Water turbine synchronous generator set carbon brush detection device and detection method

Abstract

The invention provides a water turbine synchronous generator set carbon brush detection device and detection method, relates to the technical field of hydroelectric equipment detection, and solves the problem that installation parameters are out of control due to lack of objective measurement data of a carbon brush. The device comprises a data acquisition unit and a data processing display unit which are connected with each other, in the data acquisition unit, an outer shell is configured to be adaptively inserted into a brush holder of a water turbine synchronous generator set carbon brush, an angle sensor measures the relative inclination angle between the outer shell and the surface of a collecting ring, and a pressure sensor measures the pressure applied to the outer surface of the outer shell; in the data processing display unit, a controller receives and processes signals output by the angle sensor and the pressure sensor respectively, and a display module displays an angle measurement value and a pressure measurement value which are processed by the controller respectively. Accurate quantitative detection of the carbon brush installation angle and the spring pressure can be realized, so that field installation and debugging work is guided, and the operation reliability of a generator set is improved.

Description

Technical Field

[0001] This invention relates to the field of hydropower equipment testing technology, specifically to a carbon brush testing device and method for a hydro turbine synchronous generator set. Background Technology

[0002] Hydropower, as a crucial component of the clean energy system, relies heavily on the synchronous generator set of its core power equipment, the turbine, whose operational stability directly impacts grid security and power generation efficiency. This unit generates a synchronous magnetic field through its excitation system, with the sliding contact device consisting of carbon brushes and slip rings being the key element in introducing the rotor excitation current. The quality of the carbon brush installation process, particularly its contact geometry with the slip ring surface and the spring pressure it experiences, is a critical factor determining contact resistance, frictional loss, and even the long-term reliability of the equipment. Improper control of installation parameters will directly trigger a series of operational failures, severely impacting unit safety.

[0003] In actual operation and maintenance, the installation and adjustment of carbon brushes have long faced the problem of a lack of technical measurement methods. To ensure the stability of current conduction and optimize wear characteristics, the working surface of the carbon brush often needs to maintain a specific contact tilt angle with the slip ring surface. The accurate setting of this angle is crucial for forming a uniform and stable contact interface. However, dedicated angle measurement tools are generally lacking on site, and maintenance personnel usually rely on visual observation and personal experience for judgment and adjustment. This method is not only highly subjective, but also makes it difficult to ensure that the angle of a single carbon brush conforms to the design specifications, and even more so to ensure the consistency of the angle among many carbon brushes in the same unit. The resulting differences in contact conditions can become a direct cause of uneven wear, abnormal heating, and even sparking of carbon brushes.

[0004] The spring pressure applied to the back of the carbon brush is another key parameter for maintaining constant contact with the slip ring. The pressure value needs to be precisely controlled within a reasonable range: excessive pressure will drastically accelerate the mechanical wear of the carbon brush and slip ring, shortening component life; insufficient pressure will lead to increased contact resistance, causing localized overheating and potentially arcing, severely damaging the surface finish of the slip ring. Currently, there is also a lack of specialized tools in the field for convenient and accurate measurement of this spring pressure. Therefore, whether the pressure on each carbon brush is balanced and within the optimal range is often unknown, making pressure adjustment lack data-driven support and hindering precise control.

[0005] Faced with the lack of measurement capabilities for both angle and pressure, current on-site handling methods are mostly limited to repeated manual trials and experience-based adjustments. This approach is not only inefficient and time-consuming, but its accuracy also depends entirely on individual skill, resulting in significant uncertainty and randomness. It fails to fundamentally eliminate the operational hazards inherent in the large variations in installation processes, leading to frequent problems such as carbon brush sparking, abnormal wear of slip rings, and premature carbon brush wear. These issues can even cause unplanned unit shutdowns, resulting in significant economic losses.

[0006] Therefore, there is an urgent need in the field of hydropower equipment testing technology to develop a dedicated technology and device that can overcome the aforementioned shortcomings. An ideal technical solution should be able to simultaneously, quickly, and accurately acquire key physical parameters of carbon brush installation, especially the contact tilt angle and spring contact pressure, thereby providing objective and quantitative data guidance for on-site installation, commissioning, and maintenance. Only by achieving standardization and consistency of installation parameters can related faults be effectively prevented, and the operational stability and reliability of generator sets improved. This is of significant practical importance for ensuring the safe and efficient operation of hydropower systems. Summary of the Invention

[0007] The purpose of this invention is to solve the problem of uncontrolled installation parameters of carbon brushes in synchronous turbine generator sets due to a lack of objective measurement data. Therefore, a carbon brush testing device and method for synchronous turbine generator sets are proposed. This invention can accurately quantify and detect the carbon brush installation angle and spring pressure, thereby guiding on-site installation and commissioning work, improving the reliability of generator set operation, and reducing operation and maintenance costs.

[0008] The present invention employs the following technical solutions to achieve its objective: A carbon brush detection device for a hydro turbine synchronous generator set includes a data acquisition unit and a data processing and display unit connected together. The data acquisition unit includes a housing, an angle sensor, and a pressure sensor. The housing is configured to fit into the brush holder of the carbon brush of the turbine synchronous generator set. The angle sensor is located inside the housing and is used to measure the relative tilt angle between the housing and the surface of the slip ring. The pressure sensor is located on the housing, with its sensing surface flush with one of the outer surfaces of the housing, and is used to measure the pressure applied to the outer surface. The data processing and display unit includes a controller and a display module; the controller is communicatively connected to the angle sensor and the pressure sensor respectively, and is used to receive and process the signals output by the angle sensor and the pressure sensor respectively; the display module is electrically connected to the controller, and is used to display the angle measurement value and pressure measurement value obtained by the controller after processing.

[0009] Preferably, the angle sensor is a digital absolute rotary encoder; the angle sensor is configured to acquire the contact tilt angle signal between the housing and the slip ring surface in real time, and its measurement range is adapted to the design value range of the carbon brush contact tilt angle.

[0010] Preferably, the pressure sensor is a thin-film pressure sensor; the sensing surface of the thin-film pressure sensor is flush with the outer surface of the housing for contacting the carbon brush pressure spring, and is configured to acquire the analog pressure signal applied by the carbon brush spring in real time.

[0011] Preferably, the shape and size of the outer casing are configured to be the same as the shape of the carbon brush of the turbine synchronous generator set, so that the outer casing can be directly inserted into and adapted to the brush holder of the carbon brush of the turbine synchronous generator set; one end of the outer casing is provided with a test angle, which is linked to the rotating shaft of the angle sensor and is configured to simulate the end of the carbon brush and fit in contact with the surface of the slip ring in the working state.

[0012] Specifically, the data acquisition unit and the data processing and display unit are connected for data communication via a wired communication interface or a wireless communication module; the wired communication interface or the wireless communication module is configured to establish a data transmission channel between the angle sensor, the pressure sensor and the controller respectively.

[0013] Specifically, the controller is a microcontroller; the microcontroller has a built-in logic calculation program and signal conversion module; The logic calculation program is configured to perform rationality checks on the received angle signal and pressure signal respectively, and generate and issue a reminder signal when the measured value exceeds a preset threshold. The signal conversion module is configured to convert the analog or digital signals transmitted by the angle sensor and the pressure sensor into angle measurement values ​​and pressure measurement values ​​that can be directly read on the display module.

[0014] Preferably, the display module is a liquid crystal display screen; the liquid crystal display screen is electrically connected to the controller and is used to display the angle measurement value and the pressure measurement value in real time; the liquid crystal display screen is also configured to support human-machine interaction function, receive externally input calibration instructions and send them to the controller to trigger the zero-point calibration operation of the angle sensor.

[0015] Preferably, the data processing and display unit further includes a power module; the power module is a rechargeable lithium battery, which is electrically connected to the power-consuming components in the data acquisition unit and the data processing and display unit, respectively, to provide an independent power supply for the entire carbon brush detection device.

[0016] Preferably, the data processing and display unit further includes a power management module; the power management module is electrically connected to the rechargeable lithium battery and the controller respectively; the power management module is configured to monitor the remaining power of the rechargeable lithium battery in real time, and when the remaining power is lower than a preset alarm threshold, send a low power signal to the controller, and the controller controls the display module to display low power warning information.

[0017] This invention also provides a method for detecting carbon brushes in a hydro-turbine synchronous generator set, using the aforementioned carbon brush detection device. The method includes the following steps: S1. Place the data acquisition unit on a known calibration reference surface, and input an angle correction command to the controller through the data processing and display unit to make the angle measurement value displayed by the display module return to zero, thus completing the zero-point calibration operation of the angle sensor. S2. Remove the carbon brush from the brush holder to be tested, insert the calibrated data acquisition unit into the brush holder, make the test angle at the end of the housing fit against the surface of the slip ring, and fasten the pressure spring of the brush holder onto the housing, so that the sensing surface of the pressure sensor bears the spring pressure; at this time, the angle sensor and the pressure sensor start to work, respectively collecting the contact tilt angle signal and the spring pressure signal, and respectively transmitting them to the data processing and display unit; S3. The display module reads the angle measurement value and pressure measurement value displayed in real time after being processed by the controller; the angle measurement value is compared with the preset design angle range to determine whether the current contact tilt angle meets the requirements; at the same time, the pressure measurement value is compared with the preset qualified pressure range and recorded. S4. If the angle measurement value is determined in step S3 to be outside the preset design angle range, adjust the installation position or posture of the corresponding brush holder according to the real-time display of the display module until the angle measurement value is stable within the preset design angle range. For the pressure measurement value, repeat steps S2 and S3 to obtain the pressure measurement values ​​of multiple brush holders and perform statistical comparison. Replace the pressure spring of brush holders whose pressure measurement values ​​exceed the preset qualified pressure range or are significantly different from the pressure measurement values ​​of other brush holders.

[0018] Preferably, in step S3, the controller performs logical calculations and verifications on the received angle and pressure signals, including comparing the real-time measurement values ​​with preset thresholds. When the angle measurement value or the pressure measurement value exceeds its corresponding preset threshold, the controller generates an alert signal and controls the display module to issue visual or auditory alert information to indicate that the current measurement value is abnormal.

[0019] In summary, due to the adoption of this technical solution, the beneficial effects of this invention are as follows: This invention, by integrating angle and pressure sensors into the device, achieves for the first time the synchronous and accurate quantitative measurement of two key physical parameters during carbon brush installation. This changes the previous reliance on the personal experience of maintenance personnel and manual debugging, providing objective and reliable data support for on-site installation, and fundamentally solving the potential problems of abnormal carbon brush wear, sparking, and overheating caused by angle deviation and pressure imbalance.

[0020] In this invention, the data acquisition unit has the same external dimensions as a real carbon brush and can be directly inserted into the brush holder of the generator set, realizing a true simulation and non-destructive testing of the carbon brush's working state. The entire device requires no structural modification to the generator set, and the operation process is simple, significantly improving the convenience and feasibility of testing.

[0021] The intelligent processing and display unit in this invention not only converts sensor signals into intuitive digital readings in real time, but also features data verification and threshold warning functions. This simplifies the judgment process for maintenance personnel, making angle adjustment and pressure equalization operations more reliable, thereby significantly shortening the installation and commissioning cycle and reducing the technical threshold and reliance on skilled workers.

[0022] This invention fills the technological gap in dedicated testing tools in this field, transforming carbon brush installation from an experience-based craft into a quantifiable, controllable, and reproducible technical process. Its application can effectively ensure the stable operation of hydro-generator units, reduce unplanned downtime, and has significant engineering practical value and promising prospects for improving power generation efficiency, reducing maintenance costs, and extending the lifespan of core components. Attached Figure Description

[0023] The present invention is described in detail with reference to the following figures, which include three figures as follows: Figure 1 This is a schematic diagram of the carbon brush detection device for a synchronous generator set of a water turbine according to the present invention; Figure 2 This is a schematic diagram showing the structural and positional connections of the components in the device of the present invention; Figure 3 This is a schematic diagram illustrating the overall process of the carbon brush detection method for hydro-turbine synchronous generator sets according to the present invention. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0025] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0026] Example 1 A carbon brush detection device for a hydro-turbine synchronous generator set, see below. Figure 1 As shown in the diagram, the device mainly consists of two parts: a data acquisition unit for collecting field parameters and a data processing and display unit for processing and displaying the collected data; the two units are connected by a communication link.

[0027] Combination Figure 2 As illustrated, the core of the data acquisition unit is a specially designed outer casing. The external shape and dimensions of this casing are specifically designed to perfectly fit and smoothly insert into the brush holder used to secure carbon brushes on the synchronous generator set of the hydro turbine, thus replacing the actual carbon brushes during measurement. An angle sensor is integrated inside the casing. This sensor detects the rotational tilt of its own shaft relative to a reference, thereby measuring the relative tilt angle when the end of the casing contacts the surface of the slip ring. Simultaneously, a thin-film pressure sensor is embedded on the surface of the casing facing the spring inside the brush holder. The sensing surface of this pressure sensor is flush with the outer surface of the casing. When the casing is inserted into the brush holder and the pressure spring is engaged, the force applied by the spring acts directly and evenly on the sensing surface of the pressure sensor, thereby accurately detecting the spring pressure value.

[0028] The data processing and display unit includes a controller and a display module. The controller is a microcontroller serving as the control core; the display module is an LCD screen for information output. In this embodiment, the microcontroller establishes a connection with the angle and pressure sensors in the data acquisition unit via a data cable or wireless communication, receiving raw electrical signals from these two sensors in real time. The program embedded within the microcontroller processes and converts these signals into easily understandable angle and pressure measurement values. The LCD screen, connected to the microcontroller, is responsible for displaying these real-time calculated angle and pressure measurement values ​​for operators to read and record.

[0029] Example 2 Based on Example 1, this example provides a detailed and preferred description of the various features of the carbon brush detection device for hydro-turbine synchronous generator sets.

[0030] In this embodiment, the outer shell is injection molded from high-strength engineering plastic, and its external dimensions are designed to be consistent with the carbon brush of a certain type of hydro turbine synchronous generator set, for example, 65mm in length, 32mm in width, and 25mm in height, and to ensure that it can be smoothly inserted into the corresponding brush holder.

[0031] The angle sensor is a digital absolute rotary encoder, model JY-ME01, with a measurement range of 0 to 365 degrees and a resolution of 0.01 degrees. The angle sensor is configured to acquire the contact tilt angle signal between the housing and the slip ring surface in real time. Specifically, the angle sensor is embedded inside the housing so that its rotating shaft is linked to the test angle at one end of the housing.

[0032] The pressure sensor is a thin-film pressure sensor, model FSR402, with a measurement range of 0.05 to 0.3 MPa and a measurement accuracy of 0.05 MPa. The sensing surface of the thin-film pressure sensor is flush with the outer surface of the housing for contact with the carbon brush pressure spring, and is configured to acquire the analog pressure signal applied by the carbon brush spring in real time.

[0033] In this embodiment, the data processing and display unit also has an independent housing made of aluminum alloy to ensure its structural strength and heat dissipation performance. The microcontroller used is an STM32F103C8T6, responsible for receiving the angle and pressure electrical signals transmitted from the data acquisition unit.

[0034] The microcontroller has a built-in logic calculation program and a signal conversion module. The logic calculation program is configured to perform validity checks on the received angle and pressure signals, and generate and issue an alert signal when the measured values ​​exceed a preset threshold. The signal conversion module is configured to convert the analog or digital signals from the angle and pressure sensors into angle and pressure measurement values ​​that can be directly read on the display module. For the specific sensor application in this embodiment, the signal conversion module mainly performs A / D conversion, converting analog signals into digital signals.

[0035] The display module is an LCD screen, specifically a 3.5-inch TFT LCD screen with a resolution of 480×320. It is connected to the microcontroller via serial port to display the angle and pressure measurement values ​​in real time. In addition, the LCD screen is also configured to support human-machine interaction, receiving externally input calibration commands and sending them to the microcontroller to trigger the zero-point calibration operation of the angle sensor.

[0036] In this embodiment, the data processing and display unit further includes a power module; the power module is a rechargeable lithium battery, which is electrically connected to the power-consuming components in the data acquisition unit and the data processing and display unit, respectively, to provide an independent working power supply for the entire carbon brush detection device.

[0037] The power module specifically uses a 4000mAh rechargeable lithium battery with an output voltage of 3.7V, which is converted to 5V via DC-DC boost, thereby simultaneously powering the data acquisition unit and the data processing and display unit.

[0038] In this embodiment, the data processing and display unit further includes a power management module; the power management module is electrically connected to the rechargeable lithium battery and the microcontroller respectively; the power management module is configured to monitor the remaining power of the rechargeable lithium battery in real time, and when the remaining power is lower than a preset alarm threshold, send a low power signal to the microcontroller, which then controls the LCD screen to display low power warning information.

[0039] The power management module specifically uses the CN3065 chip to monitor the lithium battery voltage in real time. When the voltage is lower than 3.0V, the red warning indicator light on the display screen will light up to prompt charging.

[0040] In this embodiment, the data acquisition unit and the data processing and display unit are connected for data communication via a wired communication interface or a wireless communication module; the wired communication interface or wireless communication module is configured to establish data transmission channels between the angle sensor, the pressure sensor and the microcontroller respectively.

[0041] As a preferred embodiment, the data acquisition unit and the data processing and display unit adopt Bluetooth wireless transmission, using the HC-05 Bluetooth module, whose transmission distance is within 10 meters, which is sufficient to meet the needs of on-site operation; at the same time, USB wired transmission interfaces are reserved on both types of units, so that when there is strong electromagnetic interference on site, the wired transmission mode can be switched to ensure stable data transmission.

[0042] Example 3 Based on the above embodiments, this embodiment provides a method for detecting carbon brushes in a hydro-turbine synchronous generator set, which uses the carbon brush detection device in embodiment 1 or 2. Figure 3 This document provides a brief overview of the overall process of the method, which can be viewed concurrently. The key steps of the method can be summarized as follows: S1. Place the data acquisition unit on a known calibration reference surface, and input an angle correction command to the controller through the data processing and display unit to make the angle measurement value displayed by the display module return to zero, thus completing the zero-point calibration operation of the angle sensor. S2. Remove the carbon brush from the brush holder to be tested, insert the calibrated data acquisition unit into the brush holder, make the test angle at the end of the housing fit against the surface of the slip ring, and fasten the pressure spring of the brush holder onto the housing so that the sensing surface of the pressure sensor bears the spring pressure; at this time, the angle sensor and the pressure sensor start to work, respectively acquiring the contact tilt angle signal and the spring pressure signal, and transmitting them to the data processing and display unit respectively. S3. The display module reads the angle measurement value and pressure measurement value displayed in real time after being processed by the controller; the angle measurement value is compared with the preset design angle range to determine whether the current contact tilt angle meets the requirements; at the same time, the pressure measurement value is compared with the preset qualified pressure range and recorded. S4. If the angle measurement value determined in step S3 is not within the preset design angle range, adjust the installation position or posture of the corresponding brush holder according to the real-time display of the display module until the angle measurement value is stable within the preset design angle range. For the pressure measurement value, obtain the pressure measurement values ​​of multiple brush holders by repeating steps S2 and S3 and perform statistical comparison. Replace the pressure spring of the brush holder whose pressure measurement value exceeds the preset qualified pressure range or is significantly different from the pressure measurement values ​​of other brush holders.

[0043] In a preferred embodiment, in step S3, the controller performs logical calculations and verifications on the received angle and pressure signals, including comparing the real-time measured values ​​with preset thresholds. When the angle or pressure measured value exceeds its corresponding preset threshold, the controller generates an alert signal and controls the display module to issue visual or auditory alert information to indicate that the current measured value is abnormal.

[0044] This embodiment will now follow the steps described above to explain in detail how to systematically guide operators through the entire process from equipment preparation and on-site measurement to result analysis and adjustment. This approach ensures the standardization of testing work, the accuracy of data, and the effectiveness of adjustments.

[0045] First, the device calibration process in step S1 is executed. The operator turns on the power to the data processing and display unit, and the internal rechargeable lithium battery begins to power the entire system, causing the display screen to light up and enter working mode. The data acquisition unit is placed vertically and stably on a verified horizontal reference platform, ensuring that its bottom surface is completely in contact with the platform. At this point, theoretically, the test angle plane at the end of the data acquisition unit should be parallel to the horizontal plane, and the simulated tilt angle of its contact with the slip ring should be 0 degrees. Next, the angle correction command is input to the controller through the human-machine interface on the display screen of the data processing and display unit. After receiving the command, the controller drives the built-in angle sensor to execute the zero-point calibration procedure. The calibration process is rapid, usually completed within a few seconds. After calibration, the angle measurement value displayed on the screen is reset to 0.00 degrees, establishing an accurate reference for subsequent field measurements.

[0046] After calibration, the process proceeds to step S2: on-site installation and data acquisition. Taking a specific test of a hydropower plant unit as an example, after necessary safety preparations, the operator removes the carbon brush from the brush holder to be tested. The calibrated data acquisition unit is then inserted into the empty brush holder in the same direction until the test angle at its outer end is in close contact with the surface of the rotating slip ring. The original pressure spring mechanism of the brush holder is then fastened to the outer shell of the data acquisition unit, ensuring that the force-applying end of the spring acts entirely on the pressure sensor sensing area on the back of the shell. At this point, the data acquisition unit completely simulates the working state of the carbon brush, and the device begins to operate automatically. The angle sensor continuously measures the real-time contact tilt angle between the test angle and the slip ring surface, determined by the brush holder's installation posture, while the pressure sensor simultaneously measures the actual pressure value applied by the spring. These real-time signals are stably transmitted to the data processing and display unit via a data cable or wireless link.

[0047] Proceed to step S3 for data reading and judgment. The operator waits a few seconds for the measured values ​​displayed on the screen to stabilize before taking and recording the readings. For example, in one test, the screen might stably display an angle measurement of 7.45 degrees and a pressure measurement of 0.20 MPa. The operator needs to compare the read angle value with the preset design requirement range, for example, 7.5 degrees ± 0.1 degrees, to determine if it meets the standard. Simultaneously, the operator compares the read pressure value with the preset acceptable pressure range, for example, 0.15 MPa to 0.20 MPa, and records this value as the raw data for subsequent overall pressure balance analysis. This step can be repeated for all carbon brushes of the unit to obtain a complete set of installation parameter datasets.

[0048] Finally, in step S4, adjustments are performed based on the measurement results. If the angle measurement of a carbon brush is 10.2 degrees, exceeding the allowable range, the operator can make minor adjustments to the position and orientation of the brush holder's mounting base or bracket based on real-time feedback from the display screen, observing the angle change during the adjustment process until it stabilizes within the design range, for example, adjusted to 7.52 degrees. For pressure measurements, by comparing the recorded data of all carbon brushes, anomalies are identified where the pressure significantly deviates from the standard range or differs excessively from other carbon brush pressure values, such as a carbon brush with a pressure of only 0.08 MPa. The pressure is corrected by replacing the internal pressure spring; after replacement, the pressure value must be remeasured to confirm that it has returned to a reasonable and balanced range. After all adjustments are completed, a retest can be performed to ultimately ensure that the installation angle and spring pressure of all carbon brushes meet the design requirements and maintain good consistency.

[0049] As a preferred embodiment, to ensure the long-term measurement accuracy and reliability of the device, the data acquisition unit should be maintained after the testing work is completed, for example, by cleaning it with a soft cloth. When the data processing display unit indicates low battery, its built-in lithium battery should be charged promptly. In addition, the device should be sent to a qualified institution regularly, or its angle and pressure sensors should be calibrated and verified using a standard instrument, to ensure that they are always in optimal working condition.

Claims

1. A carbon brush detection device for a hydro-turbine synchronous generator set, characterized in that: This includes a connected data acquisition unit and a data processing and display unit; The data acquisition unit includes a housing, an angle sensor, and a pressure sensor. The housing is configured to fit into the brush holder of the carbon brush of the turbine synchronous generator set. The angle sensor is located inside the housing and is used to measure the relative tilt angle between the housing and the surface of the slip ring. The pressure sensor is located on the housing, with its sensing surface flush with one of the outer surfaces of the housing, and is used to measure the pressure applied to the outer surface. The data processing and display unit includes a controller and a display module; the controller is communicatively connected to the angle sensor and the pressure sensor respectively, and is used to receive and process the signals output by the angle sensor and the pressure sensor respectively; The display module is electrically connected to the controller and is used to display the angle measurement value and pressure measurement value obtained by the controller after processing.

2. The carbon brush detection device for a hydro-turbine synchronous generator set according to claim 1, characterized in that: The angle sensor is a digital absolute rotary encoder; the angle sensor is configured to acquire the contact tilt angle signal between the housing and the slip ring surface in real time, and its measurement range is adapted to the design value range of the carbon brush contact tilt angle.

3. The carbon brush detection device for a hydro-turbine synchronous generator set according to claim 1 or 2, characterized in that: The pressure sensor is a thin-film pressure sensor; the sensing surface of the thin-film pressure sensor is flush with the outer surface of the housing for contact with the carbon brush pressure spring, and is configured to acquire the analog pressure signal applied by the carbon brush spring in real time.

4. The carbon brush detection device for a hydro-turbine synchronous generator set according to claim 1, characterized in that: The shape and size of the outer casing are configured to be the same as the shape of the carbon brush of the turbine synchronous generator set, so that the outer casing can be directly inserted into and adapted to the brush holder of the carbon brush of the turbine synchronous generator set; a test angle is provided at one end of the outer casing, which is linked to the rotating shaft of the angle sensor and is configured to simulate the end of the carbon brush and fit in contact with the surface of the slip ring in the working state.

5. The carbon brush detection device for a hydro-turbine synchronous generator set according to claim 1, characterized in that: The data acquisition unit and the data processing and display unit are connected for data communication via a wired communication interface or a wireless communication module; the wired communication interface or the wireless communication module is configured to establish a data transmission channel between the angle sensor, the pressure sensor and the controller respectively.

6. The carbon brush detection device for a hydro-turbine synchronous generator set according to claim 1, characterized in that: The controller is a microcontroller; the microcontroller has a built-in logic calculation program and a signal conversion module. The logic calculation program is configured to perform rationality checks on the received angle signal and pressure signal respectively, and generate and issue a reminder signal when the measured value exceeds a preset threshold. The signal conversion module is configured to convert the analog or digital signals transmitted by the angle sensor and the pressure sensor into angle measurement values ​​and pressure measurement values ​​that can be directly read on the display module.

7. The carbon brush detection device for a hydro-turbine synchronous generator set according to claim 1 or 6, characterized in that: The display module is an LCD screen; the LCD screen is electrically connected to the controller and is used to display the angle measurement value and the pressure measurement value in real time; the LCD screen is also configured to support human-machine interaction function, receive externally input calibration commands and send them to the controller to trigger the zero-point calibration operation of the angle sensor.

8. The carbon brush detection device for a hydro-turbine synchronous generator set according to claim 1, characterized in that: The data processing and display unit also includes a power module; the power module is a rechargeable lithium battery, which is electrically connected to the power-consuming components in the data acquisition unit and the data processing and display unit, respectively, to provide an independent power supply for the entire carbon brush detection device.

9. The carbon brush detection device for a hydro-turbine synchronous generator set according to claim 8, characterized in that: The data processing and display unit further includes a power management module; the power management module is electrically connected to the rechargeable lithium battery and the controller respectively; the power management module is configured to monitor the remaining power of the rechargeable lithium battery in real time, and when the remaining power is lower than a preset alarm threshold, send a low power signal to the controller, and the controller controls the display module to display low power warning information.

10. A method for detecting carbon brushes in a hydro-turbine synchronous generator set, characterized in that, Using the carbon brush detection device according to claim 1, the method includes the following steps: S1. Place the data acquisition unit on a known calibration reference surface, and input an angle correction command to the controller through the data processing and display unit to make the angle measurement value displayed by the display module return to zero, thus completing the zero-point calibration operation of the angle sensor. S2. Remove the carbon brush from the brush holder to be tested, insert the calibrated data acquisition unit into the brush holder, make the test angle at the end of the housing fit against the surface of the slip ring, and fasten the pressure spring of the brush holder onto the housing, so that the sensing surface of the pressure sensor bears the spring pressure; at this time, the angle sensor and the pressure sensor start to work, respectively collecting the contact tilt angle signal and the spring pressure signal, and respectively transmitting them to the data processing and display unit; S3. Read the angle measurement value and pressure measurement value that are displayed in real time after being processed by the controller through the display module; The measured angle value is compared with the preset design angle range to determine whether the current contact tilt angle meets the requirements; at the same time, the measured pressure value is compared with the preset qualified pressure range and recorded. S4. If it is determined in step S3 that the angle measurement value is not within the preset design angle range, then adjust the installation position or posture of the corresponding brush holder according to the real-time display of the display module until the angle measurement value is stable within the preset design angle range. For pressure measurement values, by repeating steps S2 and S3, multiple pressure measurement values ​​of brush holders are obtained and statistically compared. For brush holders whose pressure measurement values ​​exceed the preset qualified pressure range or differ significantly from other brush holder pressure measurement values, their pressure springs are replaced.

11. The method for detecting carbon brushes in a hydro-turbine synchronous generator set according to claim 10, characterized in that: In step S3, the controller performs logical calculations and verifications on the received angle and pressure signals, including comparing the real-time measurement values ​​with preset thresholds. When the angle or pressure measurement value exceeds its corresponding preset threshold, the controller generates a reminder signal and controls the display module to issue visual or auditory reminder information to indicate that the current measurement value is abnormal.

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