A full-flow intelligent pressure-regulating pipeline power generation device

Abstract

The present application relates to the technical field of energy recovery, in particular to a full-flow intelligent pressure regulating pipeline power generation equipment, comprising transmission assemblies, self-adaptive gearboxes, high-efficiency permanent magnet motors, and intelligent pressure regulating modules, full-flow protection modules, inverter modules and installation adaptation modules connected in sequence; the transmission assemblies can realize two driving modes of water flow impact type or water pipe embedded type through a plurality of groups of bearing sleeves arranged in annular array, adjusting shafts and bevel gear transmission structures. In operation, the water flow drives the impeller to rotate the driving shaft, and the self-adaptive gearbox adjusts the driving motor to generate electricity. The present application can flexibly adapt to different pipeline working conditions, stably transmit power, reliably supply power, intelligently regulate and control, comprehensively protect, improve power generation efficiency and operation stability, reduce operation and maintenance costs, and is suitable for various pipeline water flow energy recovery scenes.

Description

Technical Field

[0001] This invention relates to the field of energy recovery technology, specifically to a full-flow intelligent pressure regulating pipeline power generation device. Background Technology

[0002] As is well known, in the field of energy recovery and utilization, the kinetic energy contained in pipeline water flow has significant recovery value, leading to the development of related pipeline power generation equipment. However, existing pipeline power generation equipment has many shortcomings in practical applications, making it difficult to meet the requirements for efficient and stable operation under different working conditions. On the one hand, the driving methods of existing equipment are relatively simple, mostly only adaptable to one type of pipeline scenario, either open or closed. When facing different types of pipeline systems, different structural equipment needs to be replaced, resulting in poor versatility and increased application costs and operational complexity. On the other hand, in the power transmission process, the transmission structure design of existing equipment is not reasonable enough, making it difficult to achieve smooth power collection and transmission, and easily affected by water flow fluctuations, leading to unstable power generation efficiency. At the same time, the power supply for the regulating components in existing equipment is mostly wired, and the regulating components often involve rotational movement. Wired power supply is prone to problems such as wire entanglement and wear, which not only affects the stability of power supply but also damages the sealing performance of the equipment, increasing the risk of failure. Furthermore, the existing equipment's pressure regulation and protection mechanisms are inadequate, failing to adapt accurately to changes in water flow conditions in real time. Moreover, the protection scope is insufficient to cover the entire process from water inflow to power output, making it susceptible to damage from abnormal conditions such as overload, overvoltage, and dry running, thus affecting operational safety and reliability. Therefore, developing a pipeline power generation device that can adapt to various operating conditions, provide stable power transmission, reliable power supply, intelligent regulation, and comprehensive protection has become a pressing technical challenge in the field of pipeline energy recovery. Summary of the Invention

[0003] Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a full-flow intelligent pressure-regulating pipeline power generation device.

[0004] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: a full-flow intelligent pressure-regulating pipeline power generation device, comprising a transmission assembly, an adaptive gearbox, a high-efficiency permanent magnet motor, and an intelligent pressure-regulating module, a full-flow protection module, an inverter module, and an installation adapter module, connected in sequence; the transmission assembly includes a drive shaft and a sealed bearing housing, the drive shaft is provided with a bearing sleeve, the bearing sleeve is provided with an adjusting shaft, the top end of the adjusting shaft is provided with an impeller, the bottom end of the adjusting shaft is located inside the drive shaft and is provided with a first bevel tooth, the bearing sleeve is provided with multiple sets arranged in a circular array around the drive shaft as the axis, and the... A sealed bearing housing is connected to one end of the drive shaft via an adjusting shell. One end of the sealed bearing housing is provided with a sealing shell. A magnetically coupled resonant wireless power supply mechanism is provided between the sealing shell and the adjusting shell. A drive motor is provided inside the adjusting shell. The output end of the drive motor is provided with a mounting shaft. One end of the mounting shaft extends into the interior of the drive shaft and is provided with a second bevel tooth. The second bevel tooth meshes with multiple first bevel teeth. One end of the drive shaft is connected to the adaptive gearbox. The transmission assembly realizes water flow impact drive or water pipe embedded drive. Both drive methods can drive the adaptive gearbox to rotate.

[0005] Furthermore, the high-efficiency permanent magnet motor generates 430V, and its output terminal is electrically connected to the input terminal of the inverter module. The inverter module outputs a stable 400V voltage and is connected to the power grid. The adaptive gearbox is equipped with a multi-stage gear set and a torque buffer mechanism. The gearbox main shaft is rigidly connected to the input terminal of the high-efficiency permanent magnet motor through a flexible coupling to achieve smooth power transmission. The intelligent pressure regulating module includes an electric regulating valve, a telescopic compensation valve, and an intelligent controller. The electric regulating valve and the telescopic compensation valve are connected in series in the main channel of the pipeline. The intelligent controller is electrically connected to the electric regulating valve and the telescopic compensation valve to collect the water pressure, flow rate signal, and motor output voltage signal in the pipeline in real time and dynamically adjust the valve opening.

[0006] Furthermore, the full-flow protection module includes a flow sensor, a pressure sensor, an overload protector, an overpressure protector, and an anti-dry-run detector. Each sensor and protector is electrically connected to the intelligent controller, covering the entire process from water entering the pipeline to power generation output, thus achieving comprehensive protection for the equipment.

[0007] Furthermore, the inner wall of the adjusting shell is provided with an iron ring, and an electromagnet is provided on the outer side of the mounting shaft, with the electromagnet abutting against the inner wall of the iron ring.

[0008] Furthermore, the magnetically coupled resonant wireless power supply mechanism includes a transmitting coil, a transmitting resonant capacitor, a transmitting control board, a receiving coil, a receiving resonant capacitor, a receiving control board, and an energy storage module. The transmitting coil, the transmitting resonant capacitor, and the transmitting control board are installed on the inner wall of the sealed shell, and the receiving coil, the receiving resonant capacitor, the receiving control board, and the energy storage module are installed on the inner wall of the adjusting shell.

[0009] Furthermore, the inverter module adopts a three-phase three-level topology, incorporates silicon carbide power devices, and combines an improved SVPWM modulation algorithm to achieve efficient conversion from 430V AC to 400V standard AC.

[0010] Furthermore, the intelligent controller adopts an STM32H7 series microprocessor, with a built-in 12-bit ADC acquisition module and an acquisition frequency of not less than 100Hz. The intelligent controller also integrates a 4G communication module, which can realize remote data transmission and control.

[0011] Furthermore, multiple electromagnets are evenly distributed along the mounting axis, each electromagnet has a rated voltage of 24V and a rated attraction force of 50N-100N, and the surface of the electromagnet is provided with an insulating protective layer.

[0012] (III) Beneficial Effects Compared with the prior art, the present invention provides a full-flow intelligent pressure regulating pipeline power generation device, which has the following beneficial effects: This full-flow intelligent pressure regulating pipeline power generation equipment achieves flexible adaptation of the drive mode. Through the reasonable design of the transmission components, it can select water flow impact drive or water pipe embedded drive according to the pipeline working conditions. It can adapt to different scenarios such as large flow open pipelines and closed pipelines, which greatly improves the versatility of the equipment and reduces the application cost in different scenarios.

[0013] The stability and reliability of power transmission are improved. Multiple sets of bearing sleeves in the transmission components are arranged in a ring array with the drive shaft as the axis. Multiple adjusting shafts can synchronously drive the drive shaft to rotate, realizing the smooth collection of power. At the same time, with the speed change and torque buffering effect of the adaptive gearbox, it can effectively absorb the load fluctuations caused by water flow impact, ensure the smooth transmission of power to the high-efficiency permanent magnet motor, reduce equipment wear, and extend service life.

[0014] The problem of power supply for rotating parts has been solved by setting up a magnetic coupling resonant wireless power supply mechanism between the sealed shell and the adjusting shell, realizing contactless power supply between the fixed and rotating parts. This avoids the problems of wired power supply such as wire tangling and wear, while improving the sealing performance of the equipment. The energy storage module can also ensure stable power supply to the drive motor under extreme conditions, further enhancing operational reliability.

[0015] Equipped with intelligent and precise pressure regulation and control capabilities, the intelligent pressure regulation module collects pipeline operating conditions and equipment operation signals in real time through an intelligent controller, dynamically adjusting valve openings to accurately adapt to changes in water flow and pressure. The drive motor can also fine-tune the adjustment shaft angle through a bevel gear structure, thereby adjusting the impeller orientation, optimizing water flow impact thrust, and improving power generation efficiency. It achieves full-process safety protection; the full-channel protection module integrates multiple sensors and protectors, covering the entire process from water entering the pipeline to power output. It can promptly detect abnormal operating conditions such as overload, overvoltage, and dry running and trigger protection commands, effectively preventing fault escalation and ensuring the safe operation of equipment and the power grid. It facilitates remote operation and maintenance management; the communication module integrated into the intelligent controller enables remote data transmission of equipment operating status and command issuance, eliminating the need for on-site monitoring, reducing operation and maintenance costs, and facilitating centralized management of multiple devices, improving operation and maintenance efficiency. Attached Figure Description

[0016] Figure 1 This is a first-view structural schematic diagram of the present invention applied to a closed pipeline working condition; Figure 2 This is a second-view structural schematic diagram of the present invention applied to a closed pipeline working condition; Figure 3 This is a first-view structural schematic diagram of the present invention applied to an open pipeline working condition; Figure 4 This is a second-view structural schematic diagram of the present invention applied to open pipeline conditions; Figure 5 This is a front half-sectional view of the structure of the present invention applied to an open pipeline environment; Figure 6 For the present invention Figure 3 A magnified left half-section view of the structure of the central drive shaft.

[0017] In the diagram: 1. Drive shaft; 2. Sealed bearing housing; 3. Bearing sleeve; 4. Adjusting shaft; 5. Impeller; 6. First bevel gear; 7. Adjusting shell; 8. Sealing shell; 9. Drive motor; 10. Mounting shaft; 11. Second bevel gear; 12. Iron ring; 13. Electromagnet; 14. Transmitting coil; 15. Transmitting control board; 16. Receiving coil; 17. Receiving control board; 18. Energy storage module; 19. Adaptive gearbox. Detailed Implementation

[0018] 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.

[0019] Please see Figures 1 to 6 This invention relates to a full-flow intelligent pressure-regulating pipeline power generation device, comprising a transmission assembly, an adaptive gearbox 19, a high-efficiency permanent magnet motor, and an intelligent pressure-regulating module, a full-flow protection module, an inverter module, and an installation adapter module, all connected in sequence. The transmission assembly includes a drive shaft 1 and a sealed bearing housing 2. The drive shaft 1 has a bearing sleeve 3, and the bearing sleeve 3 contains an adjusting shaft 4. The top end of the adjusting shaft 4 has an impeller 5, and the bottom end of the adjusting shaft 4 is located inside the drive shaft 1 and has a first bevel tooth 6. Multiple sets of bearing sleeves 3 are arranged in a circular array around the drive shaft 1. The sealed bearing housing 2 is connected to one end of the drive shaft 1 via an adjusting shell 7. One end of the sealed bearing housing 2 has a sealing shell 8, and a magnetically coupled resonant wireless power supply is located between the sealing shell 8 and the adjusting shell 7. The structure includes a drive motor 9 inside the regulating housing 7, with a mounting shaft 10 at the output end of the drive motor 9. One end of the mounting shaft 10 extends into the drive shaft 1 and has a second bevel tooth 11, which meshes with multiple first bevel teeth 6. One end of the drive shaft 1 is connected to the adaptive gearbox 19. The transmission assembly enables either water flow impact drive or pipe-embedded drive, both of which can rotate the adaptive gearbox 19. In this embodiment, the device is fixed to the target pipeline system by installing an adapter module. The drive method is selected according to the pipeline conditions. For a high-flow open pipeline, a water flow impact drive is used (the impeller 5 is exposed at the pipe end, directly receiving the water flow impact); for a closed pipeline, a pipe-embedded drive is used (the impeller 5 is embedded inside the pipe, and the water flows along the pipe through the impeller 5). The water flow acts on the impeller 5, driving the drive shaft 1 to rotate via the regulating shaft 4. The drive shaft 1 then transmits the collected power to the adaptive gearbox 19. The adaptive gearbox 19 adjusts the speed / torque of the power supply to drive a high-efficiency permanent magnet motor to generate electricity. The magnetically coupled resonant wireless power supply mechanism supplies power to the drive motor 9 inside the regulating housing 7. The drive motor 9 drives the mounting shaft 10 to rotate through its output end. The second bevel tooth 11 of the mounting shaft 10 drives the first bevel tooth 6, which meshes with it, to rotate. This allows the first bevel tooth 6 to drive the regulating shaft 4 to rotate. The regulating shaft 4 rotates stably through the sealing sleeve, thereby adjusting the orientation angle of the impeller 5 and thus adjusting the thrust caused by the water impact, thereby adjusting the water flow power generation efficiency. The intelligent pressure regulating module and the full-flow protection module monitor the pipeline conditions and equipment status in real time and dynamically adjust the operating parameters. The inverter module processes the generated electricity and connects it to the power grid. When the full-flow protection module detects abnormal conditions (such as overload, overvoltage, dry running) or needs to actively shut down, the intelligent controller issues a command to adjust the valve opening through the intelligent pressure regulating module to cut off the water flow power and achieve a smooth shutdown of the equipment.

[0020] In this scheme, the high-efficiency permanent magnet motor generates 430V, and its output terminal is electrically connected to the input terminal of the inverter module. The inverter module outputs a stable 400V voltage and is connected to the power grid. The adaptive gearbox 19 is equipped with a multi-stage gear set and a torque buffer mechanism. The gearbox main shaft is rigidly connected to the input terminal of the high-efficiency permanent magnet motor through a flexible coupling to achieve smooth power transmission. The intelligent pressure regulating module includes an electric regulating valve, a telescopic compensation valve, and an intelligent controller. The electric regulating valve and the telescopic compensation valve are connected in series in the main channel of the pipeline. The intelligent controller is electrically connected to the electric regulating valve and the telescopic compensation valve to collect the water pressure, flow rate signal, and motor output voltage in the pipeline in real time. The system uses a pressure signal to dynamically adjust the valve opening. A high-efficiency permanent magnet motor generates 430V AC power, which is then converted into a stable 400V standard AC power by the inverter module, matching the grid connection voltage requirements. The multi-stage gear set within the adaptive gearbox dynamically adjusts the transmission ratio according to the water flow speed. A torque buffer mechanism absorbs impact loads during power transmission, and a flexible coupling ensures a rigid connection between the gearbox and the motor, guaranteeing coaxiality of power transmission. An electric regulating valve and a telescopic compensation valve are connected in series in the main channel. The intelligent controller collects real-time water pressure, flow rate signals, and motor output voltage signals from the pipeline, and dynamically adjusts the valve opening through a closed-loop control algorithm, changing the water flow and pressure. This achieves precise conversion of the generated voltage to the grid standard voltage, improving grid connection compatibility and stability; reduces vibration and energy loss during power transmission, avoids damage to the motor from impact loads, and extends equipment lifespan; and dynamically adjusts the voltage to adapt to different water flow conditions (such as flow fluctuations and pressure changes), improving the equipment's adaptability and reliability.

[0021] In this solution, the full-flow protection module includes a flow sensor, a pressure sensor, an overload protector, an overpressure protector, and an anti-dry-run detector. Each sensor and protector is electrically connected to the intelligent controller, covering the entire process from water entering the pipeline to power generation output, achieving comprehensive protection for the equipment. The full-flow protection module constructs a full-process monitoring network through multiple types of sensors and protectors: the flow sensor monitors water flow rate, the pressure sensor monitors pipeline pressure, the overload protector monitors motor load, the overpressure protector monitors power generation voltage, and the anti-dry-run detector monitors pipeline liquid level. Each monitoring unit transmits signals to the intelligent controller in real time. The controller presets safety thresholds, and triggers a protection command when the detected signal exceeds the threshold. This achieves full-process coverage protection from water entering the pipeline to power output, enabling timely warnings and handling of faults such as insufficient flow, excessive pressure, equipment overload, abnormal voltage, and dry-run, preventing the escalation of faults that could damage equipment or cause grid fluctuations, thus improving equipment operational safety.

[0022] In this design, the inner wall of the adjusting housing 7 is provided with an iron ring 12, and the outer side of the mounting shaft 10 is provided with an electromagnet 13. The electromagnet 13 abuts against the inner wall of the iron ring 12. The iron ring 12 on the inner wall of the adjusting housing 7 and the electromagnet 13 on the outer side of the mounting shaft 10 form an electromagnetic positioning structure. When the electromagnet 13 is energized, it generates a magnetic force to attract the iron ring 12, making the electromagnet 13 tightly abut against the inner wall of the iron ring 12, thus limiting and constraining the rotational attitude of the mounting shaft 10. This improves the coaxiality and stability of the mounting shaft 10 during rotation, reduces meshing deviation caused by the shaking of the mounting shaft 10, reduces transmission noise and wear, ensures the accuracy of power transmission, and enhances the stability of the angle adjustment of the adjusting shaft 4.

[0023] In this scheme, the magnetically coupled resonant wireless power supply mechanism includes a transmitting coil 14, a transmitting resonant capacitor, a transmitting control board 15, a receiving coil 16, a receiving resonant capacitor, a receiving control board 17, and an energy storage module 18. The transmitting coil 14, the transmitting resonant capacitor, and the transmitting control board 15 are installed on the inner wall of the sealed shell 8, and the receiving coil 16, the receiving resonant capacitor, the receiving control board 17, and the energy storage module 18 are installed on the inner wall of the adjusting shell 7. The magnetically coupled resonant wireless power supply mechanism realizes wireless power supply through the energy transfer path of "transmission, resonance, and reception". The transmitting control board 15 drives the transmitting coil 14 and the transmitting resonant capacitor to generate a resonant magnetic field. The receiving coil 16 and the receiving resonant capacitor obtain energy from the magnetic field through magnetic coupling resonance. After rectification and voltage regulation by the receiving control board 17, the energy storage module 18 is charged or the drive motor 9 is directly powered. The transmitting end is installed on the fixed sealed shell 8, and the receiving end is installed on the adjusting shell 7 that rotates with the drive shaft 1, realizing contactless power supply between the rotating part and the fixed part. The problem of wired power supply for the rotating component adjustment housing 7 has been solved, avoiding the problems of wire tangling and wear, and improving the sealing performance of the equipment. At the same time, the energy storage module 18 can ensure stable power supply for the drive motor 9 under extreme conditions, enhancing the reliability of equipment operation.

[0024] In this solution, the inverter module adopts a three-phase three-level topology, incorporates silicon carbide power devices, and combines an improved SVPWM modulation algorithm to achieve efficient conversion from 430V AC to 400V standard AC. Compared to the traditional two-level topology, the three-phase three-level topology reduces output voltage harmonics. The built-in silicon carbide power devices feature low switching losses and high temperature resistance. The improved SVPWM (Space Vector Pulse Width Modulation) algorithm optimizes the voltage vector synthesis strategy to improve modulation accuracy, achieving efficient conversion from 430V AC to 400V standard AC. This improves power conversion efficiency, reduces energy loss during conversion, reduces harmonic distortion of the output power, and ensures power quality connected to the grid. The high reliability of the silicon carbide devices allows the inverter to adapt to harsher operating environments and extends equipment lifespan.

[0025] In this solution, the intelligent controller uses an STM32H7 series microprocessor with a built-in 12-bit ADC acquisition module and a sampling frequency of no less than 100Hz. The intelligent controller also integrates a 4G communication module, enabling remote data transmission and control. The STM32H7 series microprocessor boasts high-performance computing capabilities, allowing for rapid processing of multi-channel monitoring signals. The built-in 12-bit ADC (analog-to-digital converter) acquisition module accurately converts analog signals (pressure, flow, voltage) into digital signals with a sampling frequency ≥100Hz, ensuring real-time signal acquisition. The integrated 4G communication module enables data interaction between the controller and the remote monitoring platform via a mobile network, supporting remote command issuance and equipment status uploading. This improves signal acquisition accuracy and data processing efficiency, resulting in faster responses to intelligent voltage regulation and protection commands, ensuring timely and accurate equipment control. The 4G remote communication function enables remote monitoring and maintenance of the equipment, eliminating the need for on-site personnel, reducing maintenance costs, and facilitating centralized management of multiple devices.

[0026] In this design, multiple electromagnets 13 are evenly distributed circumferentially along the mounting shaft 10. Each electromagnet 13 has a rated voltage of 24VDC and a rated attraction force of 50N-100N. An insulating protective layer is provided on the surface of each electromagnet 13. The even distribution of the electromagnets 13 along the mounting shaft 10 ensures that the electromagnetic attraction force on the mounting shaft 10 is evenly distributed in a ring. The electromagnets 13 use a 24V rated voltage to match the low-voltage power supply system of the equipment, and the rated attraction force of 50N-100N can meet the positioning requirements of the mounting shaft 10. The insulating protective layer on the surface prevents the electromagnets 13 from contacting the iron ring 12 or other metal parts, thus avoiding short circuits. The evenly distributed electromagnets 13 ensure balanced force on the mounting shaft 10, further improving rotational stability and preventing component wear caused by excessive local force. The design also ensures stable operation of the electromagnets 13 by matching the equipment's power supply system. The insulating protective layer enhances the electrical safety of the equipment and prevents short-circuit faults from affecting equipment operation. Example 1: High-flow open pipeline operation (water flow impact drive).

[0027] Background: This embodiment is applied to a large open-type water diversion pipeline system with a pipe diameter of 1.2m and a water flow range of 500-1000m³. 3 The water flow rate is 2.5-4 m / s, and the ambient temperature is -10℃ to 40℃. It is necessary to achieve efficient recovery of water flow energy and connect it to the 10kV power distribution network.

[0028] Equipment composition and parameters: Transmission components: The drive shaft 1 is made of 45 steel, with a diameter of 120mm and a length of 800mm; the sealed bearing housing 2 is equipped with a double-row angular contact ball bearing (inner diameter 60mm, outer diameter 130mm); 4 sets of bearing sleeves 3 are evenly arranged circumferentially on the drive shaft 1 (circular array distribution, with an included angle of 90° between adjacent bearing sleeves 3), and the adjusting shaft 4 in each set of bearing sleeves 3 has a diameter of 40mm. The top of the adjusting shaft 4 is equipped with a biomimetic airfoil impeller 5 (4 blades, blade root thickness 12mm, blade tip thickness 3mm, and surface coated with polytetrafluoroethylene anti-corrosion coating). The impeller 5 is exposed 150mm from the end of the pipe, directly bearing the impact of water flow; the first bevel tooth 6 at the bottom of the adjusting shaft 4 meshes with the second bevel tooth 11 (module 3, number of teeth 20) on the mounting shaft 10 for transmission.

[0029] Other core components: An 8mm thick electrical pure iron ring 12 is fixed to the inner wall of the adjusting shell 7; four electromagnets 13 (rated voltage 24V, rated suction force 80N, with an epoxy insulation protective layer on the surface) are evenly distributed circumferentially on the outer side of the mounting shaft 10; the drive motor 9 inside the adjusting shell 7 is a 1000W DC servo motor (rated speed 2000rpm, aluminum alloy heat dissipation shell); the transmitting coil 14 and receiving coil 16 of the magnetic coupling resonant wireless power supply mechanism are both wound with Litz wire (80 turns, inner diameter 120mm), with a resonant frequency of 300kHz; the energy storage module 18 is a 24V / 15Ah lithium-ion battery pack (integrated BMS protection system).

[0030] Adaptive module parameters: The adaptive gearbox 19 features a 3-speed gear set (transmission ratio range 1:3-1:8) and a torque buffer mechanism (buffer spring elastic coefficient 35N / mm). The gearbox main shaft is rigidly connected to a high-efficiency permanent magnet motor (generating voltage 430V, rated power 500kW) via a flexible coupling. The intelligent pressure regulating module uses a DN300 electric ball valve (adjustment accuracy ±1%, working pressure 0.1-2.5MPa) connected in series with a telescopic compensation valve. The intelligent controller uses an STM32H743 microprocessor (built-in 12-bit ADC acquisition module, acquisition frequency 100Hz, integrated 4G communication module). The full-channel protection module includes an electromagnetic flow sensor (measurement range 0.1-1200m³). 3 / h, accuracy ±0.5%FS), pressure sensor (measurement range 0-4MPa), overload protector (rated current 1200A), overvoltage protector (protection threshold 480V) and ultrasonic anti-dry running detector (detection distance 50-500mm); the inverter module adopts a three-phase three-level topology, with built-in 1200V / 80A silicon carbide MOSFET, combined with an improved SVPWM modulation algorithm; the installation adapter module fixes the equipment to the end of the water diversion channel through flange connection (nominal pressure 2.5MPa) and adjustable bracket (adjustment stroke 100mm), and the bottom of the bracket is equipped with a 15mm thick rubber shock-absorbing pad.

[0031] Work process: Deployment phase: Fix the entire device to the end of the water diversion channel pipeline by installing the flange connector of the adapter module and the adjustable bracket. Adjust the height of the bracket so that the axis of impeller 5 is consistent with the water flow direction, and ensure that the exposed part of impeller 5 is completely within the water flow impact range.

[0032] Start-up and transmission: The water flow impacts the exposed impeller 5, driving the four sets of adjusting shafts 4 to rotate synchronously. The first bevel tooth 6 at the bottom of the adjusting shaft 4 drives the second bevel tooth 11 and the mounting shaft 10 to rotate through meshing, thereby driving the drive shaft 1 to rotate (multiple sets of impellers 5 work together to improve the stability of power output); the drive shaft 1 transmits the collected rotational power to the adaptive gearbox 19.

[0033] Power generation and regulation: The adaptive gearbox 19 dynamically adjusts the transmission ratio according to the water flow velocity (increasing the transmission ratio when the flow velocity is high and decreasing the transmission ratio when the flow velocity is low). The torque buffer mechanism absorbs the load fluctuations caused by the water flow impact. The adjusted power drives the high-efficiency permanent magnet motor to generate 430V AC power. At the same time, the magnetic coupling resonant wireless power supply mechanism supplies power to the drive motor 9 in the regulating shell 7 through the resonant coupling of the transmitting coil 14 and the receiving coil 16. The drive motor 9 finely adjusts the angle of the adjusting shaft 4 through the mounting shaft 10 and the bevel gear structure, so that the impeller 5 always faces the optimal angle (30°-45°) with the water flow direction, improving the impact thrust and power generation efficiency. The intelligent controller collects the operating condition signals of the flow sensor and pressure sensor and the output voltage signal of the motor in real time. It dynamically adjusts the opening of the electric regulating valve through the closed-loop algorithm (reducing the opening when the flow is too large and increasing the opening when the pressure is too high). The expansion and contraction compensation valve compensates for the displacement deviation caused by the thermal expansion and contraction of the pipeline. The inverter module converts the 430V AC power into a stable 400V standard AC power, which is then stepped up and connected to the 10kV distribution network.

[0034] Shutdown and Protection: When the full-flow protection module detects that the water flow rate is below 100m³ / h 3 When the flow rate is insufficient ( / h), the pipeline pressure exceeds 3MPa (overpressure), or the motor load exceeds 1500A (overload), the intelligent controller immediately issues a command to fully close the electric regulating valve to cut off the water flow power, and at the same time controls the high-efficiency permanent magnet motor to stop. If the anti-dry running detector detects that the water level in the diversion channel is below 80mm (dry running risk), it directly triggers the emergency shutdown procedure to avoid damage to the equipment due to idling. All status data is uploaded to the remote monitoring platform through the 4G communication module, which makes it easy for maintenance personnel to monitor the equipment status in real time.

[0035] Example 2: Closed pipe working condition (embedded drive inside water pipe).

[0036] Application Context: This embodiment is applied to an urban water supply network system (closed pipeline), with a pipe diameter of 500mm and a water flow rate range of 100-300m³.3 The system requires a flow rate of 1.2-2 m / s, a working pressure of 0.8-1.5 MPa, and an ambient temperature of 5℃ to 35℃. It needs to achieve low-noise, low-disturbance power generation and be connected to a 380V industrial power grid.

[0037] Equipment composition and parameters: Transmission components: The drive shaft 1 is made of 304 stainless steel (corrosion resistant), with a diameter of 80mm and a length of 600mm; the sealed bearing housing 2 is equipped with a double-row angular contact ball bearing (inner diameter 40mm, outer diameter 80mm); three sets of bearing sleeves 3 are evenly arranged circumferentially on the drive shaft 1 (circular array distribution, with an included angle of 120° between adjacent bearing sleeves 3), and the adjusting shaft 4 in each set of bearing sleeves 3 has a diameter of 30mm. The top is equipped with an embedded impeller 5 (3 blades, blade root thickness 10mm, blade tip thickness 2mm, and a gap of ≤5mm between the impeller and the inner wall of the pipe to avoid water flow disturbance). The impeller 5 is embedded in the pipe and is coaxial with the pipe; the first bevel tooth 6 at the bottom of the adjusting shaft 4 meshes with the second bevel tooth 11 (module 2, number of teeth 18) on the mounting shaft 10. The adjusting shaft 4 and the bearing sleeve 3 adopt a double-layer sealing structure (inner layer nitrile rubber sealing ring, outer layer mechanical sealing ring, and high-temperature grease in between).

[0038] Other core components: The inner wall of the adjusting shell 7 is fixed with a 6mm thick electrical pure iron ring 12; three electromagnets 13 (rated voltage 24V, rated suction force 60N, with an epoxy insulation protective layer on the surface) are evenly distributed circumferentially on the outer side of the mounting shaft 10; the drive motor 9 inside the adjusting shell 7 is a 500W DC servo motor (rated speed 1500rpm, aluminum alloy heat dissipation shell); the transmitting coil 14 and receiving coil 16 of the magnetic coupling resonant wireless power supply mechanism are both wound with Litz wire (60 turns, inner diameter 100mm), with a resonant frequency of 200kHz; the energy storage module 18 is a 24V / 10Ah lithium-ion battery pack (integrated BMS protection system).

[0039] Adaptive module parameters: The adaptive gearbox 19 features a 2-stage transmission gear set (transmission ratio range 1:2-1:5) and a torque buffer mechanism (buffer spring elastic coefficient 25N / mm). The gearbox main shaft is rigidly connected to a high-efficiency permanent magnet motor (generating voltage 430V, rated power 100kW) via a flexible coupling. The intelligent pressure regulating module uses a DN200 electric ball valve (adjustment accuracy ±1%, working pressure 0.1-2.5MPa) connected in series with a telescopic compensation valve. The intelligent controller uses an STM32H750 microprocessor (built-in 12-bit ADC acquisition module, acquisition frequency 100Hz, integrated 4G communication module). The full-channel protection module includes an electromagnetic flow sensor (measurement range 0.1-500m). 3 / h, accuracy ±0.5%FS), pressure sensor (measurement range 0-2.5MPa), overload protector (rated current 300A), overvoltage protector (protection threshold 480V) and ultrasonic anti-dry running detector (detection distance 50-500mm); the inverter module adopts a three-phase three-level topology, with built-in 1200V / 50A silicon carbide MOSFET, combined with an improved SVPWM modulation algorithm; the installation adapter module is embedded into the middle section of the closed pipeline through flange connection (nominal pressure 1.6MPa) and adjustable bracket (adjustment stroke 80mm), and 12mm thick rubber shock-absorbing pads are installed at the contact point between the bracket and the pipeline (to reduce operating noise).

[0040] Work process: Deployment phase: The equipment is embedded in the middle section of the closed water supply network by installing the flange connection of the adapter module. The adjustable bracket is adjusted to make the axis of the equipment coincide with the axis of the pipeline to ensure that the impeller 5 does not affect the normal water supply of the pipeline after being embedded (water flow resistance ≤5%). The sealing structure ensures the sealing of the pipeline.

[0041] Start-up and transmission: Water flows through the embedded impeller 5 along the closed pipe, driving the impeller 5 to rotate and driving the adjustment shaft 4 to rotate. The three sets of adjustment shafts 4 are driven synchronously to rotate the drive shaft 1 through the meshing of the first bevel tooth 6 and the second bevel tooth 11 (the ring array of adjustment shafts 4 makes the drive shaft 1 bear force evenly and reduces vibration and noise); the drive shaft 1 transmits the rotational power to the adaptive gearbox 19.

[0042] Power generation and regulation: The adaptive gearbox 19 dynamically adjusts the transmission ratio according to the water flow velocity in the water supply network (1:5 transmission ratio at a flow velocity of 1.2m / s, and 1:2 transmission ratio at a flow velocity of 2m / s). The torque buffer mechanism absorbs the load impact caused by the pressure fluctuation of the network, ensuring that the power is smoothly transmitted to the high-efficiency permanent magnet motor to generate 430V AC power. The magnetic coupling resonant wireless power supply mechanism provides stable power to the drive motor 9 in the regulating shell 7. The drive motor 9 finely adjusts the angle of the regulating shaft 4 through the mounting shaft 10, so that the impeller 5 blades form the optimal angle of attack (25°-35°) with the water flow direction, improving the power generation efficiency without affecting the water supply pressure. The intelligent controller collects the network pressure, water flow rate and motor output voltage signals in real time. When the network pressure exceeds 1.5MPa, it controls the electric regulating valve to increase the opening to reduce the water flow resistance. When the flow rate is less than 100m³ / s, it controls the electric regulating valve to increase the opening to reduce the water flow resistance. 3 At / h, the valve opening is reduced to increase the water flow rate to ensure power generation; the expansion and contraction valve compensates for the thermal expansion and contraction displacement of the closed pipeline caused by temperature changes, avoiding pipeline stress damage to the equipment; the inverter module converts 430V AC power into stable 400V standard AC power, which is directly connected to the 380V industrial power grid.

[0043] Shutdown and Protection: When the full-flow protection module detects that the pipeline pressure is lower than 0.3MPa (insufficient pressure), the motor output voltage exceeds 480V (overvoltage), or the load exceeds 350A (overload), the intelligent controller issues a command to adjust the opening of the electric regulating valve to the minimum (maintaining the basic water supply flow) and simultaneously controls the high-efficiency permanent magnet motor to stop smoothly; if the anti-dry running detector detects that the liquid level in the pipeline is lower than 50mm (such as water interruption due to pipeline maintenance), it immediately triggers an emergency shutdown and sends an alarm signal to the remote monitoring platform; the intelligent controller uploads the equipment operating parameters (flow rate, pressure, power generation, equipment temperature) to the monitoring platform in real time through the 4G communication module, and maintenance personnel can remotely issue commands such as shutdown and parameter adjustment to achieve unattended operation and maintenance.

[0044] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A full-flow intelligent pressure-regulating pipeline power generation device, characterized in that, The system includes a transmission assembly, an adaptive gearbox (19), a high-efficiency permanent magnet motor, and a smart voltage regulation module, a full-flow protection module, an inverter module, and an installation adapter module, all connected in sequence. The transmission assembly includes a drive shaft (1) and a sealed bearing housing (2). The drive shaft (1) is provided with a bearing sleeve (3), and the bearing sleeve (3) is provided with an adjusting shaft (4). The top end of the adjusting shaft (4) is provided with an impeller (5), and the bottom end of the adjusting shaft (4) is located inside the drive shaft (1) and is provided with a first bevel tooth (6). The bearing sleeve (3) is provided with multiple sets and arranged in a ring array with the drive shaft (1) as the axis. The sealed bearing housing (2) is connected to one end of the drive shaft (1) through an adjusting shell. (7) Connection, one end of the sealed bearing seat (2) is provided with a sealing shell (8), and a magnetic coupling resonant wireless power supply mechanism is provided between the sealing shell (8) and the adjusting shell (7). The interior of the adjusting shell (7) is provided with a drive motor (9), and the output end of the drive motor (9) is provided with a mounting shaft (10). One end of the mounting shaft (10) extends into the interior of the drive shaft (1) and is provided with a second bevel tooth (11). The second bevel tooth (11) meshes with multiple first bevel teeth (6). One end of the drive shaft (1) is connected to the adaptive gearbox (19). The transmission assembly realizes water flow impact drive or water pipe embedded drive. Both drive methods can drive the adaptive gearbox (19) to rotate.

2. The intelligent pressure-regulating pipeline power generation device according to claim 1, characterized in that, The high-efficiency permanent magnet motor generates 430V, and its output end is electrically connected to the input end of the inverter module. The output end of the inverter module outputs a stable 400V voltage and is connected to the power grid. The adaptive gearbox (19) is equipped with a multi-stage gear set and a torque buffer mechanism. The gearbox main shaft is rigidly connected to the input end of the high-efficiency permanent magnet motor through an elastic coupling to achieve smooth power transmission. The intelligent pressure regulating module includes an electric regulating valve, a telescopic compensation valve and an intelligent controller. The electric regulating valve and the telescopic compensation valve are connected in series in the main channel of the pipeline. The intelligent controller is electrically connected to the electric regulating valve and the telescopic compensation valve to collect the water pressure, flow rate signal and motor output voltage signal in the pipeline in real time and dynamically adjust the valve opening.

3. The intelligent pressure-regulating pipeline power generation device according to claim 1, characterized in that, The full-flow protection module includes a flow sensor, a pressure sensor, an overload protector, an overpressure protector, and an anti-dry-run detector. Each sensor and protector is electrically connected to the intelligent controller, covering the entire process from water entering the pipeline to power generation output, thus achieving comprehensive protection for the equipment.

4. The intelligent pressure-regulating pipeline power generation device with full flow channel as described in claim 1, characterized in that, The inner wall of the adjusting shell (7) is provided with an iron ring (12), and the outer side of the mounting shaft (10) is provided with an electromagnet (13), which abuts against the inner wall of the iron ring (12).

5. The intelligent pressure-regulating pipeline power generation device with full flow channel as described in claim 1, characterized in that, The magnetically coupled resonant wireless power supply mechanism includes a transmitting coil (14), a transmitting end resonant capacitor, a transmitting end control board (15), a receiving coil (16), a receiving end resonant capacitor, a receiving end control board (17), and an energy storage module (18). The transmitting coil (14), the transmitting end resonant capacitor, and the transmitting end control board (15) are installed on the inner wall of the sealed shell (8), and the receiving coil (16), the receiving end resonant capacitor, the receiving end control board (17), and the energy storage module (18) are installed on the inner wall of the adjusting shell (7).

6. The intelligent pressure-regulating pipeline power generation device according to claim 1, characterized in that, The inverter module adopts a three-phase three-level topology, incorporates silicon carbide power devices, and combines an improved SVPWM modulation algorithm to achieve efficient conversion from 430V AC to 400V standard AC.

7. The intelligent pressure-regulating pipeline power generation device according to claim 2, characterized in that, The intelligent controller uses an STM32H7 series microprocessor, has a built-in 12-bit ADC acquisition module with an acquisition frequency of no less than 100Hz, and integrates a 4G communication module to realize remote data transmission and control.

8. The intelligent pressure regulating pipeline power generation device according to claim 1, characterized in that, The electromagnets (13) are evenly distributed around the mounting shaft (10). Each electromagnet (13) has a rated voltage of 24V and a rated suction force of 50N-100N. The surface of the electromagnet (13) is provided with an insulating protective layer.

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