A fan foundation uneven settlement monitoring device, method and system

Abstract

This invention discloses a monitoring device, method, and system for monitoring uneven settlement of wind turbine foundations, belonging to the field of wind power equipment testing technology. The device includes upper and lower horizontal annular connecting pipes fixed to the wind turbine tower, and sixteen sets of equidistantly distributed vertical connecting pipes connecting the two. The connecting pipes are filled with an antifreeze testing liquid, and the walls of the vertical connecting pipes have transparent reading areas with graduated lines. Utilizing the principle of communicating vessels, when uneven settlement of the foundation causes the tower to tilt, the liquid level in each vertical pipe responds synchronously. By reading the scale at the point of maximum liquid level change and combining it with geometric proportional relationships, the degree of uneven settlement (tilt rate) of the wind turbine foundation can be calculated. This invention has a simple structure, is easy to install, utilizes a purely mechanical structure with strong anti-interference capabilities, and can achieve accurate all-weather monitoring of wind turbine foundation settlement in complex outdoor environments without the need for power supply.

Description

Technical Field

[0001] This invention relates to the field of wind turbine equipment safety testing technology, specifically to a wind turbine foundation uneven settlement monitoring device, monitoring method and system, which is particularly suitable for monitoring uneven settlement of large wind turbine foundations. Background Technology

[0002] Wind power generation, as an environmentally friendly and efficient new energy source, has seen rapid development in my country in recent years. Wind turbines are often deployed in remote and complex areas such as offshore, mountains, and deserts, making maintenance and repair difficult. Therefore, the safety monitoring of wind turbine foundations is particularly crucial. As the core structure bearing the load of the turbine, the foundation is prone to uneven settlement under long-term loads, geological changes, and extreme weather conditions (heavy rain, strong winds). Uneven settlement can lead to turbine tower tilting, abnormal meshing of the main shaft and gearbox, bearing overheating, blade flutter, and in severe cases, even turbine collapse, threatening equipment safety and the personal safety of maintenance personnel. Currently, the benchmark network for monitoring uneven settlement of wind turbine foundations is established as follows: the distance between the benchmark points and the wind turbine is not less than 5 times the tower height, and the benchmarks are located in geologically stable areas, with no fewer than 3 benchmarks forming a closed leveling loop to avoid the influence of wind turbine loads and construction disturbances; monitoring point layout: 4 to 6 monitoring points are evenly arranged along the foundation ring flange, and auxiliary monitoring points are added at a position of 1.5 to 2m at the bottom of the tower to ensure data representativeness. The mainstream methods for monitoring uneven settlement of wind turbine foundations are mainly divided into two categories: one is the traditional manual measurement method, which uses a level or theodolite to periodically measure the elevation of the foundation settlement points. This method has drawbacks such as low monitoring efficiency and insufficient data temporal resolution. In addition, the inconvenient transportation and harsh environment of wind farm sites increase the difficulty of manual measurement. The other is the automated monitoring method, represented by the hydrostatic level method. Existing hydrostatic level devices have problems such as complex structure, cumbersome installation, weak anti-interference ability, and high cost. Moreover, most of them have a single measurement orientation, making it difficult to accurately judge the settlement differences of different orientations of the wind turbine foundation. They are also greatly affected by the ambient temperature and are prone to liquid surface fluctuation interference, which leads to a decrease in measurement accuracy and cannot stably adapt to the long-term, multi-point uneven settlement monitoring needs of wind turbine foundations.

[0003] Therefore, developing a wind turbine foundation uneven settlement monitoring device that is simple in structure, easy to install, has high measurement accuracy, strong anti-interference ability, and low cost has become the key to solving the current difficulties in wind turbine foundation monitoring. Summary of the Invention

[0004] To address the technical shortcomings of existing wind turbine foundation uneven settlement monitoring devices, such as complex structure, cumbersome installation, insufficient measurement accuracy, weak anti-interference ability, and inability to achieve multi-point monitoring, this invention provides a wind turbine foundation uneven settlement monitoring device, method, and system. Utilizing the core principle of communicating vessel balance, it achieves high-precision monitoring of multi-point uneven settlement of wind turbine foundations, while simplifying the device structure, reducing costs, improving environmental adaptability, and meeting the long-term monitoring needs of various wind turbine foundations.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a wind turbine foundation uneven settlement monitoring device, comprising a wind turbine tower, an upper horizontal annular connecting pipe, a lower horizontal annular connecting pipe, a vertical connecting pipe, a fixing buckle, an injection port, and a drain valve. The upper horizontal annular connecting pipe and the lower horizontal annular connecting pipe, which are fixed on the wind turbine tower, are connected by multiple sets of equidistantly distributed vertical connecting pipes. The vertical connecting pipes are filled with antifreeze detection liquid, and the pipe wall of the vertical connecting pipes is provided with a transparent reading area with scale lines. The top of the upper horizontal annular connecting pipe is provided with an injection port, and the bottom of the lower horizontal annular connecting pipe is provided with a drain valve.

[0006] Furthermore, the vertical connecting pipes are configured in sixteen groups and are evenly arranged along the circumference of the wind turbine tower.

[0007] Furthermore, the fixing buckles are equidistantly arranged between the horizontal annular connecting pipe and the wind turbine tower, and a rubber buffer pad is provided between the fixing buckles and the horizontal annular connecting pipe.

[0008] Furthermore, both the horizontal annular connecting pipe and the vertical connecting pipe are made of steel pipe, and the transparent reading area is made of transparent glass or acrylic material and embedded in the middle of the vertical connecting pipe.

[0009] Furthermore, the antifreeze testing liquid is methyl silicone oil.

[0010] The method for monitoring uneven settlement of the wind turbine foundation of the above-mentioned device includes the following steps: S1: Installation and calibration: Fix the monitoring device to the bottom of the wind turbine tower near the wind turbine foundation, inject antifreeze detection liquid through the injection port, and adjust the device to be horizontal so that the liquid level in all vertical connecting pipes is at the same initial scale. S2: Routine monitoring, utilizing the principle of communicating vessels, when uneven settlement of the fan foundation causes the tower to tilt, the liquid level in each vertical communicating pipe changes; S3: Reading analysis, observe the liquid level scale of each transparent reading zone, select the vertical connecting pipe with the highest liquid level reading and the vertical connecting pipe with the lowest liquid level reading, and record the difference in liquid level reading ΔH; S4: Uneven settlement analysis of the foundation. Based on the positive correlation between the liquid level reading difference ΔH and the settlement value of the foundation monitoring points, and combined with the distances R and r of the two monitoring points from the center line of the tower, the settlement monitoring values ​​of the corresponding monitoring points of the foundation are calculated. The formula for calculating the settlement monitoring values ​​of the corresponding monitoring points of the foundation is as follows:

[0011] Where R is the distance from the base settlement monitoring point to the center line of the tower, and r is the distance from the initial liquid level of the vertical connecting pipe to the center line of the tower.

[0012] Furthermore, the specific process of installation and calibration in step S1 is as follows: The device is initially fixed to the tower using the fixing clips, and antifreeze liquid is injected into the middle area of ​​the vertical connecting pipe; Fine-tune the position of the device to ensure that the liquid in all vertical connecting pipes is at the same scale line, and then tighten the fixing buckle.

[0013] Furthermore, the routine monitoring in step S2 includes periodic manual inspection and reading, or remote automatic reading monitoring in conjunction with image recognition equipment.

[0014] Furthermore, in step S4, the base corresponding orientation monitoring point is located on a circle with radius R centered on the tower centerline, and is not limited to a fixed point.

[0015] A wind turbine foundation uneven settlement monitoring system based on the above-mentioned device, the system includes the monitoring device, a data acquisition module and a data processing terminal, the data acquisition module is used to acquire liquid level data of each vertical connecting pipe, and the data processing terminal is used to calculate the foundation settlement value according to the liquid level difference ΔH and the geometric ratio and generate an early warning signal.

[0016] Compared with the prior art, the present invention has the following beneficial effects: This innovative multi-point fusion design breaks through traditional technical bottlenecks: Multiple measuring points are equidistantly arranged around the tower, achieving a deep fit between the communicating vessel principle and annular multi-point tilt detection. Compared to existing single-point detection devices, it can accurately quantify the overall settlement orientation of the wind turbine foundation based on data from each measuring point, and quickly identify single-point anomalies caused by local deformation by comparing the differences in liquid level readings at each measuring point. This significantly improves the comprehensiveness and accuracy of the detection, effectively capturing subtle cumulative settlement changes in the foundation.

[0017] Strong anti-interference capability and adaptable to complex outdoor environments: Based on the principle of communicating vessel fluid mechanics, it does not require complex and precise electronic sensing structures and is minimally affected by outdoor electromagnetic interference, wind, and light, ensuring measurement stability under harsh outdoor conditions.

[0018] It is highly versatile, easy to install and operate, and simple to perform initial calibration. No professional construction team is required, which greatly improves testing efficiency. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the wind turbine foundation uneven settlement monitoring device of the present invention; Figure 2 This is a top view of the measuring point arrangement of the present invention; Figure 3 This is a partial structural diagram of the vertical connecting pipe of the present invention; Figure 4 This is a schematic diagram showing the location of the vertical connecting pipe and the foundation settlement monitoring point according to the present invention; In the diagram, 1 is the wind turbine tower; 2 is the upper horizontal annular connecting pipe; 12 is the lower horizontal annular connecting pipe; 3 is the vertical connecting pipe; 4 is the fixing buckle; 5 is the transparent reading area; 6 is the liquid injection port; 7 is the liquid drain valve; 8 is the wind turbine foundation; and 9 is the settlement monitoring point. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0021] In the description of this invention, it should be noted that the terms "upper", "middle", "lower", "inner", "outer", "both sides", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the purpose of simplifying the description of this invention and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0022] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0023] Please see Figures 1 to 4 This invention provides a device and method for monitoring uneven settlement of wind turbine foundations.

[0024] 1. Implementation of the device structure like Figure 1As shown, this embodiment of the invention provides a wind turbine foundation uneven settlement monitoring device, including a wind turbine tower 1, an upper horizontal annular connecting pipe 2, a lower horizontal annular connecting pipe 12, a vertical connecting pipe 3, a fixing buckle 4, an injection port 6, and a drain valve 7.

[0025] The upper horizontal annular connecting pipe 2 and the lower horizontal annular connecting pipe 2 are connected by multiple sets of equidistantly distributed vertical connecting pipes 3. The vertical connecting pipes 3 are filled with antifreeze detection liquid, and the walls of the vertical connecting pipes 3 are provided with transparent reading areas 5, which have graduations. The upper horizontal annular connecting pipe 2 has an injection port 6 at its top, and the lower horizontal annular connecting pipe 2 has a drain valve 7 at its bottom. The injection port 6 at the top of the upper horizontal annular connecting pipe is used to add detection liquid; the drain valve 7 in the lower horizontal annular connecting pipe is used to replace the detection liquid.

[0026] This structure utilizes the principle of communicating vessels to convert a slight inclination on the horizontal plane into a liquid level difference in the vertical tube. The upper and lower double-layer annular tube structure enhances the overall rigidity of the device, while the design of the injection port and drain valve facilitates liquid replacement and maintenance. The transparent reading area allows for intuitive observation.

[0027] like Figure 2 As shown, preferably, the vertical connecting pipes 3 are arranged in sixteen groups, evenly distributed along the circumference of the wind turbine tower 1. The circular arrangement of the sixteen measuring points enables 360-degree all-around monitoring. Compared with traditional 4-point or 6-point monitoring, this scheme can more accurately detect minute settlement anomalies in any direction of the wind turbine foundation, achieving precise location of the settlement.

[0028] like Figure 1 As shown, the fixing clips 4 are equidistantly arranged between the horizontal annular connecting pipe and the wind turbine tower 1, and a rubber buffer pad is provided between the fixing clips 4 and the horizontal annular connecting pipe. The rubber buffer pad acts as a buffer layer, avoiding wear or stress damage to the connecting pipe caused by hard metal contact, while allowing for slight deformation adaptation between the device and the tower, ensuring the stability of the monitoring data.

[0029] like Figure 3 As shown, both the horizontal annular connecting pipe and the vertical connecting pipe 3 are made of steel pipe, and the transparent reading area 5 is made of transparent glass or acrylic material and embedded in the middle of the vertical connecting pipe 3. The steel pipe material ensures the mechanical strength and weather resistance of the device in harsh outdoor environments; the transparent material embedded in the middle ensures structural strength and provides a clear reading view, preventing liquid evaporation and external contamination.

[0030] Preferably, the antifreeze testing liquid is methyl silicone oil. Methyl silicone oil has an extremely low freezing point and good chemical stability, which enables it to remain stable in a liquid state in complex environments such as high cold and high temperature where the fan is located, without corroding the pipeline, ensuring that the measurement accuracy is not affected by temperature.

[0031] 2. Implementation of Monitoring Methods The present invention also provides a method for monitoring uneven settlement of wind turbine foundations based on the above-mentioned device, comprising the following steps: S1: Installation and calibration.

[0032] The monitoring device is fixed to the bottom of the wind turbine tower 1 using the fixing clips 4. Antifreeze detection liquid such as methyl silicone oil is injected through the injection port 6. The device is leveled so that the liquid level in all the vertical connecting pipes 3 is at the same initial scale (usually the middle of the transparent reading area), and then the fixing clips are tightened.

[0033] S2: Routine monitoring.

[0034] Utilizing the principle of communicating vessels, when the wind turbine foundation settles unevenly, it will cause the wind turbine tower 1 to tilt. At this time, the liquid surface, which was originally horizontal, will find a horizontal level again due to gravity, causing the liquid level in each vertical communicating pipe 3 to change (one side rises, and the other side falls).

[0035] S3: Reading analysis.

[0036] Observe the liquid level scale of each transparent reading zone 5 and find the point where the liquid level change is the maximum (i.e., the point where the difference between the highest and lowest liquid level is the largest). Select the vertical connecting pipe 3 with the highest liquid level reading and the vertical connecting pipe 3 with the lowest liquid level reading, and record their liquid level reading difference ΔH.

[0037] S4: Analysis of uneven settlement of foundation.

[0038] Based on the positive correlation between the liquid level reading difference ΔH and the settlement value of the foundation monitoring point, and combined with the distances R and r of the two monitoring points from the center line of the tower, the settlement monitoring value of the corresponding azimuth monitoring point 9 of the foundation is calculated.

[0039] Furthermore, the calculation formula is as follows:

[0040] Where R is the distance from the base settlement monitoring point to the center line of the tower, and r is the distance from the initial liquid level of the vertical connecting pipe to the center line of the tower.

[0041] Based on the principle of similar triangles, this calculation formula can accurately convert the observed liquid level reading difference into the base settlement monitoring value. Combined with the synchronous response of sixteen sets of vertical connecting pipes in the circumference to liquid level changes, it can identify abnormal fan tilt based on the liquid level reading difference and calculate the degree of uneven settlement (tilt rate) of the fan foundation, thus realizing the leap from qualitative monitoring to quantitative monitoring.

[0042] This method is simple to operate and requires no expensive electronic equipment or complex computing instruments. Settlement anomalies can be quickly identified through intuitive changes in liquid level, and the settlement amount can be calculated using simple geometric relationships, significantly reducing monitoring costs and the difficulty of manual inspection. The working principle of this invention is based on the principle of communicating vessels in fluid statics. In a static liquid, the pressure on the same horizontal plane is equal. When the wind turbine tower tilts, the liquid level inside the device remains horizontal, generating a liquid level difference in the vertical connecting pipe. By reading this liquid level difference and combining it with the geometric ratio between the device's installation radius and the foundation radius, the degree of uneven settlement (tilt rate) of the wind turbine foundation can be deduced. This device amplifies minute foundation settlement displacements into visible vertical pipe liquid level movements through the liquid medium, achieving highly sensitive and interference-resistant settlement monitoring.

[0043] This invention provides a simple, low-cost, and highly interference-resistant monitoring solution through an innovative double-layered annular connecting pipe and multiple sets of vertical reading tubes, combined with an antifreeze liquid medium. Compared with existing technologies, this invention eliminates the need for power supplies and complex electronic components, completely solving the problems of inaccurate measurements caused by outdoor electromagnetic interference and temperature differences. The layout of 16 circumferential measuring points enables precise location of settlement. Utilizing the principle of communicating vessels, minute settlement is transformed into a direct liquid level difference, achieving routine, high-precision, and maintenance-free monitoring of uneven settlement of wind turbine foundations, thus possessing extremely high engineering application value.

[0044] The monitoring system of this invention includes a device, a data acquisition module, and a data processing terminal. The module acquires liquid level data, and the terminal calculates settlement and issues early warnings. Through automated data acquisition, calculation, and early warning, the system improves the intelligence level of monitoring, provides real-time warnings of abnormal settlement, and ensures the safe operation of the blower.

[0045] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A wind turbine foundation differential settlement monitoring device, characterized in that, It includes a wind turbine tower (1), an upper horizontal annular connecting pipe (2), a lower horizontal annular connecting pipe (12), a vertical connecting pipe (3), a fixing buckle (4), an injection port (6), and a drain valve (7). The upper horizontal annular connecting pipe (2) and the lower horizontal annular connecting pipe (12) fixed on the wind turbine tower (1) are connected by multiple sets of equally spaced vertical connecting pipes (3). The vertical connecting pipe (3) is filled with antifreeze detection liquid. The wall of the vertical connecting pipe (3) is provided with a transparent reading area (5) and a scale line is provided on the transparent reading area (5). The top of the upper horizontal annular connecting pipe (2) is provided with an injection port (6), and the bottom of the lower horizontal annular connecting pipe (12) is provided with a drain valve (7).

2. The apparatus for monitoring uneven settlement of a fan foundation according to claim 1, wherein The vertical connecting pipes (3) are arranged in sixteen groups and are evenly distributed along the circumference of the wind turbine tower (1).

3. The apparatus for monitoring uneven settlement of a fan foundation according to claim 1, wherein The fixing buckles (4) are equidistantly arranged between the horizontal annular connecting pipe and the wind turbine tower (1), and a rubber buffer pad is provided between the fixing buckles (4) and the horizontal annular connecting pipe.

4. The apparatus for monitoring uneven settlement of a fan foundation according to claim 1, wherein Both the horizontal annular connecting pipe and the vertical connecting pipe (3) are made of steel pipe, and the transparent reading area (5) is made of transparent glass or acrylic material and is embedded in the middle of the vertical connecting pipe (3).

5. The wind turbine foundation uneven settlement monitoring device according to claim 1, characterized in that, The antifreeze testing liquid is methyl silicone oil.

6. The method for monitoring uneven settlement of wind turbine foundations using the apparatus described in any one of claims 1-5, characterized in that, Includes the following steps: S1: Installation and calibration: Fix the monitoring device to the bottom of the wind turbine tower (1) near the wind turbine foundation (8), inject antifreeze detection liquid through the injection port (6), and adjust the device to be horizontal so that the liquid level in all vertical connecting pipes (3) is at the same initial scale. S2: Routine monitoring, using the principle of communicating vessels, when uneven settlement of the fan foundation causes the tower to tilt, the liquid level in each vertical communicating pipe (3) changes; S3: Reading analysis, observe the liquid level scale of each transparent reading area (5), select the vertical connecting pipe (3) with the highest liquid level reading and the vertical connecting pipe (3) with the lowest liquid level reading, and record the difference in liquid level reading ΔH; S4: Analysis of uneven settlement of the foundation. Based on the positive correlation between the difference in liquid level readings ΔH and the settlement value of the foundation monitoring points, and combined with the distances R and r of the two monitoring points from the center line of the tower, the settlement monitoring value of the corresponding azimuth monitoring point (9) of the foundation is calculated. The formula for calculating the settlement monitoring value of the corresponding azimuth monitoring point (9) of the foundation is as follows: Where R is the distance from the base settlement monitoring point to the center line of the tower, and r is the distance from the initial liquid level of the vertical connecting pipe to the center line of the tower.

7. The method for monitoring uneven settlement of wind turbine foundations according to claim 6, characterized in that, The specific process of installation and calibration in step S1 is as follows: The device is initially fixed to the tower by the fixing buckle (4), and antifreeze liquid is injected into the middle area of ​​the vertical connecting pipe; Fine-tune the position of the device to ensure that the liquid in all vertical connecting pipes (3) is at the same scale line, and then tighten the fixing buckle (4).

8. The method for monitoring uneven settlement of wind turbine foundations according to claim 6, characterized in that, The routine monitoring in step S2 includes periodic manual inspection and reading, or remote automatic reading monitoring in conjunction with image recognition equipment.

9. The method for monitoring uneven settlement of wind turbine foundations according to claim 6, characterized in that, In step S4, the basic corresponding orientation monitoring point (9) is located on a circle with radius R centered on the tower centerline, and is not limited to a fixed position.

10. A wind turbine foundation uneven settlement monitoring system based on the device described in any one of claims 1-5, characterized in that, The system includes the monitoring device, the data acquisition module and the data processing terminal. The data acquisition module is used to acquire the liquid level data of each vertical connecting pipe (3). The data processing terminal is used to calculate the foundation settlement value based on the liquid level difference ΔH and the geometric ratio and generate an early warning signal.

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