Wear monitoring system and method for heavy duty gas turbine generator ground carbon brush

Abstract

This application proposes a wear monitoring system and method for grounding carbon brushes of heavy-duty gas turbine generators. The method includes: a non-contact ranging probe, installed on the generator brush holder or brush handle, for real-time measurement of carbon brush distance; a non-contact temperature measuring probe, installed on the generator brush holder or brush handle, for real-time measurement of carbon brush temperature; a local display device, electrically connected to the ranging probe and the temperature probe respectively, for receiving carbon brush distance and temperature, processing the data, and displaying it locally; and a distributed control system (DCS), electrically connected to the local display device, for receiving the processed carbon brush wear data and temperature data, and storing, configuring, and alarming the data at thresholds. The technical solution proposed in this application solves the risks of mechanical injury, electric shock, and environmental safety associated with manual inspection, while simultaneously achieving real-time data recording and early warning management, significantly improving the safety and reliability of generator grounding carbon brush maintenance.

Description

Technical Field

[0001] This application relates to the field of carbon brush wear monitoring technology, and in particular to a wear monitoring system and method for grounding carbon brushes of heavy-duty gas turbine generators. Background Technology

[0002] In heavy-duty gas turbine generator operating systems, the shaft grounding carbon brush is a seemingly small but crucial component. Through direct contact with the generator shaft, it establishes an electrical connection between the shaft and the ground, serving purposes such as shaft grounding, shaft voltage and current detection, and rotor grounding protection. It plays an irreplaceable role in ensuring the safe and stable operation of the generator. In practical engineering applications, problems such as poor contact and excessively rapid carbon brush wear are frequently encountered. If these issues are not detected and addressed promptly, they may cause the electrical connection between the shaft and the ground to be broken, leading to catastrophic damage to the heavy-duty gas turbine and generator.

[0003] Currently, most wear inspections of grounding carbon brushes in heavy-duty gas turbine generators are conducted manually on-site. The wear condition of the generator shaft grounding carbon brushes directly affects its grounding reliability. While manual inspection is a traditional maintenance method and is simple to operate, it has many hidden dangers and shortcomings in practice. Mechanical injury risk: The carbon brushes are usually installed close to the generator's rotating shaft or high-speed rotating components (such as bearing end covers, couplings, etc.), requiring close contact with rotating equipment during inspection. If protective measures are inadequate (such as unsecured protective covers or personnel error), clothing or tools may be caught in the rotating components, causing scratches, crushing, or even more serious mechanical injuries. Electric shock risk: During generator operation, residual shaft voltage or induced voltage may exist on the shaft. If the carbon brush grounding circuit is temporarily disconnected (such as accidentally touching the lead wire during inspection), or if the grounding device has a hidden fault, personnel may experience electric shock accidents when touching the carbon brushes or shaft. Environmental safety hazards: Generator operating environments are often accompanied by high temperatures, oil contamination, and dust (such as the high temperature in steam turbine generator rooms and the humidity in hydro turbine generator rooms). During inspection, personnel are prone to slipping, burns, or inhaling dust, leading to safety problems. Lack of real-time monitoring: Manual inspections are mostly performed periodically (e.g., weekly or monthly), making it impossible to monitor carbon brush wear in real time. If sudden wear occurs between two inspections (e.g., impurities on the shaft surface causing accelerated carbon brush wear), it may fail to be detected in time, leading to grounding failure. Excessive wear not detected in time: If inspectors lack responsibility or experience, they may overlook minor carbon brush wear (e.g., localized cracking, edge wear) or fail to measure the actual length (relying only on visual estimation), resulting in carbon brush wear exceeding the critical value without replacement. In this case, poor contact between the carbon brush and the shaft prevents effective shaft voltage release, potentially causing bearing erosion, overheating, and other faults. Therefore, there is an urgent need for a safe, reliable, real-time grounding carbon brush wear monitoring scheme suitable for the harsh operating environment of heavy-duty gas turbine generators. Summary of the Invention

[0004] This application provides a wear monitoring system and method for grounding carbon brushes of heavy-duty gas turbine generators, in order to at least solve the technical problems of operation and maintenance reliability, such as mechanical injury, electric shock, environmental safety risks, poor real-time monitoring, and difficulty in timely detection of excessive wear, which exist in the prior art due to reliance on manual inspection for wear monitoring of grounding carbon brushes of heavy-duty gas turbine generators.

[0005] The first aspect of this application provides a wear monitoring system for the grounding carbon brush of a heavy-duty gas turbine generator, comprising:

[0006] A non-contact ranging probe, mounted on the generator brush holder or brush grip, is used to measure the carbon brush distance in real time. A non-contact temperature probe is installed on the generator brush holder or brush handle to measure the temperature of the carbon brushes in real time. The local display device is electrically connected to the ranging probe and the temperature probe, respectively, and is used to receive the carbon brush distance and the carbon brush temperature, and to process and display the data locally. The distributed control system (DCS) is electrically connected to the local display device and is used to receive processed carbon brush wear data and temperature data, and to perform data storage, configuration display, and threshold alarm.

[0007] Preferably, the ranging probe is an infrared ranging probe or a laser ranging probe, and its installation position is directly opposite the carbon brush end face in the brush holder sliding cavity; The local display device uses the pre-calibrated carbon brush distance as a reference value, and calculates the difference between the subsequently measured carbon brush distance and the reference value to obtain the carbon brush wear amount.

[0008] Furthermore, the temperature probe is an infrared temperature probe, and its installation position is directly opposite the carbon brush body in the brush holder sliding cavity. The temperature probe has preset emissivity parameters based on the carbon brush material.

[0009] Preferably, the DCS is configured with a carbon brush wear alarm threshold and a carbon brush temperature alarm threshold; The wear alarm threshold includes an upper alarm value and a lower alarm value, wherein the upper alarm value is used to indicate that the carbon brush wear is approaching the critical value, and the lower alarm value is used to indicate that the carbon brush wear has reached the limit. The temperature alarm threshold is based on the carbon brush temperature when the generator is fully loaded, with a preset temperature deviation value. When the real-time temperature exceeds the sum of the reference temperature and the preset temperature deviation value, a high temperature alarm is triggered.

[0010] Preferably, the ranging probe and the temperature probe are connected to a local display device or DCS via a wireless transmission module, which includes a WiFi module, a ZigBee module, or an industrial wireless communication module.

[0011] Preferably, the system further includes: an industrial camera; The industrial camera is used to acquire image information of the carbon brush, and the remaining length and surface condition of the carbon brush are analyzed through image recognition algorithms to achieve wear monitoring.

[0012] Furthermore, the DCS is also used for: The wear rate is calculated based on the rate of change of carbon brush wear over time, and an abnormal wear warning is triggered when the wear rate exceeds a preset value.

[0013] The second aspect of this application provides a method for monitoring the wear of grounding carbon brushes in heavy-duty gas turbine generators, including: Step 1: Install the non-contact ranging probe and the non-contact temperature measuring probe, with the probe facing the part of the carbon brush to be measured; Step 2: Perform initial calibration on the ranging probe and temperature probe, and use the first measured carbon brush distance as the reference value; Step 3: Real-time acquisition of the current distance and temperature of the carbon brush, determination of the difference between the current distance and the reference value, and use the difference as the carbon brush wear amount; Step 4: Transmit the carbon brush wear amount and current temperature to the DCS system; Step 5: Configure measurement points, set wear alarm thresholds and temperature alarm thresholds in the DCS system, and perform data storage and screen configuration display; Step 6: When the carbon brush wear or temperature reaches the preset alarm threshold, issue an alarm prompt of the corresponding level.

[0014] Preferably, the initial calibration includes: The emissivity parameters of the infrared temperature measuring probe are set according to the carbon brush material, and the installation position of the ranging probe is adjusted so that its optical axis is perpendicular to the end face of the carbon brush.

[0015] Furthermore, the calculation of carbon brush wear is performed by a local display device, or the raw signals from the ranging probe and temperature probe are directly transmitted to the DCS, which then performs the calculation and data processing of carbon brush wear.

[0016] The technical solutions provided by the embodiments of this application have at least the following beneficial effects: This application proposes a wear monitoring system and method for grounding carbon brushes of heavy-duty gas turbine generators. The method includes: a non-contact ranging probe, installed on the generator brush holder or brush handle, for real-time measurement of carbon brush distance; a non-contact temperature measuring probe, installed on the generator brush holder or brush handle, for real-time measurement of carbon brush temperature; a local display device, electrically connected to the ranging probe and the temperature probe respectively, for receiving carbon brush distance and temperature, processing the data, and displaying it locally; and a distributed control system (DCS), electrically connected to the local display device, for receiving the processed carbon brush wear data and temperature data, and storing, configuring, and alarming the data at thresholds. The technical solution proposed in this application solves the risks of mechanical injury, electric shock, and environmental safety associated with manual inspection, while simultaneously achieving real-time data recording and early warning management, significantly improving the safety and reliability of generator grounding carbon brush maintenance.

[0017] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0018] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein: Figure 1 This is a structural diagram of a wear monitoring system for grounding carbon brushes of heavy-duty gas turbine generators according to an embodiment of this application; Figure 2 This is a schematic diagram showing the installation location of a wear monitoring system for grounding carbon brushes of a heavy-duty gas turbine generator according to an embodiment of this application. Figure 3 This is a schematic diagram illustrating the replacement of a non-contact ranging probe and a non-contact temperature measuring probe with an industrial camera according to an embodiment of this application. Figure 4 This is a flowchart illustrating a method for monitoring the wear of grounding carbon brushes in a heavy-duty gas turbine generator according to an embodiment of this application; Figure Labels 1. Non-contact ranging probe; 2. Non-contact temperature measuring probe; 3. Local display device; 4. Distributed control system (DCS); 5. Industrial camera; 6. Brush holder; 7. Carbon brush; 8. Generator shaft; 9. Detailed Implementation

[0019] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0020] This application proposes a wear monitoring system and method for grounding carbon brushes of heavy-duty gas turbine generators. The method includes: a non-contact ranging probe, installed on the generator brush holder or brush handle, for real-time measurement of carbon brush distance; a non-contact temperature measuring probe, installed on the generator brush holder or brush handle, for real-time measurement of carbon brush temperature; a local display device, electrically connected to the ranging probe and the temperature probe respectively, for receiving carbon brush distance and temperature, processing the data, and displaying it locally; and a distributed control system (DCS), electrically connected to the local display device, for receiving the processed carbon brush wear data and temperature data, and storing, configuring, and alarming the data at thresholds. The technical solution proposed in this application solves the risks of mechanical injury, electric shock, and environmental safety associated with manual inspection, while simultaneously achieving real-time data recording and early warning management, significantly improving the safety and reliability of generator grounding carbon brush maintenance.

[0021] The wear monitoring system and method for grounding carbon brushes of heavy-duty gas turbine generators according to embodiments of this application are described below with reference to the accompanying drawings.

[0022] Example 1 Figure 1 This is a structural diagram of a wear monitoring system for grounding carbon brushes of a heavy-duty gas turbine generator according to an embodiment of this application, as shown below. Figure 1 As shown, the system includes: A non-contact ranging probe 1 is installed on the generator brush holder 6 or brush handle 7 for real-time measurement of carbon brush distance; The non-contact temperature probe 2 is installed on the generator brush holder 6 or brush handle 7 to measure the temperature of the carbon brush 8 in real time. The local display device 3 is electrically connected to the ranging probe 1 and the temperature probe 2 respectively, and is used to receive the carbon brush distance and the carbon brush temperature, and to process and display the data locally. The distributed control system DCS4 is electrically connected to the local display device 3. It is used to receive processed carbon brush wear data and temperature data, and to perform data storage, configuration display and threshold alarm.

[0023] It should be noted that the ranging probe 1 is an infrared ranging probe or a laser ranging probe, and its installation position is directly opposite the carbon brush end face in the brush holder sliding cavity, wherein the carbon brush 8 is connected to the generator shaft 9.

[0024] Specific installation locations are as follows Figure 2 As shown.

[0025] The local display device 3 uses the pre-calibrated carbon brush distance as a reference value, and calculates the difference between the subsequently measured carbon brush distance and the reference value to obtain the carbon brush wear amount.

[0026] It should be noted that the temperature probe 2 is an infrared temperature probe, and its installation position is directly opposite the carbon brush body in the brush holder sliding cavity; The temperature probe 2 is preset with emissivity parameters based on the carbon brush material.

[0027] It should be noted that the DCS4 is configured with carbon brush wear alarm threshold and carbon brush temperature alarm threshold; The wear alarm threshold includes an upper alarm value and a lower alarm value, wherein the upper alarm value is used to indicate that the carbon brush wear is approaching the critical value, and the lower alarm value is used to indicate that the carbon brush wear has reached the limit. The temperature alarm threshold is based on the carbon brush temperature when the generator is fully loaded, with a preset temperature deviation value. When the real-time temperature exceeds the sum of the reference temperature and the preset temperature deviation value, a high temperature alarm is triggered.

[0028] Furthermore, the DCS4 is also used for: The wear rate is calculated based on the rate of change of carbon brush wear over time, and an abnormal wear warning is triggered when the wear rate exceeds a preset value.

[0029] In this embodiment of the disclosure, the ranging probe 1 and the temperature probe 1 are connected to the local display device 3 or DCS4 via a wireless transmission module, which includes a WiFi module, a ZigBee module, or an industrial wireless communication module.

[0030] In the embodiments disclosed herein, such as Figure 3 As shown, the system also includes: an industrial camera 5; The industrial camera 5 is used to acquire image information of the carbon brush and analyze the remaining length and surface condition of the carbon brush through image recognition algorithms to achieve wear monitoring.

[0031] This embodiment has the following advantages: This technical solution adds infrared ranging and temperature measuring probes to display the real-time temperature and wear of the carbon brushes on the local screen or DCS screen. This avoids workers having to squeeze into narrow spaces to monitor the wear and real-time temperature of the carbon brushes, and also reduces the risk of mechanical injury to workers who are close to the high-speed rotating shaft. At the same time, it also allows for real-time recording and viewing of relevant data.

[0032] In summary, the wear monitoring system for grounding carbon brushes of heavy-duty gas turbine generators proposed in this embodiment solves the risks of mechanical injury, electric shock, and environmental safety associated with manual inspections. At the same time, it realizes real-time data recording and early warning management, significantly improving the safety and reliability of generator grounding carbon brush operation and maintenance.

[0033] Example 2 Figure 4This is a flowchart illustrating a method for monitoring the wear of grounding carbon brushes in a heavy-duty gas turbine generator according to an embodiment of this application. Figure 4 As shown, the method includes: Step 1: Install the non-contact ranging probe and the non-contact temperature measuring probe, with the probe facing the part of the carbon brush to be measured; Step 2: Perform initial calibration on the ranging probe and temperature probe, and use the first measured carbon brush distance as the reference value; Step 3: Real-time acquisition of the current distance and temperature of the carbon brush, determination of the difference between the current distance and the reference value, and use the difference as the carbon brush wear amount; Step 4: Transmit the carbon brush wear amount and current temperature to the DCS system; Step 5: Configure measurement points, set wear alarm thresholds and temperature alarm thresholds in the DCS system, and perform data storage and screen configuration display; Step 6: When the carbon brush wear or temperature reaches the preset alarm threshold, issue an alarm prompt of the corresponding level.

[0034] In this embodiment of the disclosure, the initial calibration includes: The emissivity parameters of the infrared temperature measuring probe are set according to the carbon brush material, and the installation position of the ranging probe is adjusted so that its optical axis is perpendicular to the end face of the carbon brush.

[0035] It should be noted that the calculation of carbon brush wear is performed by a local display device, or the raw signals from the ranging probe and temperature probe are directly transmitted to the DCS, which then performs the calculation and data processing of carbon brush wear.

[0036] In summary, the wear monitoring method for grounding carbon brushes of heavy-duty gas turbine generators proposed in this embodiment solves the risks of mechanical injury, electric shock, and environmental safety associated with manual inspections. At the same time, it realizes real-time data recording and early warning management, significantly improving the safety and reliability of generator set grounding carbon brush operation and maintenance.

[0037] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0038] Any process or method described in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or more executable instructions for implementing custom logic functions or processes, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as should be understood by those skilled in the art to which embodiments of this application pertain.

[0039] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A wear monitoring system for grounding carbon brushes in heavy-duty gas turbine generators, characterized in that, include: A non-contact ranging probe, mounted on the generator brush holder or brush grip, is used to measure the carbon brush distance in real time. A non-contact temperature probe is installed on the generator brush holder or brush handle to measure the temperature of the carbon brushes in real time. The local display device is electrically connected to the ranging probe and the temperature probe, respectively, and is used to receive the carbon brush distance and the carbon brush temperature, and to process and display the data locally. The distributed control system (DCS) is electrically connected to the local display device and is used to receive processed carbon brush wear data and temperature data, and to perform data storage, configuration display, and threshold alarm.

2. The monitoring system as described in claim 1, characterized in that, The ranging probe is an infrared ranging probe or a laser ranging probe, and its installation position is directly opposite the carbon brush end face in the brush holder sliding cavity. The local display device uses the pre-calibrated carbon brush distance as a reference value, and calculates the difference between the subsequently measured carbon brush distance and the reference value to obtain the carbon brush wear amount.

3. The monitoring system as described in claim 1, characterized in that, The temperature probe is an infrared temperature probe, and its installation position is directly opposite the carbon brush body in the brush holder sliding cavity. The temperature probe has preset emissivity parameters based on the carbon brush material.

4. The monitoring system as described in claim 1, characterized in that, The DCS is equipped with carbon brush wear alarm threshold and carbon brush temperature alarm threshold. The wear alarm threshold includes an upper alarm value and a lower alarm value, wherein the upper alarm value is used to indicate that the carbon brush wear is approaching the critical value, and the lower alarm value is used to indicate that the carbon brush wear has reached the limit. The temperature alarm threshold is based on the carbon brush temperature when the generator is fully loaded, with a preset temperature deviation value. When the real-time temperature exceeds the sum of the reference temperature and the preset temperature deviation value, a high temperature alarm is triggered.

5. The monitoring system as described in claim 1, characterized in that, The ranging probe and temperature probe are connected to a local display device or DCS via a wireless transmission module, which includes a WiFi module, a ZigBee module, or an industrial wireless communication module.

6. The monitoring system as described in claim 1, characterized in that, The system also includes: an industrial camera; The industrial camera is used to acquire image information of the carbon brush, and the remaining length and surface condition of the carbon brush are analyzed through image recognition algorithms to achieve wear monitoring.

7. The monitoring system as described in claim 4, characterized in that, The DCS is also used for: The wear rate is calculated based on the rate of change of carbon brush wear over time, and an abnormal wear warning is triggered when the wear rate exceeds a preset value.

8. A method for monitoring the wear of grounding carbon brushes in heavy-duty gas turbine generators, based on the wear monitoring system for grounding carbon brushes in any one of claims 1-7, characterized in that, The method includes: Step 1: Install the non-contact ranging probe and the non-contact temperature measuring probe, with the probe facing the part of the carbon brush to be measured; Step 2: Perform initial calibration on the ranging probe and temperature probe, and use the first measured carbon brush distance as the reference value; Step 3: Real-time acquisition of the current distance and temperature of the carbon brush, determination of the difference between the current distance and the reference value, and use the difference as the carbon brush wear amount; Step 4: Transmit the carbon brush wear amount and current temperature to the DCS system; Step 5: Configure measurement points, set wear alarm thresholds and temperature alarm thresholds in the DCS system, and perform data storage and screen configuration display; Step 6: When the carbon brush wear or temperature reaches the preset alarm threshold, issue an alarm prompt of the corresponding level.

9. The monitoring method as described in claim 8, characterized in that, The initial calibration includes: The emissivity parameters of the infrared temperature measuring probe are set according to the carbon brush material, and the installation position of the ranging probe is adjusted so that its optical axis is perpendicular to the end face of the carbon brush.

10. The monitoring method as described in claim 8, characterized in that, The calculation of carbon brush wear is performed by a local display device, or the raw signals from the ranging probe and temperature probe are directly transmitted to the DCS, which then performs the calculation and data processing of carbon brush wear.

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