Generator unit cooling fan vibration and deviation optimization device and monitoring method

Abstract

The invention relates to a vibration and deviation optimizing device for a cooling fan of a generator unit. The vibration and deviation optimizing device comprises a vibration monitoring and adjusting system and an intelligent control system. The vibration monitoring and adjusting system comprises a piezoelectric vibration sensor, an adjustable balancing weight, a T-shaped sliding block and a micro driving motor; the piezoelectric vibration sensors are uniformly and annularly distributed on a shell of the fan driving motor; the adjusting balancing weight is connected with the T-shaped sliding groove in the fan hub in a sliding mode through the T-shaped sliding block. The adjustable balancing weight is rigidly connected with the micro driving motor through a coupling and a threaded screw rod; and the micro driving motor is coupled with the intelligent control system through electric signals. The invention further relates to a monitoring method using the vibration and deviation optimization device for the cooling fan of the generator unit. The problems of vibration and deviation of the cooling fan in the operation process are effectively solved, the operation stability and the cooling efficiency of the cooling fan are improved, the service life of the cooling fan and the service life of a generator unit are prolonged, and the maintenance cost is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of generator heat dissipation equipment, in particular to a generator unit heat dissipation fan vibration and deviation optimization device and monitoring method. BACKGROUND

[0002] From a technical point of view, during the operation of the generator, the heat dissipation fan plays a crucial role in dissipating the heat generated by the operation of the generator in time, ensuring that the generator works stably within the appropriate temperature range. However, the heat dissipation fan currently faces two major problems of vibration and deviation in actual operation.

[0003] The vibration problem mainly comes from the manufacturing process deviation of the heat dissipation fan blades, uneven wear after long-term use, and insufficient installation precision, etc. When the heat dissipation fan rotates at high speed, these factors will cause unbalanced force, and then cause severe vibration. This vibration not only accelerates the damage of the fan itself parts (such as blade fracture, bearing excessive wear), but also transmits to the overall structure of the generator through the connecting parts, affecting the stability of the generator, reducing the power generation efficiency, and even may cause safety accidents.

[0004] The defects of the prior art are: Most of the heat dissipation fans of water power generators on the market lack effective vibration and deviation adjustment mechanisms, and often only after the failure occurs is the maintenance carried out, which not only increases the maintenance cost, but also affects the normal operation time of the generator.

[0005] Taking a certain hydropower station as an example, the hydropower station is equipped with four 10MW single-machine-capacity generator units, each of which is equipped with 7 cooling fans; according to the daily operation and maintenance statistical data, four generator units need to replace 6 cooling fans on average every year, the replacement cost of a single cooling fan is about 20000 yuan, and the generator unit needs to be shut down for 2 working days when replacing a single fan, resulting in a power generation loss of about 140000 yuan. According to the calculation, the comprehensive economic cost of the hydropower station due to the failure of the cooling fan is about 840000 yuan per year, and the fan failure has become an important factor affecting the economic benefit of the hydropower station. SUMMARY

[0006] The present application provides a generator unit heat dissipation fan vibration and deviation optimization device and monitoring method, which aims to effectively solve the vibration and deviation problems of the heat dissipation fan during operation, improve the operation stability and heat dissipation efficiency of the heat dissipation fan, prolong the service life of the heat dissipation fan and the generator unit, and reduce the maintenance cost.

[0007] To solve the above problems, the technical scheme provided by the present application is: The application discloses a vibration and deviation optimization device for a heat dissipation fan of a generator unit. The vibration monitoring and adjusting system comprises piezoelectric vibration sensors, adjustable counterweights, T-shaped sliding blocks and micro driving motors; the piezoelectric vibration sensors are uniformly arranged on the shell of a fan driving motor and used for collecting vibration data during the operation of the heat dissipation fan; the adjustable counterweight is a stepped cylindrical structure, the adjustable counterweight is slidably connected with a T-shaped sliding groove on a fan hub through the T-shaped sliding blocks; the end of the adjustable counterweight penetrates through the shell of the fan hub, and then is rigidly connected with the micro driving motor through a shaft coupling and a threaded rod; the micro driving motor is electrically coupled with the intelligent control system, and the micro driving motor is controlled to drive the shaft coupling and the threaded rod to rotate, so as to adjust the position of the adjustable counterweight in the radial direction of the fan hub.

[0008] Preferably, the device further comprises a deviation monitoring and adjusting system; the deviation monitoring and adjusting system comprises a plurality of infrared opposite-acting sensors and a plurality of electric screw rod adjusting mechanisms. The infrared opposite-acting sensors are symmetrically distributed along the circumferential direction of a fan protection net frame, are used for monitoring the position change data of the blades of the heat dissipation fan relative to the bottom of a motor mounting seat and judging whether deviation occurs or not. The electric screw rod adjusting mechanisms are uniformly distributed along the circumferential direction of the bottom of the motor mounting seat, are used for adjusting the position of the bottom of the motor mounting seat and correcting the deviation of the heat dissipation fan; the extension end of the electric screw rod adjusting mechanism is bolted with the bottom of the motor mounting seat, and the fixed end of the electric screw rod adjusting mechanism is bolted with the mounting base at the end of the fan driving motor.

[0009] Preferably, the intelligent control system comprises a data transmission and remote management module and an intelligent controller; the data transmission and remote management module is electrically coupled with the intelligent controller, is used for transmitting the operation data, vibration and deviation adjusting information of the heat dissipation fan to a mobile terminal in real time and receiving the control instructions of the mobile terminal; the intelligent controller is electrically coupled with the vibration monitoring and adjusting system and the deviation monitoring and adjusting system respectively, is used for analyzing the collected vibration data and deviation data and controlling the corresponding adjusting mechanisms to automatically adjust according to the analysis results.

[0010] Preferably, the measurement accuracy of the piezoelectric vibration sensor is ±0.01 m / s 2, the frequency response range is 0Hz~5000Hz; the micro drive motor is a DC speed reducer, the speed reduction ratio is 50:1~100:1, the output torque is not less than 0.5N·m, and the speed regulation range is 5r / min~50r / min; the infrared opposite transmission sensor is provided with 8, the detection distance of the infrared opposite transmission sensor is 0mm~100mm, the detection accuracy is ±0.1mm, and the center axis deviation of the transmitting end and the receiving end is not more than ±0.05mm; the electric screw rod adjusting mechanism is provided with 4, the maximum stroke of the electric screw rod adjusting mechanism is 50mm, the adjusting accuracy is ±0.01mm~±0.05mm, and a pressure sensor is built-in; the intelligent controller adopts an industrial-grade microprocessor, the operation speed is not less than 100MHz, at least 16 analog input interfaces are provided for connecting sensors, a vibration analysis algorithm and a deviation analysis algorithm are built-in the intelligent controller; the data transmission and remote management module adopts a 4G or 5G communication module, the data transmission rate is not less than 1Mbps, and a data encryption function is provided.

[0011] Preferably, the diameter of the end of the adjustable counterweight connected with the T-shaped sliding block is smaller than the diameter of the end close to the edge of the fan hub, and anti-skid lines are arranged on the outer circumferential surface of the larger diameter end.

[0012] Preferably, the vibration analysis algorithm comprises the following steps: Sa100. converting the vibration time domain data into frequency domain data by a fast Fourier transform algorithm, and identifying the main vibration frequency; the fast Fourier transform algorithm is expressed by the following formula: Wherein: X[k] is used to represent the frequency domain discrete signal value vibration frequency domain data, k represents the kth frequency point, and X[k] is the vibration amplitude at the frequency; x[n] is used to represent the time domain discrete signal value vibration time domain data, n represents the nth sampling point, and x[n] is the vibration amplitude of the sampling point; N is used to represent the total sampling number of the sampling points, the total sampling number of the vibration time domain data; j is used to represent the imaginary unit; π is used to represent the constant of the circular constant; k is used to represent the frequency point index of the frequency domain, the frequency sequence number, and the actual frequency is expressed by the following formula: Wherein: is used to represent the actual frequency, that is, the physical frequency corresponding to the kth frequency point; Sa200. comparing the main vibration frequency with the fan rotating speed frequency, and then performing the following steps according to the comparison result: If the main vibration frequency is consistent with the fan rotating speed frequency, it is determined that the vibration is caused by mass imbalance, and then step Sa300 is performed; If the main vibration frequency is twice or more than the fan speed frequency, it is determined that the vibration originates from blade installation deviation or uneven wear, and then step Sa400 is executed. Sa300. The spatial position of the adjustable counterweight is adjusted by a counterweight adjustment control algorithm, thereby changing the mass distribution of the cooling fan and reducing vibration. Sa400. Based on the differences in vibration amplitude among various sensors, the location of the specific faulty blade can be determined; The bias analysis algorithm includes the following steps: Sb100. Real-time monitoring and comparative analysis of the leaf occlusion time data and leaf occlusion position data collected by each of the infrared beam sensors; Sb200. Calculate the deflection direction and offset distance of the cooling fan spindle; Sb300. When the data collected by the infrared beam sensor meets the preset infrared monitoring anomaly judgment conditions, it is determined that the cooling fan spindle has an axial deviation. Sb400. The extension and retraction of each of the electric lead screw adjustment mechanisms is controlled and adjusted according to the electric lead screw adjustment algorithm.

[0013] The Preferably, the counterweight adjustment control algorithm includes the following steps: Sc100. Control each of the piezoelectric vibration sensors to synchronously collect the axial vibration acceleration data, radial vibration acceleration data and circumferential vibration acceleration data of the cooling fan, and then construct a three-dimensional data matrix of angle-vibration amplitude-frequency, and determine the vibration peak angle corresponding to the vibration amplitude peak and the corresponding main vibration frequency; Sc200. Calculate the unbalanced force in the direction corresponding to the peak vibration angle, expressed by the following formula: Wherein: F u The characterization is used to represent the unbalanced force; m is used to represent the fan mass. Used to characterize angular velocity; e is used to characterize the distance of the center of mass from the axis; Sc300. With the vibration peak angle as the center, select the adjustable counterweight within a range of ±30° as the first adjustment area, and at the same time select the adjustable counterweight within a range of ±30° in the diagonal direction of the vibration peak angle as the symmetrical adjustment area. Sc400. Calculate the adjustment efficiency value of each adjustable counterweight in the first adjustment area and the symmetrical adjustment area, then sort them from high to low according to the adjustment efficiency value and preferentially select the adjustable counterweight with the adjustment efficiency value greater than the manually preset efficiency threshold for adjustment; the adjustment efficiency value is expressed by the following formula: Wherein: E is used to characterize the adjustment efficiency value; The radial distance that the adjustable counterweight needs to be adjusted is represented by t, which represents the time required for adjustment. Sc500. For each candidate adjustable counterweight, calculate its adjusted load, expressed as follows: Wherein: F is used to characterize the adjusted load; Used to characterize the mass of the counterweight; If the adjusted load is less than or equal to 0.8 times the maximum load of the threaded screw, then the adjustable counterweight block is selected for individual adjustment. If the adjusted load is greater than 0.8 times the maximum load of the threaded screw, then select 2 or 3 symmetrical adjustable counterweights from the sorting results of step Sc400 and redistribute the adjustment amount until the adjusted load of each adjustable counterweight is less than or equal to 0.7 times the maximum load of the threaded screw. During the adjustment of the adjustable counterweight, the vibration amplitude is collected at a preset frequency. When the reduction rate of vibration amplitude after adjustment of any of the adjustable counterweights is less than the preset counterweight adjustment threshold, the adjustment of the adjustable counterweight is stopped and the next candidate adjustable counterweight is switched. Sc600. After all the adjustable counterweights have been adjusted, if the overall vibration amplitude still exceeds the preset safety threshold, the residual unbalanced force is calculated, and then the adjustable counterweight with the opposite direction to the residual unbalanced force is selected for a second adjustment until the vibration amplitude is less than or equal to the safety threshold.

[0014] Preferably, the electric lead screw adjustment algorithm includes the following steps: Sd100. The fan shaft offset coordinates are calculated based on the infrared beam sensor and expressed by the following formula: Where: x and y are used to represent the coordinates in the horizontal and vertical directions with the fan axis center as the origin, respectively; k is used to represent the ratio coefficient between the sensor distance and the axis offset; , These are used to characterize the average values ​​of the obstruction position deviations along the horizontal and vertical axes detected by two infrared beam sensors that are symmetrical about the theoretical axis of the fan. Sd200. Calculate the offset distance and offset direction angle of the fan shaft, expressed by the following formula: Where: L represents the offset distance; a represents the offset direction angle; Sd300. When the offset distance is greater than a manually preset offset distance threshold, calculate the extension / retraction amount of each of the electric lead screw adjustment mechanisms, expressed by the following formula: Where: R is used to characterize the radius of the motor mounting base; Used to characterize the extension or retraction of the electric lead screw adjustment mechanism located in the positive direction of the horizontal axis; Used to characterize the extension or retraction of the electric lead screw adjustment mechanism located in the negative direction of the horizontal axis; Used to characterize the extension or retraction of the electric lead screw adjustment mechanism located in the positive direction of the longitudinal axis; Used to characterize the extension or retraction of the electric lead screw adjusting mechanism located in the negative direction of the longitudinal axis; the negative sign is used to characterize the shortening of the electric lead screw adjusting mechanism, and the positive sign is used to characterize the extension of the electric lead screw adjusting mechanism; Sd400. The adjusted load is calculated based on the initial load of each of the electric lead screw adjustment mechanisms, and is expressed by the following formula: Wherein: F0 is used to characterize the initial load; G is used to characterize the total weight of the fan drive motor and the cooling fan; F i The adjusted load is used to characterize the i-th electric lead screw adjustment mechanism; Used to characterize the load change of the i-th electric lead screw adjustment mechanism; k F Used to characterize the load factor; Sd500. Determine whether the adjusted load of each of the electric lead screw adjustment mechanisms meets the manually preset safety margin threshold, and then perform the following operations based on the determination result: If the adjusted load of each of the electric lead screw adjustment mechanisms is less than or equal to 0.8 multiplied by the safety margin threshold, then the extension amount calculated in step Sd300 is deemed valid. If the adjusted load of any of the electric lead screw adjusting mechanisms is greater than 0.8 times the safety margin threshold, then the extension / retraction amount of each of the electric lead screw adjusting mechanisms is adjusted proportionally, expressed by the following formula: in: The corrected extension / retraction amount is used to characterize the i-th electric lead screw adjusting mechanism; F max Used to characterize the safety margin threshold; Sd600. After the electric lead screw adjustment mechanism is adjusted according to the extension amount obtained in step Sd500, the infrared beam sensor is controlled to collect deviation data and calculate the new offset distance. If the newly calculated offset distance is less than or equal to the preset target accuracy, the adjustment is determined to be complete. If the newly calculated offset distance is greater than the target accuracy, steps Sd100 to Sd600 are executed again.

[0015] Preferably, the infrared monitoring anomaly determination conditions include blade occlusion time deviation triggering conditions, blade occlusion position offset triggering conditions, signal continuity and integrity triggering conditions, and environmental interference and special operating condition triggering conditions, wherein: The blade occlusion time deviation triggering conditions include single-sensor single-occlusion time deviation triggering conditions, symmetrical sensor occlusion time difference deviation triggering conditions, and multi-blade occlusion time fluctuation deviation triggering conditions, wherein: The trigger condition for the single-sensor single-occlusion time deviation is as follows: when the difference between the single-occlusion time of the blade detected by any of the infrared beam sensors and the average value of the occlusion time of the infrared beam sensor in the last 100 samplings exceeds ±5%, an anomaly is triggered. The trigger condition for the symmetrical sensor occlusion time difference deviation is as follows: when the time difference between the occlusion of the same blade of the two sets of infrared beam sensors symmetrically distributed along the circumference of the cooling fan exceeds the preset abnormal judgment threshold, an abnormality is triggered. The trigger condition for the multi-blade occlusion time fluctuation deviation is: if the standard deviation of the occlusion time of 5 consecutively monitored blades passing through the same infrared beam sensor exceeds 0.3ms, an anomaly is triggered. The blade occlusion position offset triggering condition includes a single sensor occlusion position offset triggering condition and a multi-sensor position offset trend triggering condition, wherein: The trigger condition for the single sensor occlusion position offset is as follows: if the lateral position of the blade occlusion light detected by any of the infrared beam sensors deviates from the initial calibration position by more than ±0.1mm, an anomaly is triggered. The triggering condition for the multi-sensor position offset trend is as follows: continuously collect position data of the blade blocking light from 8 infrared beam sensors. If 2 or more infrared beam sensors in any direction continuously detect a position offset of ≥0.05mm in the same direction for 3 consecutive times, an anomaly is triggered. The signal continuity and integrity triggering conditions include a single detection no signal triggering condition, a continuous multi-turn signal loss triggering condition, and an abnormal signal strength triggering condition, wherein: The single-detection no-signal trigger condition is: if any of the infrared beam sensors does not detect a blade obstruction signal within the time it takes for the cooling fan to rotate one revolution, then an anomaly is triggered. The trigger condition for the continuous multi-turn signal loss is: if the same infrared beam sensor detects a blade obstruction signal at least once during 3 consecutive turns of the cooling fan, or if there is no obstruction signal for 2 consecutive turns, then an anomaly is triggered. The signal strength abnormality triggering condition is as follows: real-time monitoring of the received signal strength of the infrared beam sensor; if the signal strength is lower than 70% of the rated operating strength of the device, and after excluding external factors such as dust obstruction and light interference, it still does not recover for 10 seconds, then an abnormality is triggered. The environmental interference and special operating condition triggering conditions include instantaneous strong light interference triggering conditions and low temperature environment signal delay triggering conditions, wherein: The instantaneous strong light interference triggering condition is as follows: when an instantaneous strong light appears in the environment around the infrared beam sensor, causing the infrared beam sensor receiver to falsely detect an unobstructed signal, and the duration of the false detection signal exceeds 0.1 seconds, an anomaly is triggered. The low-temperature environment signal delay trigger condition is as follows: when the ambient temperature is below -5℃, if the difference between the blade occlusion time detected by the infrared beam sensor and the standard occlusion time at 25℃ exceeds ±8%, and the infrared beam sensor in other temperature areas does not have this deviation, then an anomaly is triggered.

[0016] A monitoring method utilizing the aforementioned generator set cooling fan vibration and deflection optimization device includes the following steps: S100. During the operation of the cooling fan, the vibration data of the cooling fan is collected by the piezoelectric vibration sensor, and the vibration data is transmitted to the intelligent control system; The infrared beam sensor is controlled to monitor the position change data of the cooling fan blades in real time, and the position change data is transmitted to the intelligent control system. S200. The vibration data and the position change data are analyzed by the vibration analysis algorithm and the deviation analysis algorithm of the intelligent control system, respectively; S300. Based on the analysis results of step S300, the position of the adjustable counterweight is adjusted by the counterweight adjustment control algorithm, thereby changing the mass distribution of the cooling fan and reducing vibration; the position of the fan drive motor is adjusted by multiple electric screw adjustment mechanisms controlled by the electric screw adjustment algorithm, thereby correcting the deflection of the cooling fan. S400. The intelligent control system stores the fan's operating data in a local database, and simultaneously transmits the fan's operating data, vibration, and deflection adjustment information to the mobile terminal in real time through the data transmission and remote management module, and receives control commands from the mobile terminal.

[0017] Compared with the prior art, the present invention has the following advantages: 1. Efficient monitoring and precise adjustment: This invention uses a vibration and deflection monitoring system to monitor the operating status of the cooling fan in real time and from all angles. Once a vibration or deflection problem occurs, the corresponding adjustment mechanism is quickly activated for precise adjustment, effectively preventing further deterioration of the fault.

[0018] 2. Extend equipment lifespan: This invention can significantly reduce wear on various components of the cooling fan by reducing vibration and deflection, thus extending the fan's lifespan. It also reduces damage to other components of the generator set, thereby improving the stability and reliability of the entire generator system.

[0019] 3. Improved heat dissipation efficiency: This invention ensures that the fan is in good operating condition, allowing airflow to act evenly on the generator, thereby improving the heat dissipation effect and ensuring that the generator operates efficiently at a suitable temperature.

[0020] 4. Intelligent remote management: The intelligent control system of this invention realizes data storage and remote transmission, which makes it convenient for operators to understand the operation of the fan anytime and anywhere, make timely decisions, and thus improve management efficiency. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the installation structure of the motor unit cooling fan vibration and deflection optimization device according to a specific embodiment of the present invention; Figure 2 This is a schematic diagram of the counterweight device structure of the motor unit cooling fan vibration and deflection optimization device according to a specific embodiment of the present invention; Figure 3 This is a schematic diagram of the system workflow of a specific embodiment of the present invention.

[0022] The components include: 1. Fan protective mesh frame; 2. Cooling fan; 3. Fan hub; 4. Cooling fan main shaft; 5. Fan drive motor; 6. Infrared beam sensor; 7. T-slot; 8. Piezoelectric vibration sensor; 9. Electric lead screw adjustment mechanism; 10. Motor mounting base; 11. Miniature drive motor; 12. Adjustable counterweight; 13. Fan hub housing; 14. Coupling and threaded screw; 15. T-slot slider. Detailed Implementation

[0023] The present invention will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. After reading the present invention, any modifications of the present invention in various equivalent forms by those skilled in the art will fall within the scope defined by the appended claims.

[0024] This invention application claims protection for a generator set cooling fan vibration and deflection optimization device, such as... Figure 1 , 2 As shown, it includes a vibration monitoring and adjustment system and an intelligent control system, wherein: The vibration monitoring and adjustment system includes a piezoelectric vibration sensor 8, an adjustable counterweight 12, a T-shaped slider 15, and a micro drive motor 11. The piezoelectric vibration sensor 8 is evenly distributed around the housing of the fan drive motor 5 to collect vibration data during the operation of the cooling fan 2. The adjustable counterweight 12 has a stepped cylindrical structure and is slidably connected to the T-shaped groove 7 on the fan hub 3 via the T-shaped slider 15. The end of the adjustable counterweight 12 passes through the fan hub housing 13 and is then rigidly connected to the micro drive motor 11 via a coupling and a threaded screw 14. The micro drive motor 11 is electrically coupled to the intelligent control system and is controlled by the intelligent control system to drive the coupling and the threaded screw 14 to rotate, thereby adjusting the position of the adjustable counterweight 12 in the radial direction of the fan hub 3.

[0025] In this specific embodiment, the measurement accuracy of the piezoelectric vibration sensor 8 is ±0.01 m / s. 2 The frequency response range is 0Hz~5000Hz; the micro drive motor 11 is a DC geared motor with a reduction ratio of 50:1~100:1, an output torque of not less than 0.5N·m, and a speed adjustment range of 5r / min~50r / min; there are 8 infrared beam sensors 6, with a detection distance of 0mm~100mm, a detection accuracy of ±0.1mm, and a center axis deviation between the transmitting and receiving ends not exceeding ±0.05mm; there are 4 electric lead screw adjustment mechanisms 9, with a maximum stroke of 50mm, an adjustment accuracy of ±0.01mm~±0.05mm, and a built-in pressure sensor; the intelligent controller uses an industrial-grade microprocessor with a computing speed of not less than 100MHz, and has at least 16 analog input interfaces for connecting sensors. The intelligent controller has built-in vibration analysis algorithms and bias analysis algorithms; the data transmission and remote management module uses a 4G or 5G communication module with a data transmission rate of not less than 1Mbps and has data encryption function.

[0026] It should be noted that the vibration monitoring and adjustment system works as follows: multiple high-precision vibration sensors are evenly distributed on the housing of the fan drive motor 5 of the cooling fan 2 to accurately capture the fan's own vibration caused by blade deviation, wear, etc. If a piezoelectric vibration sensor is used, its working principle is based on the piezoelectric effect. When certain dielectrics are deformed by external force in a certain direction, internal polarization occurs, and charges are generated on their surface. When the external force is removed, the dielectric returns to its uncharged state.

[0027] The charge Q generated is proportional to the external force F acting on the sensor, expressed by equation (1): (1) Where: d ij Used to characterize the piezoelectric constant, different piezoelectric materials have different piezoelectric constants.

[0028] By measuring the charge Q, the magnitude of the external force generated by the vibration can be indirectly obtained, thus yielding relevant vibration information. Built-in sensors collect vibration data from all directions in real time during the operation of the cooling fan and transmit it to the intelligent controller.

[0029] The intelligent controller incorporates advanced vibration analysis algorithms, enabling rapid processing and analysis of received vibration data. When the vibration amplitude A exceeds the preset safety threshold A0, the controller immediately initiates the vibration adjustment program. The vibration amplitude can be obtained by processing and converting the voltage signal (related to the amount of charge generated by the vibration) collected by the vibration sensor.

[0030] Multiple adjustable counterweights 12 are installed on the hub of the wind turbine, and each adjustable counterweight 12 is installed at a specific position on the hub by means of a threaded connection. According to the principle of moment of inertia in physics (moment of inertia is a measure of the inertia of a rigid body rotating about an axis (the property of a rotating object to maintain its uniform circular motion or to remain at rest), it is represented by the letter I or J.

[0031] In rotational dynamics, the role of moment of inertia is equivalent to that of mass in linear dynamics. It can be formally understood as the inertia of an object with respect to rotational motion, and is used to establish the relationship between several quantities such as angular momentum, angular velocity, torque, and angular acceleration. The moment of inertia is represented by I and expressed by the following formula (2): (2) Where: m i Used to characterize infinitesimal mass elements; r i Used to characterize the distance from the mass element to the axis of rotation.

[0032] Based on the vibration analysis results, the controller controls the micro drive motor 11 to drive the coupling and the threaded screw 14 to rotate, thereby adjusting the radial position of the adjustable counterweight 12 on the hub, changing the mass distribution of the fan, and reducing vibration.

[0033] Relationship between unbalanced force and vibration amplitude: When the fan rotates, an unbalanced force F is generated due to the blades. u The unbalanced force will cause the fan to vibrate. According to Newton's second law F=ma, in circular motion, the centrifugal force is expressed by the following formula (3): (3) Where: unbalanced force F u This will cause the fan's center of mass to deviate, thus causing vibration. Let the fan's mass be m, the distance of its center of mass from the axis be e, and the angular velocity be ω, then the unbalanced force is expressed by the following formula (4): (4).

[0034] The vibration amplitude A and the unbalanced force Fu have a certain functional relationship, which can be expressed as A = f(F). u Generally speaking, the amplitude of vibration is directly proportional to the unbalanced force.

[0035] The adjustment principle of the adjustable counterweight 12 is as follows: Let the mass of the counterweight be m. p Its distance from the center of the wheel hub is r p The overall mass of the fan is M, and the initial distance from the center of mass to the center of the hub is e0. After adjusting the position of the counterweight, the distance from the center of mass to the center of the hub becomes e1. According to the formula for the center of mass, we get the following equation (5): (5) Where: r p0 This is the distance from the initial position of the counterweight to the center of the wheel hub. The controller controls the micro-drive motor 11 to drive the coupling and screw 14 to rotate, thereby adjusting the radial position r of the adjustable counterweight 12 on the wheel hub. p The value of changes the mass distribution of the fan, thereby altering the moment of inertia and reducing e1, thus balancing the unbalanced force F caused by the blade problem. u This effectively reduces vibration.

[0036] It should be further noted that the diameter of the end of the adjustable counterweight 12 connected to the T-shaped slider 15 is smaller than the diameter of the end near the edge of the fan hub 3, and anti-slip texture is provided on the outer circumference of the larger diameter end.

[0037] It should be further explained that the vibration analysis algorithm includes the following steps: Sa100. The vibration time-domain data is converted into frequency-domain data by the Fast Fourier Transform algorithm, thereby identifying the main vibration frequencies; the Fast Fourier Transform algorithm is expressed by the following formula (6): (6) Where: X[k] is used to characterize the frequency domain discrete signal value vibration frequency domain data, k represents the kth frequency point, and X[k] is the vibration amplitude at that frequency; x[n] is used to characterize the time domain discrete signal value vibration time domain data, n represents the nth sampling point, and x[n] is the vibration amplitude at that sampling point; N is used to characterize the number of sampling points, the total number of samplings of the vibration time domain data; j is used to characterize the imaginary unit; π is used to characterize the constant of pi; k is used to characterize the frequency domain frequency point index, the frequency number is from 0 to N-1, and the corresponding actual frequency is expressed by the following formula (7): (7) in: Used to characterize the actual frequency, that is, the physical frequency corresponding to the k-th frequency point.

[0038] Sa200. Compare the main vibration frequency with the fan speed frequency, and then perform the following steps based on the comparison results: If the main vibration frequency is the same as the fan speed frequency, it is determined that the vibration originates from mass imbalance, and then step Sa300 is executed.

[0039] If the main vibration frequency is twice or more than the fan speed frequency, it is determined that the vibration originates from blade installation deviation or uneven wear, and then step Sa400 is executed.

[0040] Sa300 adjusts the spatial position of the adjustable counterweight 12 through a counterweight adjustment control algorithm, thereby changing the mass distribution of the cooling fan 2 and reducing vibration.

[0041] Sa400. Based on the differences in vibration amplitude among the various sensors, the location of the specific faulty blade can be determined.

[0042] The bias analysis algorithm includes the following steps: Sb100. Real-time monitoring and comparative analysis of the leaf occlusion time data and leaf occlusion position data collected by each infrared beam sensor 6.

[0043] Sb200. Calculate the deflection direction and offset distance of the cooling fan spindle 4.

[0044] Sb300. When the data collected by the infrared beam sensor 6 meets the preset infrared monitoring anomaly judgment conditions, it is determined that the cooling fan spindle 4 has a axial deviation.

[0045] Sb400. The extension and retraction of each electric lead screw adjustment mechanism 9 is controlled and adjusted according to the electric lead screw adjustment algorithm.

[0046] It should be further explained that the installation steps for the vibration monitoring and adjustment system are as follows: Sx100. Sensor Installation: Install 6-8 piezoelectric vibration sensors (selected with a measurement accuracy of ±0.01m / s). 2 The piezoelectric vibration sensors 8 (with a frequency response range of 0-5000Hz) are evenly installed on the housing of the fan drive motor 5 of the cooling fan 2 according to design requirements (one sensor is installed every 45°-60° along the circumference of the motor housing). Ensure that the piezoelectric vibration sensors 8 and the housing of the fan drive motor 5 are tightly bonded using a special adhesive (the flatness error of the bonding surface is <0.1mm to avoid vibration signal attenuation due to gaps and ensure data accuracy). The sensors are then connected via shielded cable (using anti-interference shielded twisted-pair cable, 0.5mm diameter). 2 Connect the piezoelectric vibration sensor 8 to the analog input interface of the intelligent controller, and ground the shielding layer at one end (grounding resistance < 4Ω) to prevent signal interference.

[0047] Sx200. Adjustable counterweight 12 and transmission mechanism installation: T-shaped groove 7 (groove width 8mm, groove depth 5mm) and internal thread hole are pre-machined on the fan hub 3. A 2mm high limiting boss is set at the end of the T-shaped groove 7 (to prevent the counterweight from excessive displacement and detachment from the hub). Annular scale lines are machined on the surface of the fan hub 3 (scale values ​​are marked at 5mm intervals to facilitate manual calibration of the counterweight position during the debugging stage). The adjustable counterweight 12 (adopting a stepped cylindrical structure, with an M8 external thread at the bottom and a pitch of 1.25mm, a 10mm wide sliding guide cylinder in the middle, and a hemispherical anti-collision design at the top, with a single weight of 20-50g) is installed through a T-shaped slider 15 and a T-shaped groove 7. Then, the threaded rod (trapezoidal thread Tr8×2) is passed through the threaded hole of the adjustable counterweight 12 and rigidly connected to the micro drive motor 11 (DC geared motor, reduction ratio 50:1-100:1, output torque ≥0.5N·m, speed adjustable from 5-50r / min) through a coupling. The micro drive motor 11 is fixed on a special bracket next to the fan hub 3 (the coaxiality error between the bracket and the hub is <0.2mm). Finally, a protective cover (made of stainless steel, 1mm thick) is installed to cover the transmission components to prevent dust from entering and affecting the transmission accuracy. Heat dissipation holes (3mm in diameter, 10mm in spacing) are made on the protective cover.

[0048] Sx300. Control line connection: Connect the power cable of the micro drive motor 11 (use RVV2×0.75mm). 2 Connect the cable to the power output port of the intelligent controller (output voltage 12V / 24V, select according to motor model), and the control cable (RVV4×0.5mm). 2Connect the cable to the PWM output port of the intelligent controller to ensure that the forward and reverse control of the micro drive motor 11 is normal.

[0049] It should be further explained that the core decision-making logic of the counterweight adjustment control algorithm is the priority principle for selecting multiple counterweights: 1. Prioritize vibration source location: Locate the area of ​​maximum vibration using multi-sensor data, and prioritize the selection of counterweights in that area and its symmetrical area. For example, if sensor 3 detects the largest vibration amplitude (exceeding the threshold by 20%) among the 6 sensors, then prioritize adjusting the counterweights at the corresponding angle (e.g., 180°) and the symmetrical angle (0°) of sensor 3, using the principle of "symmetric cancellation" to quickly balance the local unbalanced force.

[0050] 2. Prioritize Efficiency Adjustment: Select the counterweight with the smallest deviation between its initial position and the "target equilibrium position". For example, if calculations show that a 0.02m counterweight needs to be added in the radial direction, prioritize adjusting the counterweight with a radius difference of ≤0.01m between the current radius and the target radius to reduce motor drive stroke and shorten adjustment time.

[0051] 3. Prioritize load balancing: Avoid over-adjusting a single counterweight (each adjustment should not exceed 30% of the total stroke). When significant adjustments are required, select 2-3 symmetrically distributed counterweights for coordinated adjustment. For example, when balancing a 100N unbalanced force, select two symmetrical counterweights, each bearing 50N of the adjustment, rather than a single counterweight bearing 100N, to prevent excessive load on the threaded rod.

[0052] It should be further explained that the counterweight adjustment control algorithm includes the following steps: Sc100 controls each piezoelectric vibration sensor 8 to synchronously collect axial vibration acceleration data, radial vibration acceleration data and circumferential vibration acceleration data of the cooling fan 2, and then constructs a three-dimensional data matrix of angle-vibration amplitude-frequency, and determines the vibration peak angle corresponding to the vibration amplitude peak and its corresponding main vibration frequency.

[0053] Sc200. Calculate the unbalanced force in the direction corresponding to the peak vibration angle, and then determine the "high stress region" (the angle range in which the unbalanced force exceeds the threshold). The unbalanced force is expressed by the following formula (8): (8) Wherein: F u Used to characterize unbalanced forces; m is used to characterize fan mass; Used to characterize angular velocity; e is used to characterize the distance of the center of mass from the axis.

[0054] Sc300. With the vibration peak angle as the center, select adjustable counterweights 12 within a range of ±30° as the first adjustment area (e.g., when θ=90°, select counterweights within a range of 75°-105°). At the same time, select adjustable counterweights 12 within a range of ±30° diagonally opposite the vibration peak angle as the symmetrical adjustment area, forming a "paired adjustment group".

[0055] Sc400. Calculate the adjustment efficiency value of each adjustable counterweight 12 in the first adjustment area and the symmetrical adjustment area, and then sort them from high to low according to the adjustment efficiency value and prioritize the adjustment of adjustable counterweight 12 with adjustment efficiency value greater than the preset efficiency threshold (prioritize the selection of counterweights with E≥0.8 (preset high efficiency threshold)); the adjustment efficiency value is expressed by the following formula (9): (9) Where: E is used to characterize the adjustment efficiency value; The radial distance that the adjustable counterweight 12 needs to be adjusted is used to characterize: t is used to characterize the time required for adjustment.

[0056] Sc500. For each candidate adjustable counterweight 12, calculate its adjusted load, expressed as follows (10): (10) Where: F is used to characterize the adjusted load; Used to characterize the mass of the counterweight.

[0057] If the adjusted load is less than or equal to 0.8 times the maximum load of the threaded screw, then select the adjustable counterweight 12 for individual adjustment.

[0058] If the adjusted load is greater than 0.8 times the maximum load of the threaded screw, then select 2 or 3 symmetrical adjustable counterweights 12 from the sorting results of step Sc400 and redistribute the adjustment amount until the adjusted load of each adjustable counterweight 12 is less than or equal to 0.7 times the maximum load of the threaded screw.

[0059] During the adjustment of the adjustable counterweight 12, vibration amplitude is collected at a preset frequency. When the reduction rate of vibration amplitude after adjustment of any adjustable counterweight 12 is less than a preset counterweight adjustment threshold, the adjustment of that adjustable counterweight 12 is stopped and the system switches to the next candidate adjustable counterweight 12. (For example, if the piezoelectric vibration sensor 8 provides vibration data every 0.5 seconds, and the reduction rate of vibration amplitude after adjustment of a certain counterweight is <30% (preset effective threshold)...) Sc600. After all the adjustable counterweights 12 have been adjusted, if the overall vibration amplitude still exceeds the preset safety threshold, the residual unbalanced force is calculated, and then an adjustable counterweight 12 in the opposite direction to the residual unbalanced force is selected for a second adjustment until the vibration amplitude is less than or equal to the safety threshold.

[0060] It should be further explained that the algorithm instance verification of the counterweight adjustment control algorithm is as follows: Assuming the fan is equipped with 6 counterweights (distributed at 0°, 60°, 120°, 180°, 240°, and 300°), the sensor detects the largest vibration amplitude in the 120° direction (0.4mm, exceeding the threshold of 0.2mm), and it is calculated that an unbalanced force of 80N needs to be balanced.

[0061] 1. Area selection: Prioritize adjusting the counterweights in the 120°±30° (90°-150°) and symmetrical areas of 300°±30° (270°-330°), i.e., the counterweights at the 120° and 300° positions.

[0062] 2. Efficiency ranking: The current radius of the 120° counterweight is 0.1m, and it needs to be adjusted to 0.12m. =0.02m, adjustment time 2 seconds); the current radius of the 300° counterweight is 0.11m, and needs to be adjusted to 0.13m ( =0.02m, adjustment time 2 seconds), both have the same E value, and are both efficient candidates.

[0063] 3. Load verification: The adjustment load of a single counterweight is F = 0.02kg × (314rad / s)2 × 0.02m ≈ 39.4N, which is less than the maximum load of the threaded rod of 50N. Therefore, 120° and 300° counterweights are selected for coordinated adjustment, each bearing 40N of unbalanced force. After adjustment, the vibration amplitude is reduced to 0.15mm, which meets the requirements.

[0064] It should be noted that the present invention also includes a bias monitoring and adjustment system; the bias monitoring and adjustment system includes multiple sets of infrared beam sensors 6 and multiple electric screw adjustment mechanisms 9; the infrared beam sensors 6 are symmetrically distributed along the circumference of the fan protective mesh frame 1, and are used to monitor the positional change data of the blades of the cooling fan 2 relative to the motor mounting base 10 and determine whether bias has occurred; the electric screw adjustment mechanisms 9 are evenly distributed along the circumference of the motor mounting base 10, and are used to adjust the position of the motor mounting base 10 and correct the bias of the cooling fan 2; the telescopic end of the electric screw adjustment mechanism 9 is bolted to the motor mounting base 10, and the fixed end of the electric screw adjustment mechanism 9 is bolted to the mounting base at the end of the fan drive motor 5.

[0065] It should be further explained that the workflow of the bias monitoring and adjustment system is as follows: 1. Off-center data acquisition: Multiple infrared beam sensors 6 are symmetrically installed along the circumference on the fan guard frame 1 of the cooling fan 2. When the cooling fan 2 rotates normally, the blades block the infrared light in a regular pattern; When the cooling fan 2 deviates from its original direction, the timing and position of the blades blocking the infrared light will become abnormal, and the infrared beam sensor 6 will transmit this signal to the intelligent controller.

[0066] 2. Bias Adjustment: The fan drive motor 5 of the cooling fan 2 is mounted on the adjustable motor mounting base 10. The bottom of the motor mounting base 10 has four electric lead screw adjustment mechanisms. After receiving the bias signal from the infrared beam sensor 6, the controller first calculates the direction and distance that the cooling fan 2 needs to be adjusted. Then, using geometric methods such as the principle of similar triangles or spatial vector operations, it determines the specific adjustment amount of each electric lead screw adjustment mechanism 9. For example, a coordinate system is established with the fan axis as the origin. The offset direction vector is determined based on the sensor signal, and the required extension or reduction length h of each electric lead screw adjustment mechanism is calculated. i (i=1,2,3,4). Subsequently, the intelligent controller controls the corresponding electric screw adjustment mechanism 9 to extend or shorten through rotational transmission, precisely adjusting the position of the fan drive motor 5, and finally returning the cooling fan 2 to the center position, correcting the misalignment problem.

[0067] It should be further explained that the installation process for the bias monitoring and adjustment system is as follows: 1. Installation of Infrared Through-beam Sensors 6: Eight infrared through-beam sensors 6 (detection distance 0-100mm, accuracy ±0.1mm) are evenly and symmetrically installed along the circumference of the fan guard frame 1 of the cooling fan 2, with an included angle of 45° between adjacent sensors. During installation, use a level and calipers to ensure that the sensor transmitter and receiver are strictly aligned (center axis deviation ≤ ±0.05mm), and maintain a detection distance of 3-5cm from the fan blades (achieved by adjusting the height of the sensor bracket). Connect the sensor's power cable (RVV2×0.5mm). 2 Connect to the controller's 12V DC power supply port, signal cable (RVVP2×0.5mm). 2 The shielded wire is connected to the digital input interface of the intelligent controller, and the shielding layer is grounded.

[0068] 2. Installation of Electric Lead Screw Adjustment Mechanism 9: Four electric lead screw adjustment mechanisms 9 (maximum stroke 50mm, adjustment accuracy ±0.01-±0.05mm, equipped with pressure sensors) are evenly distributed around the bottom circumference of the motor mounting base 10 (adjacent mechanisms at a 90° angle). Through different telescopic combinations, the mounting base can be moved in multiple directions and its angle fine-tuned on the horizontal plane. The nut end of the electric lead screw is fixed to the bottom of the motor mounting base 10 with bolts (M10×20mm, strength grade 8.8) (spring washers are added to prevent loosening). The fixed end of the lead screw is fixed to the mounting foundation with anchor bolts (M12×50mm, strength grade 10.9) (foundation flatness error <0.1mm / m) to provide reliable support. The power cord of the electric lead screw adjustment mechanism 9 (RVV3×1.0mm) is connected. 2 Connect the cable (adapted to the power requirements of the mechanism) to the power output module of the intelligent controller (output voltage 24V / 36V, matched according to the mechanism model), and the control signal line (RVVP4×0.75mm). 2 Connect the shielded wire to the PWM output port of the intelligent controller, and connect the pressure sensor signal line to the analog input interface of the intelligent controller to ensure that the intelligent controller can receive pressure feedback data in real time and avoid damage to the mechanism due to excessive load during adjustment. After installation, manually test the extension and retraction function of the electric lead screw to ensure that its stroke is smooth and without jamming, and that the motor mounting base 10 does not wobble significantly during adjustment.

[0069] It should be further explained that, in order to improve the accuracy and reliability of bias monitoring, the following abnormal trigger conditions have been added to the monitoring logic of the infrared beam sensor, covering multiple dimensions such as time deviation, position offset, signal continuity and environmental interference, to ensure timely identification of fan bias problems.

[0070] The anomaly detection conditions for infrared monitoring include triggering conditions for blade occlusion time deviation, blade occlusion position offset, signal continuity and integrity, and environmental interference and special operating conditions. The blade occlusion time deviation triggering conditions include single-sensor single-occlusion time deviation triggering conditions, symmetrical sensor occlusion time difference deviation triggering conditions, and multi-blade occlusion time fluctuation deviation triggering conditions, among which: The trigger condition for single-sensor single-occlusion time deviation is as follows: when the difference between the single-occlusion time of the blade detected by any infrared beam sensor 6 and the average value of the occlusion time of the infrared beam sensor 6 in the last 100 samplings exceeds ±5%, an anomaly is triggered.

[0071] For example, if the historical average occlusion time of a certain sensor is 20ms, and the detection time is 19ms or 21ms, the trigger condition is met.

[0072] The trigger condition for the symmetrical sensor occlusion time difference deviation is as follows: When the time difference between the occlusion of the same blade of two sets of infrared beam sensors 6 symmetrically distributed along the circumference of the cooling fan 2 exceeds a preset anomaly judgment threshold, an anomaly is triggered. For example, if sensor 1 detects occlusion for 20ms and the symmetrical sensor 5 detects occlusion for 20.6ms, the time difference of 0.6ms > 0.5ms, triggering an anomaly.

[0073] The trigger condition for the multi-blade occlusion time fluctuation deviation is: if the standard deviation of the occlusion time of 5 consecutively monitored blades passing through the same infrared beam sensor 6 exceeds 0.3ms, it indicates that the occlusion time is unstable during the blade rotation process and there may be a bias, thus triggering an anomaly.

[0074] The blade occlusion position offset triggering conditions include single-sensor occlusion position offset triggering conditions and multi-sensor position offset trend triggering conditions, among which: The single-sensor occlusion position offset trigger condition is as follows: if the lateral position of the blade occlusion light detected by any infrared beam sensor 6 deviates from the initial calibration position (the standard position set during equipment installation and commissioning) by more than ±0.1mm, an anomaly is triggered. For example, if the initial calibration position is 1mm to the left of the sensor center, and a certain detection position is 1.2mm to the left, the deviation of 0.2mm > 0.1mm triggers an anomaly.

[0075] The multi-sensor position offset trend trigger condition is as follows: Continuously collect position data of the blade blocking light from eight infrared beam sensors 6. If two or more infrared beam sensors 6 in any direction continuously detect a position offset ≥0.05mm in the same direction for three consecutive times, an anomaly is triggered. For example, if the front sensors 2 and 6 detect a forward offset of 0.06mm, 0.07mm, and 0.05mm respectively for three consecutive times, an anomaly is triggered.

[0076] Signal continuity and integrity triggering conditions include single-detection no-signal triggering conditions, continuous multi-turn signal loss triggering conditions, and abnormal signal strength triggering conditions, among which: The single-detection no-signal trigger condition is: if any infrared beam sensor 6 does not detect a blade obstruction signal within the time it takes for the cooling fan 2 to rotate 1 revolution (the theoretical period is calculated based on the fan's rated speed, such as 0.02 seconds when the speed is 3000 r / min), then an abnormality is triggered.

[0077] The trigger condition for continuous signal loss is: if the same infrared beam sensor 6 detects blade obstruction signal at least once during 3 consecutive rotations of the cooling fan 2, or if there is no obstruction signal for 2 consecutive rotations, an anomaly is triggered, and the sensor circuit and installation status are checked simultaneously.

[0078] The signal strength abnormality trigger condition is as follows: real-time monitoring of the received signal strength of the infrared beam sensor 6. If the signal strength is lower than 70% of the rated working strength of the equipment, and after excluding external factors such as dust obstruction and light interference, it still does not recover for 10 seconds, then an abnormality is triggered, indicating that the sensor may be aging or malfunctioning.

[0079] Environmental interference and special operating condition triggering conditions include instantaneous strong light interference triggering conditions and low temperature environment signal delay triggering conditions, among which: The instantaneous strong light interference trigger condition is as follows: when a momentary strong light appears in the environment around the infrared beam sensor 6, causing the receiver of the infrared beam sensor 6 to falsely detect an unobstructed signal, and the duration of this false detection signal exceeds 0.1 seconds, an anomaly is triggered. At the same time, the system automatically starts the anti-interference filtering algorithm to eliminate invalid signals.

[0080] The low-temperature environment signal delay trigger condition is as follows: when the ambient temperature is below -5℃, if the difference between the blade occlusion time detected by the infrared beam sensor 6 and the standard occlusion time at 25℃ exceeds ±8%, and the infrared beam sensor 6 in other temperature areas does not have this deviation, then an abnormality is triggered, prompting the operator to pay attention to the low-temperature adaptability of the equipment.

[0081] It should be further explained that the electric lead screw adjustment algorithm includes the following steps: Sd100. The fan shaft offset coordinates are calculated based on the infrared beam sensor 6 and expressed by the following formula (11): (11) Where: x and y are used to characterize the coordinates in the horizontal and vertical directions with the fan axis as the origin, respectively; k is used to characterize the ratio of sensor distance to axis offset, calibrated by the installation dimensions, such as k=0.8; , The average values ​​of the obstruction position deviations along the horizontal and vertical axes are respectively used to characterize the two infrared beam sensors 6 that are symmetrical about the theoretical axis of the fan.

[0082] Sd200. Calculate the offset distance and offset direction angle of the fan shaft, expressed by the following formula (12): (12) Where: L represents the offset distance; a represents the offset direction angle.

[0083] Sd300. When the offset distance is greater than the manually preset offset distance threshold, calculate the extension and retraction of each electric lead screw adjustment mechanism 9, and express it according to the following formulas (13), (14), (15), and (16): (13) (14) (15) (16) Where: R is used to characterize the radius of the motor mounting base 10; Used to characterize the extension and retraction of the electric lead screw adjustment mechanism 9 located in the positive direction of the horizontal axis; Used to characterize the extension and retraction of the electric lead screw adjustment mechanism 9 located in the negative direction of the horizontal axis; Used to characterize the extension and retraction of the electric lead screw adjustment mechanism 9 located in the positive direction of the longitudinal axis; The sign is used to characterize the extension and retraction of the electric lead screw adjustment mechanism 9 located in the negative direction of the longitudinal axis; the negative sign is used to characterize the shortening of the electric lead screw adjustment mechanism 9, and the positive sign is used to characterize the extension of the electric lead screw adjustment mechanism 9.

[0084] Sd400. The adjusted load is calculated based on the initial load of each electric screw adjusting mechanism 9 and expressed by the following formulas (17) and (18): (17) (18) Where: F0 is used to characterize the initial load; G is used to characterize the total weight of the fan drive motor 5 and the cooling fan 2; F i Used to characterize the adjusted load of the i-th electric lead screw adjustment mechanism 9; Used to characterize the load change of the i-th electric screw adjusting mechanism 9; k F Used to characterize the loading coefficient, calibrated experimentally, such as k. F =50N / mm.

[0085] Sd500. Determine whether the adjusted load of each electric lead screw adjustment mechanism 9 meets the manually preset safety margin threshold, and then perform the following operations based on the determination result: If the adjusted load of each electric screw adjustment mechanism 9 is less than or equal to 0.8 times the safety margin threshold, then the extension amount calculated in step Sd300 is deemed valid.

[0086] If the adjusted load of any electric screw adjusting mechanism 9 is greater than 0.8 times the safety margin threshold, then the extension and retraction of each electric screw adjusting mechanism 9 shall be adjusted proportionally, as expressed by the following formula (19): (19) in: Used to characterize the corrected extension / retraction amount of the i-th electric lead screw adjusting mechanism 9; F max Used to characterize safety margin thresholds.

[0087] Sd600. After the electric lead screw adjustment mechanism 9 is adjusted according to the extension amount obtained in step Sd500, the infrared beam sensor 6 is controlled to collect deviation data and calculate the new offset distance. If the newly calculated offset distance is less than or equal to the preset target accuracy, the adjustment is determined to be complete. If the newly calculated offset distance is greater than the target accuracy, steps Sd100 to Sd600 are executed again.

[0088] It is necessary to further explain the core calculation logic of the electric lead screw adjustment algorithm: a multi-dimensional algorithm based on spatial geometry and load balance. The electric lead screw adjustment calculation takes the "fan shaft offset" as input, combined with the circumferential distribution position of the four electric lead screws (adjacent angles are 90°, set as lead screw 1-right, 2-front, 3-left, 4-rear), and determines the extension or retraction of each lead screw through spatial coordinate transformation and load distribution, ensuring that the fan shaft returns to the theoretical center after adjustment, and that the load on each lead screw does not exceed the rated value.

[0089] It should be further explained that the key parameters of the electric lead screw adjustment algorithm are defined as follows: 1. Basic parameters: Let the theoretical axis of the fan be the origin O(0,0), and the actual axis after offset be O'(x,y). The offset distance is expressed by the following formula (20): (20) The offset direction angle (the angle between the offset direction and the positive x-axis) is expressed by the following formula (21): (twenty one) 2. Lead screw parameters: The initial length of each of the four electric lead screws is H0, and the rated load is F. max Adjustment accuracy δ (±0.01-±0.05mm), maximum stroke S max (50mm).

[0090] It should be further explained that the refined calculation steps of the electric lead screw adjustment algorithm are as follows: Step 1: Offset and Direction Calculation (Based on Infrared Through-beam Sensor Data) 1. Sensor Data Acquisition: Eight infrared beam sensors 6 (distributed at 45° along the circumference of the fan protection frame 1, numbered 1-8) detect the blade occlusion position deviation in real time. Let the detection deviation value of sensor i be... (Unit: mm, positive numbers indicate the blade is deflected toward the sensor, negative numbers indicate it is moved away).

[0091] 2. Calculation of axis offset coordinates: Take the average deviation of the symmetrical sensor pairs (such as 1&5, 2&6, 3&7, 4&8) to eliminate environmental interference. The formula is as follows (22): (twenty two) Establish a sensor coordinate system, with sensor 1 corresponding to the positive x-axis direction (right) and sensor 2 corresponding to the positive y-axis direction (front). Then the axis offset coordinate is given by the following formula (23): (twenty three) Calculate the offset distance and offset direction angle to determine whether adjustment needs to be initiated (initiate when L > threshold 0.1mm).

[0092] Step 2: Calculation of the extension and retraction of the electric lead screw (based on spatial geometry and similar triangles) 1. Determining the direction of lead screw adjustment: Based on the offset direction angle α, determine which lead screw assembly needs to be "extended" or "shortened": When α is between 0° and 90° (front right): Lead screw 1 (right) needs to be shortened, lead screw 3 (left) needs to be extended, lead screw 2 (front) needs to be shortened, and lead screw 4 (back) needs to be extended; When α is between 90° and 180° (left front): lead screw 1 needs to be extended, lead screw 3 needs to be shortened, lead screw 2 needs to be shortened, and lead screw 4 needs to be extended; Similarly, adjust the direction according to the four quadrants to ensure that the extension and retraction direction of the lead screw is opposite to the offset direction.

[0093] 2. Precise calculation of expansion and contraction: Based on the principle of similar triangles, let the radius of the motor mounting base be R (the distance from the lead screw mounting point to the shaft center), then the extension / retraction of a single lead screw... The offset x / y satisfies the following equation (24): (twenty four) Where: the Δ coordinate is x or y, depending on the direction of the lead screw).

[0094] Calculate the extension / retraction of each lead screw in each direction: Left and right directions (x-axis): The extension / retraction amount of lead screw 1 is as follows (25): (25) The extension / retraction amount of lead screw 3 is as follows (26): (26) Forward and backward directions (y-axis): The extension / retraction amount of lead screw 2 is as follows (27): (27) The extension / retraction amount of lead screw 4 is as follows (28): (28) Where: a negative sign indicates shortening, and a positive sign indicates lengthening.

[0095] Specific calculation example: If x = 0.08 mm (right deflection), y = 0.06 mm (forward deflection), L = 0.1 mm, and R = 100 mm, then: The extension / retraction of lead screw 1 is 8mm: The extension of lead screw 3 is 8mm.

[0096] The extension / retraction of lead screw 2 is 6mm: The extension of lead screw 4 is 6mm.

[0097] Step 3: Load verification and expansion / contraction correction (based on pressure sensor feedback) 1. Load Calculation: Assume the total weight of the motor and fan is G. When the four lead screws bear the load evenly, the initial load F0 of a single lead screw is = After adjustment, the change in screw load... With stretching Proportional (due to load redistribution caused by mounting bracket tilt), the calculation formulas are as follows (29) and (30): (29) (30) 2. Load verification and correction: If all F i ≤0.8F max (With a safety margin), the expansion / contraction amount Δh i efficient; If a certain lead screw F i >0.8F max Then, adjust all lead screw extensions proportionally to ensure that the load does not exceed the limit after adjustment. The calculation formula is expressed as follows (31): (31) Specific calculation example: If G = 2000N, F_0 = 500N, F max =1000N, a certain lead screw ΔF i =400N (F) i =900N≤800N, exceeding the limit), then the correction factor = The lead screw extension / retraction amount is corrected to Δh. i' =Δh i ×0.75, and other lead screws are adjusted synchronously according to this coefficient to ensure that the adjustment direction remains unchanged.

[0098] Step 4: Accuracy verification after adjustment (closed-loop feedback) 1. The electric lead screw is based on the calculated extension / retraction amount Δh.i × (or the corrected Δh) i' After adjustment, the infrared beam sensor collects deviation data again and calculates the new axis position O''(x',y').

[0099] 2. If the new offset distance L' ≤ 0.05 mm (target accuracy), the adjustment is complete; if L' > 0.05 mm, repeat steps (I) to (III) for a second fine-tuning until the accuracy requirements are met.

[0100] It should be further explained that the application verification of the electric lead screw adjustment algorithm is as follows: Assuming the fan shaft offset is O'(0.1mm, 0.05mm) (0.1mm to the right, 0.05mm forward), the lead screw installation radius R=150mm, the total motor weight G=3000N, the lead screw rated load Fmax=1200N, and the load factor kF=40N / mm: 1. Calculate the offset distance: Direction angle α≈26.56° (right anterior quadrant); 2. Calculation of lead screw extension / retraction: (The right lead screw is shortened by 13.42mm); (Left lead screw extension 13.42mm); (The front lead screw is shortened by 6.71mm); (The lead screw elongation is 6.71 mm). 3. Load verification: Initial load: Load variation of lead screw 1: Adjusted load: Load variation of lead screw 3: Adjusted load: (Exceeding the standard) 4. Load Correction: Correction factor: Corrected expansion / contraction amount: Corrected load on lead screw 3: (Meets the requirements).

[0101] 5. Accuracy verification: After adjustment, the sensor detects the new shaft center O'' (0.03mm, 0.02mm), L'≈0.036mm≤0.05mm, indicating that the adjustment is qualified.

[0102] It should be noted that the intelligent control system includes a data transmission and remote management module and an intelligent controller. The data transmission and remote management module is electrically coupled to the intelligent controller, used to transmit the operating data, vibration, and deflection adjustment information of the cooling fan 2 to the mobile terminal in real time, and to receive control commands from the mobile terminal. The intelligent controller is electrically coupled to both the vibration monitoring and adjustment system and the deflection monitoring and adjustment system, used to analyze the collected vibration and deflection data, and to control the corresponding adjustment mechanisms to automatically adjust based on the analysis results. Simultaneously, the intelligent control system also has data storage and remote communication functions, capable of storing the fan's operating data for subsequent analysis, and able to promptly send abnormal situations to the operator's mobile terminal via a wireless communication module, facilitating remote monitoring and management.

[0103] It should be further explained that the installation process for the intelligent control system is as follows: 1. Main Unit Installation: Secure the intelligent control system main unit (approximately 200mm × 150mm × 80mm, weight ≤ 2kg) to a location near the generator set that is easily accessible for operation and maintenance (e.g., inside the generator control cabinet or on an independent bracket). Ensure the installation environment is well-ventilated (with ≥ 100mm of space around for heat dissipation), free from significant vibration (≥ 500mm distance from vibration sources of the generator set), and free from dust and water corrosion. Use M4 expansion bolts to secure the main unit to the mounting surface, ensuring the flatness error of the mounting surface is ≤ 0.5mm to prevent damage to internal components due to tilting of the main unit.

[0104] 2. Wiring Connection: According to the system wiring diagram, connect the signal and power lines of the piezoelectric vibration sensor 8, infrared beam sensor 6, miniature drive motor 11, electric lead screw adjustment mechanism 9, and temperature sensor to the corresponding interfaces on the intelligent controller. Label both ends of each line (e.g., "Vibration Sensor 1 - Left side of motor housing" "Electric Lead Screw 3 - Rear side of mounting base") for easy maintenance later. After wiring, tidy up the wires with cable ties to prevent messy wiring from causing signal interference or accidental pulling.

[0105] 3. Communication and Parameter Configuration: Install the 4G / 5G communication module (insert a carrier SIM card, ensuring signal strength ≥ -85dBm), and connect the module to the smart controller via the RJ45 interface. Power on the host and enter the system configuration interface. Set the data sampling interval (5 seconds / sample for regular data, 1 second / sample for vibration and deflection data), safety thresholds (vibration amplitude threshold 0.2mm, deflection distance threshold 0.1mm, temperature warning threshold 45℃), and remote alarm method (SMS + APP push notification dual alerts). Enter the operator's mobile terminal account to complete the binding between the device and the terminal. After configuration, conduct a communication test by sending test data to the mobile terminal, confirming that the data transmission delay is ≤3 seconds and there is no packet loss.

[0106] It should be noted that the installation process of the auxiliary components of this invention is as follows: 1. Installation of shock-absorbing rubber pads: Install shock-absorbing rubber pads with a Shore hardness of 40-60HA (size matching the contact area of ​​the mounting base, thickness 5-8mm) at the connection between the fan motor mounting base and the electric screw adjustment mechanism. Apply anti-slip agent to the upper and lower surfaces of the rubber pads and tighten them with bolts to reduce the transmission of fan vibration to the mounting foundation and generator set.

[0107] 2. Installation of audible and visual alarm device: Install an audible and visual alarm (alarm volume ≥85dB, light flashing frequency 1-2 times / second) next to the main unit of the intelligent control system. Connect its control line to the alarm output port of the controller. When the system detects a fault or parameter exceeds the limit, the alarm will be activated immediately to remind on-site personnel to handle the situation in a timely manner.

[0108] This application also claims a monitoring method utilizing a generator set cooling fan vibration and deflection optimization device, such as... Figure 3 As shown, it includes the following steps: S100. During the operation of the cooling fan 2, the vibration data of the cooling fan is collected by the piezoelectric vibration sensor 8 and the vibration data is transmitted to the intelligent control system; the infrared beam sensor 6 is controlled to monitor the position change data of the blades of the cooling fan 2 in real time and transmit the position change data to the intelligent control system.

[0109] S200. Vibration data and position change data are analyzed by the vibration analysis algorithm and the deviation analysis algorithm of the intelligent control system, respectively.

[0110] S300. Based on the analysis results of step S300, the position of the adjustable counterweight 12 is adjusted by the counterweight adjustment control algorithm, thereby changing the mass distribution of the cooling fan 2 and reducing vibration; the position of the fan drive motor 5 is adjusted by multiple electric screw adjustment mechanisms 9 through the electric screw adjustment algorithm, thereby correcting the bias of the cooling fan 2.

[0111] S400. The intelligent control system stores the fan's operating data in a local database. At the same time, the data transmission and remote management module transmits the operating data, vibration, and deflection adjustment information of the cooling fan 2 to the mobile terminal in real time and receives control commands from the mobile terminal.

[0112] It should be further noted that the monitoring method of the present invention also includes the following startup and initialization process before implementation: Before starting the generator set, the intelligent control system performs a self-test, sequentially checking the working status of each sensor, actuator, and communication module. If a sensor has no signal feedback, the system displays a "Sensor Fault - Please check the wiring" message on the local display and mobile terminal. If the actuator does not respond, it displays "Electric Screw / Micro Motor Fault - Please check the power supply or mechanical jamming." After passing the self-test, the system enters standby mode. Once the generator starts and the cooling fan begins to run (reaching 80% of its rated speed), it automatically switches to real-time monitoring mode.

[0113] It should be further explained that in step S100, the specific workflow is as follows: After the generator set starts, the cooling fan 2 begins to operate. The piezoelectric vibration sensor 8 collects the vibration data of the cooling fan 2 in real time, and the infrared beam sensor 6 monitors the position changes of the fan blades in real time. These data are continuously transmitted to the intelligent control system.

[0114] (1) Multi-dimensional data acquisition: The piezoelectric vibration sensor 8 synchronously acquires the axial, radial and circumferential vibration acceleration data of the fan (range 0-100m / s). 2 The infrared beam sensor 6 records the time point (accuracy ±0.1ms) and the deviation of the blocking position (accuracy ±0.05mm) of each blade blocking the light. The temperature sensor collects the ambient temperature around the fan (data is updated every 2 seconds). All data is transmitted to the controller in real time through shielded lines with a transmission rate ≥1Mbps and no data loss.

[0115] (2) Data preprocessing: The intelligent controller filters the collected raw data (using the Kalman filter algorithm) to remove environmental interference signals (such as sensor false triggering caused by vibration of other components of the unit or changes in external light) to ensure data accuracy. For example, it filters out vibration signals with frequencies <10Hz or >1000Hz (the normal vibration frequency range of the fan is 10-500Hz) and eliminates infrared signal anomalies caused by non-blade obstruction (such as the instantaneous signal of dust passing by the sensor).

[0116] It should be further explained that in step S200, the intelligent control system performs rapid analysis and processing of the received data. For vibration data, the vibration amplitude and frequency are calculated using a built-in algorithm and compared with a preset safety threshold; for data from the infrared beam sensor 6, the system analyzes the time and positional changes in light blocking by the fan blades to determine if the fan is deflected. (1) Vibration analysis: The system converts the vibration time domain data into frequency domain data through the fast Fourier transform algorithm and identifies the main vibration frequency components: If the main frequency is consistent with the fan speed frequency (e.g., when the speed is 3000 r / min, the frequency is 50 Hz), it is determined to be vibration caused by mass imbalance; if the frequency is 2 times or more of the speed frequency, it may be due to blade installation deviation or uneven wear. The system will further combine the vibration amplitude differences of each sensor to locate the specific faulty blade (e.g., "blade 3 - vibration amplitude is 40% higher than other blades, suspected wear").

[0117] (2) Bias analysis: Compare the blade occlusion time difference of the 8 infrared beam sensors. If the occlusion time detected by a certain direction sensor is continuously advanced (e.g., the right sensor is 0.03ms earlier than the left sensor), the fan bias direction is calculated by combining the occlusion position deviation data (e.g., "biased to the right, offset distance 0.08mm"). If multiple direction sensors are abnormal, it is determined that the fan shaft is tilted, and the system will start a multi-dimensional adjustment program.

[0118] It should be further explained that in step S300, if the intelligent control system determines that the fan is vibrating, it sends a control command to the micro motor based on the vibration analysis results. The micro motor drives the threaded rod to rotate, adjusting the position of the adjustable counterweight on the hub until the vibration amplitude is reduced to a safe range. If it determines that the fan is misaligned, the intelligent control system calculates the direction and distance the fan needs to be adjusted, and controls the corresponding electric screw adjustment mechanism to extend or shorten, so that the motor drives the fan to move to the center position and correct the misalignment.

[0119] (1) Vibration adjustment refinement: When the vibration is determined to be due to mass imbalance, the controller calculates the required counterweight adjustment amount based on the vibration amplitude. If the vibration amplitude is 0.4mm (exceeding the threshold of 0.2mm), combined with the fan mass and speed data, the counterweight 1 needs to be adjusted from the initial radius of 0.1m outward to 0.12m, and the counterweight 5 needs to be adjusted from 0.1m inward to 0.08m using the centroid formula. Then, the controller sends a command to the corresponding micro motor, which drives the threaded rod to rotate at a speed of 10r / min. Vibration data is collected in real time during the adjustment process. When the vibration amplitude drops to 0.15mm (below the threshold), the motor stops running, and the system records the adjustment parameters (e.g., "counterweight 1 adjustment amount +20mm, vibration reduction rate 62.5%").

[0120] (2) Detailed adjustment of bias: If the fan is detected to be biased to the right by 0.08mm, the system establishes a coordinate system with the fan axis as the origin, calculates that the electric lead screw 1 (right side) needs to be shortened by 0.06mm, the electric lead screw 3 (left side) needs to be extended by 0.06mm, and the electric lead screws 2 (front side) and 4 (rear side) remain stationary. The controller sends adjustment commands to the electric lead screws 1 and 3, and the lead screws run at a speed of 0.2mm / s. For every 0.01mm adjustment, the load is confirmed to be normal by the pressure sensor (pressure ≤ 80% of the rated load). After the adjustment is completed, the infrared beam sensor performs a second detection to confirm that the bias distance has dropped to 0.02mm, which meets the requirements.

[0121] It should be further explained that in step S400, the intelligent control system stores the fan's operating data in a local database, and simultaneously sends key data and abnormal situations to the operator's mobile terminal via a wireless communication module. The operator can remotely view the fan's operating status via mobile phone or computer, and can also adjust the parameters of the intelligent control system through remote control functions when necessary.

[0122] (1) Data display and storage: The intelligent controller displays the processed operating data (vibration amplitude, deviation distance, motor speed, ambient temperature, adjustment record) on the local touch screen in real time, and stores it in the local database according to "day / week / month" (supports data export to Excel format). At the same time, it pushes a regular data report to the mobile terminal every 5 minutes. The report includes key information such as "current status - normal / warning / fault", "number of adjustments today", and "cumulative running time".

[0123] (2) Abnormal Handling and Remote Control: When a parameter is detected to exceed the threshold (e.g., the vibration amplitude suddenly rises to 0.6 mm), the system immediately triggers an alarm (local audible and visual alarm + mobile terminal push notification) and automatically starts the emergency adjustment procedure; if the parameter still does not return to normal after adjustment (e.g., the vibration amplitude is still > 0.3 mm after 3 consecutive adjustments), a "manual intervention required" prompt is sent to the terminal, along with troubleshooting suggestions (e.g., "check if the blades are broken or if the counterweight is loose"). Operators can remotely modify system parameters via the mobile APP (e.g., temporarily increase the temperature threshold), or send a "stop maintenance" command in an emergency to control the fan to stop running.

[0124] It should be noted that, compared with the prior art, the present invention has the following significant advantages: 1. Real-time monitoring and proactive adjustment, transforming passive maintenance into proactive prevention. In existing technologies, the cooling fans of hydroelectric generators often lack effective monitoring and adjustment mechanisms, and repairs are often only carried out after a failure occurs. This invention, however, uses vibration sensors and infrared beam sensors to collect data in real time, and an intelligent controller analyzes and drives the adjustment mechanism (a micro-motor adjusts the counterweight, and an electric screw adjuster adjusts the mounting base) to resolve vibration and misalignment issues in their early stages, preventing the fault from worsening and reducing downtime and maintenance costs.

[0125] 2. Multi-system collaboration enhances the accuracy and comprehensiveness of adjustments. (1) In terms of vibration adjustment, the piezoelectric vibration sensor is used to accurately collect data. Combined with the principle of rotational inertia, the unbalanced force is dynamically balanced by an adjustable counterweight. Compared with the simple static balancing method in the existing technology, the adjustment is more accurate and can adapt to vibration changes under different working conditions.

[0126] (2) In terms of deflection adjustment, the position of the blade is monitored by symmetrically distributed infrared beam sensors, and the position of the motor is adjusted in multiple dimensions by electric screw adjustment mechanism. Compared with the traditional method of relying on manual calibration, the deflection can be corrected more quickly and accurately, ensuring uniform airflow and heat dissipation.

[0127] 3. Intelligent and remote management improves operation and maintenance efficiency. The intelligent control system integrates data and has storage and remote communication functions. It can send operational data and abnormal situations to mobile terminals, facilitating remote monitoring and management by operators. Existing technologies often require manual on-site inspections, while this invention reduces manual intervention, making operation and maintenance more efficient, and is especially suitable for generator installation environments in remote areas or those that are difficult to access.

[0128] 4. Structural design details have been optimized to enhance practicality and reliability. Features such as the T-shaped groove and limiting boss of the wheel hub, the stepped cylindrical structure and anti-slip texture of the counterweight, and the installation layout of the electric screw adjustment mechanism make the device more stable to install and smoother to adjust. It can adapt to long-term high-speed operation conditions and extend the service life of the equipment. Compared with the simple structure and easy wear design of the existing technology, it has more advantages.

[0129] It should be further noted that, considering the technical design of this invention and practical application scenarios, the effectiveness of the invention can be verified through the following data dimensions: I. Data Verification of Vibration Adjustment Effect 1. Vibration amplitude reduction rate (1) Assuming that the average vibration amplitude of the cooling fan during operation in the prior art is 0.5 mm (exceeding the safety threshold of 0.2 mm), after adopting the present invention, the vibration amplitude can be reduced to below 0.1 mm by dynamically adjusting the adjustable counterweight.

[0130] (2) Data comparison: The vibration amplitude was 0.5 mm before adjustment and 0.1 mm after adjustment, with a reduction rate of 80%, which is far below the safety threshold and meets the design goal of "reducing vibration to reduce component wear".

[0131] 2. Efficiency of balancing unbalanced forces (1) Based on the formula for calculating unbalanced force, assuming the fan mass is 5kg, the rotation speed is 3000r / min (ω≈314rad / s), and the initial centroid offset is e2=0.3mm, then the initial unbalanced force F u0 ≈5×3142×0.0003≈148N.

[0132] (2) After adjustment, the centroid offset e1 = 0.05 mm, and the unbalanced force F u1 The balance efficiency reached 83%, approximately 24.7 N, verifying the effect of counterweight adjustment on suppressing unbalanced forces.

[0133] II. Data Verification of Bias Adjustment Effect 1. Deviation correction accuracy (1) The infrared beam sensors are symmetrically distributed along the circumference (8 sensors, spaced at 45° intervals), and can detect positional offsets of ±0.1mm. Assuming the initial deflection distance of the fan is 1mm, the deflection distance can be controlled within a certain range after adjustment by the electric screw adjustment mechanism. 0.01~ Within 0.05mm, the correction accuracy reaches 90%.

[0134] (2) Corresponding heat dissipation effect: When the bias causes uneven airflow distribution, the heat dissipation efficiency decreases by about 20%; after correction, the airflow uniformity is restored, and the heat dissipation efficiency is increased to more than 98% of the design value.

[0135] 2. Adjust response speed When a bias signal is detected, the intelligent controller calculates the adjustment amount in less than 0.5 seconds, the electric lead screw adjustment mechanism completes the adjustment action in less than 2 seconds, and the total response time is less than 2.5 seconds, which is much faster than the average time for manual adjustment (about 30 minutes), effectively avoiding component wear caused by continuous bias.

[0136] III. Long-term operational benefit data 1. Extended equipment lifespan In the prior art, the average lifespan of a fan is about 2,000 hours due to vibration and misalignment issues; by adopting the present invention, the lifespan can be extended to more than 5,000 hours by reducing component wear, which is a 150% increase in service life.

[0137] 2. Reduced maintenance costs The annual maintenance cost (including downtime losses) of the traditional solution is about 5,000 yuan; due to the reduction of failures, the annual maintenance cost of this invention can be reduced to less than 1,500 yuan, a cost reduction of 70%.

[0138] IV. Data Conclusions Based on data such as vibration amplitude reduction rate, deviation correction accuracy, response speed, and long-term benefits, this solution can effectively solve the vibration and deviation problems of cooling fans in the prior art, verifying its technical feasibility and practical application value, and meeting the requirements of practicality and beneficial effects of the invention.

[0139] It is necessary to further explain that, taking the "relationship between unbalanced force and center of mass shift" in a vibration adjustment system as an example, the effectiveness of the solution is verified by substituting actual data into the formula: Hypothetical scenario: The cooling fan of a hydroelectric generator has a mass M = 10 kg. During initial operation, due to blade wear, the center of mass shifts, and the initial distance from the center of mass to the hub is e0 = 0.2 mm = 0.0002 m. The fan speed is n = 3000 r / min (i.e., angular velocity ω = 2πn / 60 = 314 rad / s). One fan with a mass m... p An adjustable counterweight of 0.1 kg, the initial position of which is r from the center of the wheel hub. p0 =0.1m, the distance r from the position of the counterweight to the center of the wheel hub after adjustment. p =0.15m.

[0140] 1. Calculate the initial unbalanced force F u F u =10kg×(314rad / s)2×0.0002m =10×98596×0.0002 =197.192N At this point, the vibration amplitude exceeds the safety threshold (assuming the threshold corresponds to an unbalanced force of 50N), and adjustment needs to be initiated.

[0141] 2. Calculate the adjusted centroid offset e1 Substitute the data according to the centroid adjustment formula: (The negative sign indicates that the direction of the center of mass shift is opposite to the direction of the counterweight adjustment, that is, the overall center of mass moves towards the equilibrium position.) 3. Calculate the unbalanced force Fu' after adjustment. F u '=10.1kg×(314rad / s)2×0.0000297m ≈10.1×98596×0.0000297 ≈29.5N 4. Conclusion After adjustment, the unbalanced force decreased from 197.192N to 29.5N, which is below the safety threshold of 50N. The vibration amplitude decreased accordingly, verifying that adjusting the position of the counterweight can effectively balance the unbalanced force, which meets the design goal of "dynamically adjusting vibration" in the scheme.

[0142] In the above detailed description, various features are combined together in a single embodiment to simplify this disclosure. This approach to disclosure should not be construed as reflecting an intention that embodiments of the claimed subject matter require more features than are explicitly stated in each claim. Rather, as reflected in the appended claims, the invention is presented with fewer features than all of the features of the single disclosed embodiment. Therefore, the appended claims are hereby explicitly incorporated into the detailed description, wherein each claim stands alone as a preferred embodiment of the invention.

[0143] The disclosed embodiments have been described above to enable any person skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be applied to other embodiments without departing from the spirit and scope of this disclosure. Therefore, this disclosure is not limited to the embodiments given herein, but is consistent with the broadest scope of the principles and novel features disclosed in this application.

[0144] The foregoing description includes examples of one or more embodiments. It is certainly impossible to describe all possible combinations of components or methods in order to describe the above embodiments, but those skilled in the art will recognize that further combinations and arrangements of the various embodiments are possible. Therefore, the embodiments described herein are intended to cover all such changes, modifications, and variations that fall within the scope of the appended claims. Furthermore, the term "comprising" as used in the specification or claims is interpreted in a manner similar to the term "including," as interpreted when used as a conjunction in the claims. Additionally, the use of any term "or" in the specification of the claims is intended to mean "non-exclusive or."

[0145] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A device for optimizing the vibration and deflection of a generator set cooling fan, characterized in that: Includes a vibration monitoring and adjustment system and an intelligent control system, among which: The vibration monitoring and adjustment system includes a piezoelectric vibration sensor (8), an adjustable counterweight (12), a T-shaped slider (15), and a micro drive motor (11). The piezoelectric vibration sensor (8) is evenly distributed around the housing of the fan drive motor (5) to collect vibration data during the operation of the cooling fan (2). The adjustable counterweight (12) is a stepped cylindrical structure. The adjustable counterweight (12) is slidably connected to the T-shaped groove (7) on the fan hub (3) through the T-shaped slider (15). The end of the adjustable counterweight (12) passes through the fan hub housing (13) and is then rigidly connected to the micro drive motor (11) through a coupling and a threaded screw (14). The micro drive motor (11) is electrically coupled to the intelligent control system and is controlled by the intelligent control system to drive the coupling and the threaded screw (14) to rotate, thereby adjusting the position of the adjustable counterweight (12) in the radial direction of the fan hub (3).

2. The generator set cooling fan vibration and deflection optimization device according to claim 1, characterized in that: It also includes a bias monitoring and adjustment system; the bias monitoring and adjustment system includes multiple sets of infrared beam sensors (6) and multiple electric screw adjustment mechanisms (9); the infrared beam sensors (6) are symmetrically distributed along the circumference of the fan protective mesh frame (1) and are used to monitor the position change data of the blades of the cooling fan (2) relative to the motor mounting base (10) and determine whether bias has occurred; the electric screw adjustment mechanisms (9) are evenly distributed along the circumference of the motor mounting base (10) and are used to adjust the position of the motor mounting base (10) and correct the bias of the cooling fan (2); the telescopic end of the electric screw adjustment mechanism (9) is bolted to the motor mounting base (10), and the fixed end of the electric screw adjustment mechanism (9) is bolted to the mounting base (5-1) at the end of the fan drive motor (5).

3. The generator set cooling fan vibration and deflection optimization device according to claim 2, characterized in that: The intelligent control system includes a data transmission and remote management module and an intelligent controller; the data transmission and remote management module is electrically coupled to the intelligent controller and is used to transmit the operating data, vibration and deflection adjustment information of the cooling fan (2) to the mobile terminal in real time and receive the control commands of the mobile terminal; the intelligent controller is electrically coupled to the vibration monitoring and adjustment system and the deflection monitoring and adjustment system respectively, and is used to analyze the collected vibration data and deflection data, and control the corresponding adjustment mechanism to automatically adjust according to the analysis results.

4. The generator set cooling fan vibration and deflection optimization device according to claim 3, characterized in that: The piezoelectric vibration sensor (8) has a measurement accuracy of ±0.01 m / s. 2 The frequency response range is 0Hz~5000Hz; the micro drive motor (11) is a DC geared motor with a reduction ratio of 50:1~100:1, an output torque of not less than 0.5N·m, and a speed adjustment range of 5r / min~50r / min; the infrared beam sensor (6) is provided with 8 units, the detection distance of the infrared beam sensor (6) is 0mm~100mm, the detection accuracy is ±0.1mm, and the deviation of the center axis of the transmitting end and the receiving end does not exceed ±0.05mm; the electric screw adjustment mechanism (9 The system has four electric lead screw adjustment mechanisms (9), with a maximum stroke of 50mm and an adjustment accuracy of ±0.01mm~±0.05mm, and a built-in pressure sensor. The intelligent controller uses an industrial-grade microprocessor with a computing speed of no less than 100MHz and has at least 16 analog input interfaces for connecting sensors. The intelligent controller has built-in vibration analysis algorithms and bias analysis algorithms. The data transmission and remote management module uses a 4G or 5G communication module with a data transmission rate of no less than 1Mbps and has data encryption functionality.

5. The generator set cooling fan vibration and deflection optimization device according to claim 4, characterized in that: The diameter of the end of the adjustable counterweight (12) connected to the T-shaped slider (15) is smaller than the diameter of the end near the edge of the fan hub (3), and anti-slip texture is provided on the outer circumferential surface of the larger diameter end.

6. The generator set cooling fan vibration and deflection optimization device according to claim 5, characterized in that: The vibration analysis algorithm includes the following steps: Sa100. The vibration time-domain data is converted into frequency-domain data using a Fast Fourier Transform (FFT) algorithm, thereby identifying the main vibration frequencies; the FFT algorithm is expressed by the following formula: Where: X[k] represents the frequency domain data of the discrete signal value vibration, k represents the kth frequency point, and X[k] is the vibration amplitude at that frequency; x[n] represents the time domain data of the discrete signal value vibration, n represents the nth sampling point, and x[n] is the vibration amplitude at that sampling point; N represents the number of sampling points, which is the total number of samples in the vibration time domain data; j represents the imaginary unit; π represents the constant pi; k represents the frequency index in the frequency domain, the frequency number (from 0 to N-1), which corresponds to the actual frequency expressed by the following formula: in: Used to characterize the actual frequency, that is, the physical frequency corresponding to the k-th frequency point; Sa200. Compare the main vibration frequency with the fan speed frequency, and then perform the following steps based on the comparison results: If the main vibration frequency is consistent with the fan speed frequency, it is determined that the vibration originates from mass imbalance, and then step Sa300 is executed; If the main vibration frequency is twice or more than the fan speed frequency, it is determined that the vibration originates from blade installation deviation or uneven wear, and then step Sa400 is executed. Sa300. The spatial position of the adjustable counterweight (12) is adjusted by the counterweight adjustment control algorithm, thereby changing the mass distribution of the cooling fan (2) and reducing vibration; Sa400. Based on the differences in vibration amplitude among various sensors, the location of the specific faulty blade can be determined; The bias analysis algorithm includes the following steps: Sb100. Real-time monitoring and comparison analysis of the leaf occlusion time data and leaf occlusion position data collected by each infrared beam sensor (6); Sb200. Calculate the deflection direction and offset distance of the cooling fan spindle (4); Sb300. When the data collected by the infrared beam sensor (6) meets the artificially preset infrared monitoring anomaly judgment conditions, it is determined that the cooling fan spindle (4) has an axial deviation. Sb400. The extension and retraction of each of the electric lead screw adjustment mechanisms (9) is controlled and adjusted according to the electric lead screw adjustment algorithm.

7. The generator set cooling fan vibration and deflection optimization device according to claim 6, characterized in that: The counterweight adjustment control algorithm includes the following steps: Sc100. Control each of the piezoelectric vibration sensors (8) to synchronously collect the axial vibration acceleration data, radial vibration acceleration data and circumferential vibration acceleration data of the cooling fan (2), and then construct a three-dimensional data matrix of angle-vibration amplitude-frequency, and determine the vibration peak angle corresponding to the vibration amplitude peak and the corresponding main vibration frequency; Sc200. Calculate the unbalanced force in the direction corresponding to the peak vibration angle, expressed by the following formula: Wherein: F u The characterization is used to represent the unbalanced force; m is used to represent the fan mass. Used to characterize angular velocity; e is used to characterize the distance of the center of mass from the axis; Sc300. With the vibration peak angle as the center, select the adjustable counterweight (12) within a range of ±30° as the first adjustment area, and at the same time select the adjustable counterweight (12) within a range of ±30° in the diagonal direction of the vibration peak angle as the symmetrical adjustment area. Sc400. Calculate the adjustment efficiency value of each adjustable counterweight (12) in the first adjustment area and the symmetrical adjustment area, then sort them from high to low according to the adjustment efficiency value and preferentially select the adjustable counterweight (12) whose adjustment efficiency value is greater than the manually preset efficiency threshold for adjustment; the adjustment efficiency value is expressed by the following formula: Wherein: E is used to characterize the adjustment efficiency value; The radial distance that the adjustable counterweight (12) needs to be adjusted is used to characterize: t is used to characterize the time required for adjustment; Sc500. For each candidate adjustable counterweight (12), calculate its adjusted load, expressed as follows: Wherein: F is used to characterize the adjusted load; Used to characterize the mass of the counterweight; If the adjusted load is less than or equal to 0.8 times the maximum load of the threaded screw, then the adjustable counterweight (12) is selected for individual adjustment; If the adjusted load is greater than 0.8 times the maximum load of the threaded screw, then select 2 or 3 symmetrical adjustable counterweights (12) from the sorting results of step Sc400 and redistribute the adjustment amount until the adjusted load of each adjustable counterweight (12) is less than or equal to 0.7 times the maximum load of the threaded screw. During the adjustment of the adjustable counterweight (12), the vibration amplitude is collected at a preset frequency. When the vibration amplitude reduction rate of any of the adjustable counterweights (12) is less than the preset counterweight adjustment threshold, the adjustment of the adjustable counterweight (12) is stopped and the next candidate adjustable counterweight (12) is switched. Sc600. After all the adjustable counterweights (12) have been adjusted, if the overall vibration amplitude still exceeds the preset safety threshold, the residual unbalanced force is calculated, and then the adjustable counterweight (12) opposite to the direction of the residual unbalanced force is selected for a second adjustment until the vibration amplitude is less than or equal to the safety threshold.

8. The generator set cooling fan vibration and deflection optimization device according to claim 7, characterized in that: The electric lead screw adjustment algorithm includes the following steps: Sd100. The fan shaft offset coordinates are calculated based on the infrared beam sensor (6) and expressed as follows: Where: x and y are used to represent the coordinates in the horizontal and vertical directions with the fan axis center as the origin, respectively; k is used to represent the ratio coefficient between the sensor distance and the axis offset; , The average values ​​of the obstruction position deviations along the horizontal axis and the vertical axis detected by the two infrared beam sensors (6) that are symmetrical about the theoretical axis of the fan are respectively used to characterize the average value of the obstruction position deviations along the horizontal axis and the vertical axis. Sd200. Calculate the offset distance and offset direction angle of the fan shaft, expressed by the following formula: Where: L represents the offset distance; a represents the offset direction angle; Sd300. When the offset distance is greater than the manually preset offset distance threshold, calculate the extension and retraction of each of the electric lead screw adjustment mechanisms (9), expressed by the following formula: Wherein: R is used to characterize the radius of the motor mounting base (10); The extension or retraction of the electric lead screw adjustment mechanism (9) located in the positive direction of the horizontal axis is used to characterize the extension or retraction amount. The extension or retraction of the electric lead screw adjustment mechanism (9) located in the negative direction of the horizontal axis is used to characterize the extension or retraction amount. The extension or retraction of the electric lead screw adjustment mechanism (9) located in the positive direction of the longitudinal axis is used to characterize the extension or retraction amount. The extension or retraction of the electric lead screw adjustment mechanism (9) located in the negative direction of the longitudinal axis is used to characterize the extension or retraction of the electric lead screw adjustment mechanism (9); the negative sign is used to characterize the shortening of the electric lead screw adjustment mechanism (9), and the positive sign is used to characterize the lengthening of the electric lead screw adjustment mechanism (9); Sd400. The adjusted load is calculated based on the initial load of each of the electric lead screw adjusting mechanisms (9), and is expressed by the following formula: Wherein: F0 is used to characterize the initial load; G is used to characterize the total weight of the fan drive motor (5) and the cooling fan (2); F i The adjusted load is used to characterize the i-th electric screw adjustment mechanism (9); Used to characterize the load change of the i-th electric screw adjusting mechanism (9); k F Used to characterize the load factor; Sd500. Determine whether the adjusted load of each of the electric lead screw adjustment mechanisms (9) meets the manually preset safety margin threshold, and then perform the following operations based on the determination result: If the adjusted load of each of the electric screw adjustment mechanisms (9) is less than or equal to 0.8 multiplied by the safety margin threshold, then the extension amount calculated in step Sd300 is deemed valid. If the adjusted load of any of the electric lead screw adjusting mechanisms (9) is greater than 0.8 times the safety margin threshold, then the extension / retraction amount of each of the electric lead screw adjusting mechanisms (9) is proportionally adjusted, expressed by the following formula: in: The corrected extension / retraction amount is used to characterize the i-th electric screw adjusting mechanism (9); F max Used to characterize the safety margin threshold; Sd600. After the electric lead screw adjustment mechanism (9) is adjusted according to the extension amount obtained in step Sd500, the infrared beam sensor (6) is controlled to collect deviation data and calculate the new offset distance. If the newly calculated offset distance is less than or equal to the preset target accuracy, the adjustment is determined to be complete. If the newly calculated offset distance is greater than the target accuracy, steps Sd100 to Sd600 are executed again.

9. The generator set cooling fan vibration and deflection optimization device according to claim 8, characterized in that: The infrared monitoring anomaly detection conditions include triggering conditions for blade occlusion time deviation, blade occlusion position offset, signal continuity and integrity, and environmental interference and special operating conditions. The blade occlusion time deviation triggering conditions include single-sensor single-occlusion time deviation triggering conditions, symmetrical sensor occlusion time difference deviation triggering conditions, and multi-blade occlusion time fluctuation deviation triggering conditions, wherein: The trigger condition for the single sensor single occlusion time deviation is as follows: when the difference between the single occlusion time of the blade detected by any of the infrared beam sensors (6) and the average value of the occlusion time of the infrared beam sensor (6) in the last 100 occlusion times exceeds ±5%, an anomaly is triggered. The trigger condition for the symmetrical sensor occlusion time difference deviation is: when the time difference between the occlusion of the same blade of the two sets of infrared beam sensors (6) symmetrically distributed along the circumference of the cooling fan (2) exceeds the preset abnormal judgment threshold, an abnormality is triggered. The triggering condition for the multi-blade occlusion time fluctuation deviation is: if the standard deviation of the occlusion time of 5 consecutively monitored blades passing through the same infrared beam sensor (6) exceeds 0.3ms, an anomaly is triggered; The blade occlusion position offset triggering condition includes a single sensor occlusion position offset triggering condition and a multi-sensor position offset trend triggering condition, wherein: The trigger condition for the single sensor occlusion position offset is: if the deviation between the lateral position of the blade occlusion light detected by any of the infrared beam sensors (6) and the initial calibration position exceeds ±0.1mm, an anomaly is triggered; The triggering condition for the multi-sensor position offset trend is as follows: continuously collect the position data of the blade blocking light from 8 infrared beam sensors (6). If 2 or more infrared beam sensors (6) in any direction continuously detect the position of the blade blocking light shifting in the same direction by ≥0.05mm 3 times, an anomaly is triggered. The signal continuity and integrity triggering conditions include a single detection no signal triggering condition, a continuous multi-turn signal loss triggering condition, and an abnormal signal strength triggering condition, wherein: The single-detection no-signal trigger condition is: if any of the infrared beam sensors (6) does not detect a blade blocking signal within the time it takes for the cooling fan (2) to rotate 1 revolution, then an abnormality is triggered; The triggering condition for the continuous multi-turn signal loss is: if the same infrared beam sensor (6) detects a blade obstruction signal at least once during the continuous 3 turns of the cooling fan (2), or if there is no obstruction signal for 2 consecutive turns, then an abnormality is triggered. The signal strength abnormality triggering condition is: real-time monitoring of the received signal strength of the infrared beam sensor (6). If the signal strength is lower than 70% of the rated working strength of the equipment, and after excluding external factors such as dust obstruction and light interference, it still does not recover for 10 seconds, then an abnormality is triggered. The environmental interference and special operating condition triggering conditions include instantaneous strong light interference triggering conditions and low temperature environment signal delay triggering conditions, wherein: The instantaneous strong light interference triggering condition is as follows: when an instantaneous strong light appears in the environment around the infrared beam sensor (6), causing the receiver of the infrared beam sensor (6) to mistakenly detect an unobstructed signal, and the duration of the mistaken detection signal exceeds 0.1 seconds, an abnormality is triggered. The low-temperature environment signal delay trigger condition is as follows: when the ambient temperature is below -5℃, if the difference between the blade occlusion time detected by the infrared beam sensor (6) and the standard occlusion time at 25℃ exceeds ±8%, and the infrared beam sensor (6) in other temperature areas does not have this deviation, then an abnormality is triggered.

10. A monitoring method utilizing the generator set cooling fan vibration and deflection optimization device according to any one of claims 1 to 9, characterized in that: Includes the following steps: S100. During the operation of the cooling fan (2), the vibration data of the cooling fan is collected by the piezoelectric vibration sensor (8), and the vibration data is transmitted to the intelligent control system; the infrared beam sensor (6) is controlled to monitor the position change data of the blades of the cooling fan (2) in real time, and the position change data is transmitted to the intelligent control system. S200. The vibration data and the position change data are analyzed by the vibration analysis algorithm and the deviation analysis algorithm of the intelligent control system, respectively; S300. Based on the analysis results of step S300, the position of the adjustable counterweight (12) is adjusted by the counterweight adjustment control algorithm, thereby changing the mass distribution of the cooling fan (2) and reducing vibration; the position of the fan drive motor (5) is adjusted by multiple electric screw adjustment mechanisms (9) controlled by the electric screw adjustment algorithm, thereby correcting the bias of the cooling fan (2). S400. The intelligent control system stores the fan's operating data in a local database, and transmits the operating data, vibration, and deflection adjustment information of the cooling fan (2) to the mobile terminal in real time through the data transmission and remote management module, and receives control commands from the mobile terminal.

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