is in communication with the piston storage groove 13 in the mounting end caps 10 at both ends. When the replacement piston 14 moves from the piston storage groove 13 on one side to the piston storage groove 13 on the other side through the detection chamber 5, it will squeeze out the deteriorated lubricating oil that was originally in the detection chamber 5 and replace it with qualified lubricating oil. This can meet the needs of emergency treatment by gradually replacing the lubricating oil in the event of deterioration of the lubricating oil detected remotely online, and ensure the normal operation of the wind turbine transmission system.

[0045] Furthermore, the lubricating oil replacement pipeline system includes an electromagnetic control valve 15 located at the bottom of the monitoring housing 2. The electromagnetic control valve 15 is connected to a recovery pipeline and an injection pipeline. The electromagnetic control valve 15 is externally connected to a waste lubricating oil recovery pipeline and a new lubricating oil replenishment pipeline. The piston receiving groove 13 is provided with a recovery pipeline 16 and an injection pipeline 17 connected to the electromagnetic control valve 15.

[0046] The online monitoring device proposed in this invention is installed on the lubrication system pipeline of a wind turbine to monitor the lubricating oil in real time. During online lubrication oil monitoring, the online control motor 18 periodically drives the sampling inner cylinder 4 to rotate by the torsional angle of one detection station. When the sampling inner cylinder 4 is driven to rotate, the detection port 5 opened on it will carry the circulating lubricating oil in the circulating sampling tube 1 into the sampling chamber 3 during the rotation. At this time, the lubricating oil is at the lowest detection station. At this time, the resistance heating layer 12 set on the inner wall of the sampling chamber 3 is turned on to pre-treat the lubricating oil in the detection station to meet the temperature requirements required for detection. The ultrasonic vibration source 11 set on the mounting end cover 10 is used to oscillate and mix the lubricating oil to prevent it from settling and causing inaccurate detection. Similarly, when it moves to the side detection station, the online monitoring sensor here will detect it again at different predetermined temperatures to achieve comprehensive detection of the lubricating oil.

[0047] When the tested lubricating oil meets all the standards for use, the tested lubricating oil will be automatically transferred back to the circulating sampling tube 1 when it is sampled again, so as to ensure the consistency of the total amount of lubricating oil in the wind turbine lubrication system pipeline after sampling.

[0048] When the tested lubricating oil does not meet the requirements, as the lubricating oil moves to the upper testing station, the injection pipe 17 connected to the piston receiving groove 13 on one side containing the replacement piston 14 is opened, and the recovery pipe 16 connected to the piston receiving groove 13 on the other side is opened. At this time, under the action of the high-pressure pump, the new lubricating oil for replacement will be injected into the testing chamber 5 through the injection pipe 17. The lubricating oil originally in the testing chamber 5 will be automatically discharged. Then, the new lubricating oil will be replenished into the generator lubrication system pipeline by rotating the sampling inner cylinder 4. This process is repeated until the generator lubrication system completes one cycle. Timely emergency treatment is carried out by gradually replacing the lubricating oil to ensure the normal operation of the wind turbine transmission system. This invention, through three core advantages—"standardized testing conditions," "automated multi-parameter monitoring," and "online proactive emergency treatment"—jointly constructs a precise, reliable, intelligent lubricating oil monitoring system with a certain degree of self-repair capability. Ultimately, it aims to achieve predictive maintenance of wind turbines, minimize unplanned downtime, prevent major equipment damage, and ensure the long-term, stable, and efficient operation of wind turbines.

[0049] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An online monitoring device for lubricating oil in a wind turbine generator, comprising a circulating sampling pipe (1) installed on the lubrication system pipeline of the wind turbine generator, characterized in that, An online monitor is installed on one side of the circulating sampling tube (1). The online monitor includes a monitoring housing (2). A sampling chamber (3) is opened inside the monitoring housing (2). A sampling port that penetrates the side wall is opened on one side of the sampling chamber (3). A sampling inner cylinder (4) is set inside the monitoring housing (2). Multiple detection ports (5) are opened on the outer side wall of the sampling inner cylinder (4). Multiple detection stations are set on the monitoring housing (2) corresponding to the detection ports (5). Multiple online monitoring sensors for detecting the lubricating oil in the detection ports (5) are set on the monitoring housing (2) at the detection stations. The monitoring housing (2) is provided with mounting end caps (10) at both ends, and the inner wall of the mounting end caps (10) at the corresponding detection station is provided with a standardized detection scenario component for pre-processing the lubricating oil detection. The monitoring housing (2) is provided with a lubricating oil emergency treatment device, which includes a lubricating oil drive assembly installed on the mounting end cover (10) and a lubricating oil replacement pipeline system installed on the mounting end cover (10). The lubricating oil drive assembly includes piston storage grooves (13) opened in both ends of the mounting end cap (10). The piston storage grooves (13) are adapted to the detection chamber (5). A replacement piston (14) is provided in the piston storage grooves (13). The replacement piston (14) moves between the piston storage grooves (13) and the detection chamber (5) when the lubricating oil is being replaced. The lubricating oil replacement pipeline system includes an electromagnetic control valve (15) located at the bottom of the monitoring housing (2). The piston receiving groove (13) is provided with a recovery pipeline (16) and an injection pipeline (17) connected to the electromagnetic control valve (15). The electromagnetic control valve (15) is connected to the recovery pipeline and the injection pipeline.

2. The online monitoring device for lubricating oil of a wind turbine generator according to claim 1, characterized in that, The online monitoring sensors include an online oil quality sensor (6), an online viscometer (7), an online particle sensor (8), and an online moisture sensor (9). The detection ends of the online monitoring sensors are all located inside the monitoring housing (2) at the detection station.

3. The online monitoring device for lubricating oil of a wind turbine generator according to claim 1, characterized in that, The standardized testing scenario component includes two sets of ultrasonic vibration sources (11) set on the mounting end cap (10). The ultrasonic vibration sources (11) are located at the testing station and are used to uniformly mix the lubricating oil during the lubricating oil testing process.

4. The online monitoring device for lubricating oil of a wind turbine generator according to claim 1, characterized in that, The inner wall of the sampling chamber (3) located at the testing station is provided with a resistance heating layer (12), which is used to heat the lubricating oil in the testing chamber (5).

5. The online monitoring device for lubricating oil of a wind turbine generator according to claim 1, characterized in that, One end of the monitoring housing (2) is provided with an online control motor (18), the output end of which extends into the sampling chamber (3) and is connected to the sampling inner cylinder (4).

6. The online monitoring device for lubricating oil of a wind turbine generator according to claim 1, characterized in that, The circulating sampling tube (1) has a snap-fit ​​opening on one side that is connected to the sampling port, and the sampling inner cylinder (4) is located inside the circulating sampling tube (1).

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