Wireless detection device and method for wire breakage and falling of high-strength bolt of movable shaft of wind power generator

Abstract

The invention discloses a wireless detection device and method for wire breakage and falling of a high-strength bolt of a movable shaft of a wind power generator, and belongs to the technical field of state monitoring of wind power generation equipment. Comprising a plurality of bolts, a plurality of varnished wires, a switching value wireless sending module, a switching value wireless receiving module and a PLC input module, the bolts are used for connecting all parts of a wind generating set moving shaft system, one ends of the varnished wires are fixed to non-conductive parts of the bolts, and the other ends of the varnished wires are electrically connected with an input interface of the switching value wireless sending module. The switching value wireless transmitting module is fixed on a rotating part of a moving axis system of the wind generating set, the switching value wireless transmitting module is in wireless communication connection with the switching value wireless receiving module, the switching value wireless receiving module is fixed on a fixed part of the wind generating set, the switching value wireless receiving module is electrically connected with the PLC input module, and the PLC input module is electrically connected with the PLC output module. The PLC input module is a prefabricated module of the wind generating set.

Description

Technical Field

[0001] This invention relates to the field of wind power equipment condition monitoring technology, specifically to a wireless detection device and method for broken or detached high-strength bolts on the moving shaft of a wind turbine. Background Technology

[0002] Wind turbine generators operate under complex outdoor conditions for extended periods. Their drive shaft system, encompassing key components such as the main shaft, gearbox shaft, generator shaft, and tower, must withstand continuous alternating loads, strong wind impacts, and vibrations. The high-strength bolts connecting these components are crucial for ensuring the overall structural stability and safe operation of the turbine. If these bolts break or fall off due to fatigue, corrosion, or loosening, it can easily lead to component displacement, transmission failure, and in severe cases, gearbox damage, main shaft seizure, or even tower collapse, resulting in significant economic losses for the wind farm.

[0003] Currently, the mainstream method for monitoring the condition of high-strength bolts in wind farms is regular manual inspection. Specifically, this involves checking whether the bolt anti-loosening lines are misaligned and conducting torque sampling to determine the bolt condition. However, this method has many drawbacks: First, the inspection cycle is long, making it difficult to capture early signs of bolt failure in real time, resulting in a lag in fault detection. Second, wind turbine nacelles, towers, and other parts are high-altitude work areas, making manual inspections high-risk and inefficient. Third, due to limitations in the accuracy of manual inspection, it is impossible to achieve full coverage and high-precision monitoring of every single bolt.

[0004] Some technical solutions attempt to use wired monitoring methods such as strain gauges and fiber optic sensors to indirectly determine the bolt condition by collecting changes in bolt preload. However, these solutions have insurmountable drawbacks in the application of wind turbine drive shaft systems: on the one hand, the wiring of sensors on rotating parts is complex, signal transmission relies on easily worn components such as slip rings, and long-term operational reliability is poor; on the other hand, the installation and maintenance costs of wired sensors are high, and they require significant modifications to the original wind turbine structure, making them unsuitable for the retrofitting and upgrading of existing units. Summary of the Invention

[0005] The purpose of this invention is to provide a wireless detection device and method for high-strength bolts on the driving shaft of a wind turbine, in order to solve the problems mentioned in the background art.

[0006] In view of the above problems, the technical solution proposed by the present invention is as follows: A wireless detection device for broken or detached high-strength bolts on the drive shaft of a wind turbine includes several bolts, several enameled wires, a wireless signal transmitting module, a wireless signal receiving module, and a PLC input module. The bolts connect various components of the wind turbine's drive shaft system. One end of each enameled wire is fixed to a non-conductive part of the bolt, and the other end is electrically connected to the input interface of the wireless signal transmitting module. The wireless signal transmitting module is fixed to the rotating component of the wind turbine's drive shaft system. The wireless signal transmitting module and the wireless signal receiving module are wirelessly connected. The wireless signal receiving module is fixed to a fixed component of the wind turbine. The wireless signal receiving module and the PLC input module are electrically connected. The PLC input module is a prefabricated module of the wind turbine. Each bolt can be individually connected to an enameled wire, and bolts located in the same location can also be connected to the same enameled wire. Specifically, both ends of the enameled wire are electrically connected to the input interface of the wireless signal transmitting module. The enameled wire passes sequentially through each bolt and is fixed to a non-conductive part of these bolts, such as the threaded head. The fixed position of the wireless transmitter module is determined by the bolts connected to it, ensuring that the module and bolts rotate together and preventing the enameled wire from tangling. Fixed components of wind turbine generators include, but are not limited to, the nacelle base or the nacelle cabinet. The bolts and enameled wire work together to convert changes in the mechanical state of the bolts into changes in the continuity of the electrical path, providing a direct basis for fault monitoring. The wireless transmitter module, in conjunction with the wireless receiver module, enables wireless signal transmission between rotating and fixed components, eliminating the need for easily worn parts such as slip rings, thus improving signal transmission stability and extending the device's lifespan.

[0007] Furthermore, it also includes a mounting base, which is fixed to the rotating component of the wind turbine generator's drive shaft system and close to the wireless transmission module for switching signals. A wire clamp is fixed to the mounting base by screws. The wire clamp fixes the enameled wire to the mounting base. The mounting base and the wire clamp cooperate to provide auxiliary fixation for the enameled wire, preventing the enameled wire from loosening or shifting due to vibrations generated by the wind turbine operation, and ensuring the stability of the connection between the enameled wire and the bolt.

[0008] Furthermore, industrial tape is adhered to the surface of the enameled wire, which secures the wire to the bolt head. The method of fixing the enameled wire to the bolt is not limited to adhesive bonding; it can also be fixed to the bolt through methods such as threading or crimping. The combination of the enameled wire and the industrial tape ensures that the wire is firmly fixed to the bolt head, reliably causing the wire to break if the bolt breaks or comes loose, thus avoiding misjudgments or missed detections due to the wire becoming loose.

[0009] Furthermore, both the wireless transmitter and receiver modules for switch quantities adopt industrial wireless data transmission modules with anti-interference functions. The combination of the two can resist electromagnetic interference generated during the operation of the wind turbine generator set, ensure the accuracy and integrity of signal transmission, avoid signal loss or mistransmission due to interference, and improve the reliability of fault monitoring.

[0010] Furthermore, the wireless switching module can be powered by a battery.

[0011] On the other hand, the present invention also proposes a wireless detection method for broken and detached high-strength bolts on the driving shaft of wind turbines, comprising the following steps: S1: Fix one end of the enameled wire to the non-conductive part of the bolt to be monitored, and connect the other end to the input interface of the switch wireless transmission module. Fix the switch wireless transmission module to the rotating part of the moving shaft system. Simultaneously complete the connection and debugging of the switch wireless receiving module and the PLC input module. After the above components are fixed, a dynamic balance test is also required on the rotating part of the moving shaft system of the wind turbine generator set. S2: The wireless transmitter module continuously monitors the electrical connectivity of each input interface. At this time, each interface is in a closed state, and the system is in normal monitoring mode. S3: When any bolt breaks or falls off, the enameled wire fixed to it is pulled off, and the circuit state of the corresponding input interface is switched to open circuit. S4: The switch quantity wireless transmission module encodes the open circuit status signal and wirelessly transmits it to the switch quantity wireless receiving module installed on the fixed component; S5: After receiving and decoding the signal, the wireless receiver module for switch quantities synchronously changes the switch quantity state of its own output terminal. S6: When the PLC input module detects a change in the status of the switch quantity, it determines that the corresponding number of bolts has malfunctioned, and then uploads the fault information to the fan monitoring system, triggering an alarm and executing the preset safety protection program.

[0012] Compared with existing technologies, the beneficial effects of this invention are as follows: This wireless detection device and method for broken or detached high-strength bolts on the driving shaft of a wind turbine, through the cooperation of enameled wire and bolt, converts the mechanical fault of the bolt into an electrical on / off signal. Combined with the wireless signal transmission of the switch quantity wireless transmission module and the switch quantity wireless reception module, it achieves real-time monitoring of the bolt status, eliminating the need for regular manual inspections and solving the problems of long inspection cycles and delayed fault detection. It also avoids the safety risks of high-altitude operations. Addressing the problems of complex wiring, reliance on slip rings leading to easy wear, high maintenance costs, and unsuitability for retrofitting existing units, this invention adopts a wireless transmission method. The switch quantity wireless transmission module rotates synchronously with the rotating parts, avoiding the use of easily damaged components such as slip rings and improving system reliability. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of the wireless detection device for broken and detached high-strength bolts on the moving shaft of a wind turbine disclosed in an embodiment of the present invention; Figure 2 This is a schematic diagram of the wiring and fixing method of the enameled wire and the bolt in the wireless detection device for broken wires and loose high-strength bolts of wind turbine drive shaft disclosed in an embodiment of the present invention.

[0014] In the diagram: 1. Bolt; 2. Enameled wire; 3. Mounting bracket; 4. Wire clamp; 5. Wireless transmitter module for switch inputs; 6. Wireless receiver module for switch inputs; 7. PLC input module; 8. Industrial tape. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] Please see Figures 1-2This invention provides a technical solution: a wireless detection device for broken or detached high-strength bolts on the drive shaft of a wind turbine, comprising several bolts 1, several enameled wires 2, a wireless signal transmitting module 5, a wireless signal receiving module 6, and a PLC input module 7. The bolts 1 are used to connect various components of the wind turbine's drive shaft system. One end of each enameled wire 2 is fixed to a non-conductive part of the bolt 1, and the other end is electrically connected to the input interface of the wireless signal transmitting module 5. The wireless signal transmitting module 5 is fixed to the rotating component of the wind turbine's drive shaft system. The wireless signal transmitting module 5 and the wireless signal receiving module 6 are wirelessly connected. The wireless signal receiving module 6 is fixed to a fixed component of the wind turbine. The wireless signal receiving module 6 and the PLC input module 7 are electrically connected. The PLC input module 7 is a prefabricated module of the wind turbine. The device operates normally. During operation, the wireless transmitter module 5 continuously acquires the electrical connection signal from the input interface. Because the enameled wire 2 is in a closed state, the module continuously outputs a closed state monitoring signal and wirelessly transmits this signal to the wireless receiver module 6. When a bolt or a group of bolts 1 breaks or falls off, its position will shift, pulling the enameled wire 2 fixed to it, causing the enameled wire 2 to break, and the corresponding electrical path will immediately switch to an open state. After capturing the open-circuit signal, the wireless transmitter module 5 will immediately encode the signal and then wirelessly transmit the encoded fault signal to the wireless receiver module 6. After receiving and decoding the signal, the wireless receiver module 6 will transmit the fault signal to the PLC input module 7. The PLC input module 7 will upload the fault information to the fan monitoring system, trigger an alarm, and execute the preset safety protection program.

[0017] As an embodiment of the present invention, it further includes a fixing base 3, which is fixed on the rotating component of the wind turbine generator's drive shaft system and close to the wireless transmission module 5. A wire clamp 4 is fixed to the fixing base 3 by screws. The wire clamp 4 fixes the enameled wire 2 to the fixing base 3. The wire clamp 4 fixes the enameled wire 2 to the fixing base 3 by clamping force, limiting the routing position of the enameled wire 2 and preventing the enameled wire 2 from shaking significantly when the rotating component rotates. When the wind turbine vibrates during operation, the fixing base 3 provides a stable support point for the enameled wire 2, and the wire clamp 4 firmly fixes the enameled wire 2 to prevent it from loosening from the bolt 1 due to vibration. The enameled wire 2 will only break when the tensile force generated by the bolt 1 breaking or falling off is greater than the tensile strength of the enameled wire 2, thereby ensuring a strong correlation between the enameled wire 2 breakage signal and the bolt 1 failure.

[0018] As an embodiment of the present invention, further, industrial tape 8 is adhered to the surface of the enameled wire 2. The industrial tape 8 fixes the enameled wire 2 to the screw head of the bolt 1. The industrial tape 8 tightly adheres and fixes the enameled wire 2 and the screw head of the bolt 1, so that the enameled wire 2 and the bolt 1 form a linkage structure. When the bolt 1 undergoes axial or radial displacement due to wire breakage or detachment, it will directly pull the enameled wire 2. If the threading or crimping method is used, the displacement of the bolt 1 will directly act on the threading or crimping point of the enameled wire 2, and the resulting tension will quickly break the enameled wire 2, thereby triggering a change in the on / off state of the electrical circuit.

[0019] As an embodiment of the present invention, both the switch quantity wireless transmitting module 5 and the switch quantity wireless receiving module 6 adopt industrial wireless data transmission modules with anti-interference function. When the wind turbine generator is running, it will generate electromagnetic interference signals, which may be mixed into the transmission signal of the switch quantity wireless transmitting module 5. The anti-interference industrial wireless data transmission module has signal filtering and anti-interference processing capabilities. Before transmitting the signal, the switch quantity wireless transmitting module 5 will first perform anti-interference encoding on the closed or open circuit signal to filter out interference noise. After receiving the signal, the switch quantity wireless receiving module 6 will extract the effective signal through the corresponding decoding algorithm, eliminate the influence of interference signals, and ensure that the signal transmitted to the PLC input module 7 is the real bolt status signal.

[0020] As an embodiment of the present invention, the switch quantity wireless transmission module 5 may be powered by a battery.

[0021] This invention also provides a technical solution: a wireless detection method for broken or detached high-strength bolts on the driving shaft of a wind turbine, comprising the following steps: S1: Fix one end of the enameled wire 2 to the non-conductive part of the bolt 1 to be monitored, connect the other end to the input interface of the wireless switch quantity transmission module 5, and fix the wireless switch quantity transmission module 5 on the rotating part of the moving shaft system. Simultaneously complete the connection and debugging of the wireless switch quantity receiving module 6 and the PLC input module 7. S2: The wireless transmitter module 5 continuously monitors the electrical connectivity of each input interface. At this time, each interface is in a closed state, and the system is in normal monitoring mode. S3: When any bolt 1 breaks or falls off, the enameled wire 2 fixed to it is pulled off, and the corresponding input interface's circuit state switches to open circuit. S4: The switch quantity wireless transmission module 5 encodes the open circuit status signal and wirelessly transmits it to the switch quantity wireless receiving module 6 installed on the fixed component; S5: After receiving and decoding the signal, the wireless receiver module 6 synchronously changes the switch state of its own output terminal. S6: When the PLC input module 7 detects a change in the status of the switch quantity, it determines that the corresponding bolt 1 has malfunctioned, and then uploads the fault information to the fan monitoring system, triggering an alarm and executing the preset safety protection program.

[0022] It should be noted that all standard parts used in this application can be purchased from the market, and can be customized according to the description and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts and equipment adopt conventional models in the prior art. The control method is automatic control through a control cabinet. The control circuit can be implemented by simple programming by those skilled in the art and is common knowledge in the field. Furthermore, since this application is mainly used to protect mechanical devices, this application will not explain the control method and circuit connection in detail.

Claims

1. A wireless detection device for broken or detached high-strength bolts on the driving shaft of a wind turbine, characterized in that, The system includes several bolts (1), several enameled wires (2), a wireless signal transmitting module (5), a wireless signal receiving module (6), and a PLC input module (7). The bolts (1) are used to connect the various components of the wind turbine generator's drive shaft system. One end of the enameled wire (2) is fixed to the non-conductive part of the bolt (1), and the other end of the enameled wire (2) is electrically connected to the input interface of the wireless signal transmitting module (5). The wireless signal transmitting module (5) is fixed on the rotating part of the wind turbine generator's drive shaft system. The wireless signal transmitting module (5) and the wireless signal receiving module (6) are wirelessly connected. The wireless signal receiving module (6) is fixed on the fixed part of the wind turbine generator. The wireless signal receiving module (6) and the PLC input module (7) are electrically connected. The PLC input module (7) is a prefabricated module of the wind turbine generator.

2. The wireless detection device for broken or detached high-strength bolts on the driving shaft of a wind turbine according to claim 1, characterized in that, It also includes a mounting base (3), which is fixed on the rotating component of the moving shaft system of the wind turbine generator set and close to the wireless transmission module (5). A wire clamp (4) is fixed on the mounting base (3) by screws, and the wire clamp (4) fixes the enameled wire (2) to the mounting base (3).

3. The wireless detection device for broken or detached high-strength bolts on the driving shaft of a wind turbine according to claim 1, characterized in that, The surface of the enameled wire (2) is adhered with industrial tape (8), which fixes the enameled wire (2) to the head of the bolt (1).

4. The wireless detection device for broken or detached high-strength bolts on the driving shaft of a wind turbine according to claim 1, characterized in that, Both the switch quantity wireless transmission module (5) and the switch quantity wireless reception module (6) adopt industrial wireless data transmission modules with anti-interference function.

5. The wireless detection device for broken or detached high-strength bolts on the driving shaft of a wind turbine according to claim 1, characterized in that, The wireless switching module (5) can be powered by a battery.

6. A wireless detection method for broken or detached high-strength bolts on the driving shaft of a wind turbine, characterized in that... For any one of the wireless detection devices for broken or detached high-strength bolts on the wind turbine drive shaft as described in claims 1-5, the following steps are included: S1: Fix one end of the enameled wire (2) to the non-conductive part of the bolt (1) to be monitored, connect the other end to the input interface of the switch quantity wireless transmission module (5), and fix the switch quantity wireless transmission module (5) on the rotating part of the moving shaft system, and simultaneously complete the connection and debugging of the switch quantity wireless receiving module (6) and the PLC input module (7); S2: The wireless transmission module (5) continuously monitors the electrical connectivity of each input interface. At this time, each interface is in the pass state and the system is in normal monitoring mode. S3: When any bolt (1) breaks or falls off, the enameled wire (2) fixed to it is pulled off, and the corresponding input interface's circuit state is switched to open circuit. S4: The switch wireless transmission module (5) encodes the open circuit status signal and wirelessly transmits it to the switch wireless receiving module (6) installed on the fixed component. S5: After receiving and decoding the signal, the wireless receiver module (6) synchronously changes the switch state of its output terminal. S6: The PLC input module (7) scans the change in the switch status, determines that the corresponding number of bolt (1) has a fault, and then uploads the fault information to the fan monitoring system, triggers the alarm and executes the preset safety protection program.

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