A fan attached type state monitoring device and method based on rigid bolt main conduction path and multi-source energy optimization

Abstract

The application discloses a fan attached type state monitoring device and method based on rigid bolt main conduction path and multi-source energy optimization, and belongs to the technical field of wind power equipment state monitoring. The existing fan attached type monitoring device generally has problems of large signal conduction loss, low monitoring precision, poor energy supply stability, and insufficient utilization rate of multi-energy sources, and is difficult to adapt to long-term accurate monitoring under the complex variable working condition of the fan. The device adopts an attached integrated structure, relies on the original rigid bolt of the fan to build a fixed main signal conduction and force conduction path, and discards the flexible conduction defects of the traditional colloid attachment. Meanwhile, a multi-source energy collection module is built, three types of energy sources, i.e., fan vibration mechanical energy, environmental wind energy and light energy, are integrated, energy optimization scheduling and voltage stabilization control strategies are matched to realize autonomous energy supply.

Description

Technical Field

[0001] This invention relates to the fields of wind power equipment condition monitoring, sensor signal transmission and micro-energy acquisition optimization technology, specifically to a wind turbine attached condition monitoring device and method based on rigid bolt main transmission path and multi-source energy optimization. Background Technology

[0002] Wind turbine generators are exposed to complex outdoor environments for extended periods, and are susceptible to various factors such as variable wind speeds, turbulence, extreme temperature differences, and mechanical fatigue. Core structures like blades, towers, and connecting bolts are highly prone to cracking, deformation, loosening, and fatigue damage. Without timely monitoring and early warning, these issues can easily lead to equipment shutdowns, component failures, and even safety accidents, severely impacting wind farm operating efficiency and maintenance safety. Therefore, high-precision, all-weather, and long-endurance wind turbine condition monitoring technology is the core support for intelligent operation and maintenance of wind power equipment.

[0003] Currently, most mainstream wind turbine condition monitoring devices in the industry adopt externally attached sensor structures, which have the advantages of convenient installation, no need to modify the main body of the equipment, and wide adaptability. However, they have many inherent technical defects in practical applications. First, traditional adhesive monitoring devices are mostly attached to the surface of wind turbine equipment using flexible media such as silicone or double-sided adhesive. The sensing signal relies on the transmission of the flexible medium. High-frequency vibration and slight structural deformation during wind turbine operation can lead to signal attenuation, phase shift, and severe noise interference, making it impossible to accurately capture subtle fault characteristics of the equipment. The monitoring data has low accuracy and poor reliability. Second, existing monitoring devices mostly use a single lithium battery or a single wind energy acquisition power supply. The single power supply mode is prone to power outages in harsh environments such as windless, rainy, and nighttime conditions, making it impossible to achieve continuous monitoring around the clock. Frequent battery replacements also significantly increase maintenance costs. Third, existing monitoring systems lack a multi-energy source collaborative optimization scheduling mechanism. The utilization rate of various energy acquisitions is low, energy loss is high, and the overall power consumption matching of the device is poor, making it difficult to adapt to the monitoring power consumption requirements of wind turbines operating under varying conditions. Fourth, traditional adhesive structures do not have a fixed rigid transmission path. Long-term vibration can easily cause sensor displacement and detachment, significantly reducing monitoring stability and service life.

[0004] In existing technologies, some solutions attempt to improve monitoring performance by reinforcing the sensor installation structure or optimizing a single power supply method. However, none of these solutions address the core issues of signal transmission path optimization and multi-source energy synergy optimization, failing to simultaneously ensure monitoring accuracy, operational stability, battery life, and adaptability to different operating conditions. Therefore, there is an urgent need to develop a wind turbine-attached condition monitoring device and method that relies on a rigid bolt-based main transmission path and is adapted to multi-source energy optimization scheduling, in order to overcome the many shortcomings of existing technologies. Summary of the Invention

[0005] Purpose of the invention

[0006] The purpose of this invention is to address the technical pain points of existing wind turbine attached condition monitoring devices, such as high signal transmission loss, low monitoring accuracy, poor power supply stability, low energy utilization, and insufficient long-term operational reliability. This invention provides a wind turbine attached condition monitoring device and method based on a rigid bolt main transmission path and multi-source energy optimization. This invention utilizes the existing connecting bolts of the wind turbine to construct a rigid main transmission path, achieving lossless and efficient transmission of equipment status signals. Simultaneously, it integrates multiple micro-energy sources and achieves efficient energy utilization through adaptive optimization strategies, ultimately realizing high-precision, all-weather, low-power, and long-life stable monitoring of the operating status of key wind turbine components.

[0007] Technical solution

[0008] To achieve the above-mentioned objectives, the present invention adopts the following technical solution:

[0009] A wind turbine attached condition monitoring device based on rigid bolt main transmission path and multi-source energy optimization includes an attached integrated monitoring housing, a rigid bolt transmission component, a multi-source energy acquisition module, an energy optimization scheduling module, a sensor acquisition module, a data processing and transmission module, and a local storage module.

[0010] The attached integrated monitoring housing is a lightweight, sealed structure that fits snugly onto the surfaces of key monitoring components such as the root of the wind turbine blades, tower flanges, and connecting bolt groups. It is waterproof, dustproof, and resistant to high and low temperatures, making it suitable for complex outdoor working conditions. The rigid bolt transmission component is fixed inside the attached integrated monitoring housing and is rigidly connected to the existing fixing bolts of the wind turbine equipment, thus constructing a unique path for main signal transmission and force transmission.

[0011] The rigid bolt transmission assembly includes a docking sleeve, a rigid transmission rod, and a positioning and locking structure. The docking sleeve is fitted onto the outside of the original fixing bolts of the fan, and the positioning and locking structure achieves a gapless rigid fit. One end of the rigid transmission rod is fixedly connected to the docking sleeve, and the other end is rigidly docked with the sensing probe of the sensing acquisition module. It is used to transmit physical signals such as vibration, stress, and micro-deformation of the fan equipment to the sensing acquisition module without attenuation.

[0012] The multi-source energy acquisition module includes a vibration energy acquisition unit, a wind energy acquisition unit, and a solar energy acquisition unit. The vibration energy acquisition unit is attached to the rigid transmission rod to collect the mechanical energy of the wind turbine's vibration. The wind energy acquisition unit is located on the windward side of the outer shell to collect ambient wind energy. The solar energy acquisition unit is embedded on the outer surface of the shell to collect solar energy. The three types of energy acquisition units independently output electrical energy to achieve synchronous acquisition of multi-source micro-energy.

[0013] The energy optimization and scheduling module is electrically connected to the multi-source energy acquisition module, the sensor acquisition module, and the data processing and transmission module. It has a built-in energy stabilization unit, energy allocation algorithm unit, and power consumption matching unit, which are used to rectify, stabilize, and filter the multi-source energy. At the same time, based on the real-time operating power consumption of the device and the environmental energy supply status, it adaptively optimizes the output ratio of various types of energy, prioritizes the use of clean energy, reduces the power consumption loss of the energy storage module, and achieves efficient energy utilization.

[0014] The sensing and acquisition module includes vibration sensors, stress sensors, deformation sensors, and temperature sensors. All sensor probes are rigidly attached to the rigid transmission rod of the rigid bolt transmission assembly, and the vibration amplitude, stress change, structural deformation, operating temperature, and other multi-dimensional status data of the wind turbine equipment are accurately collected through the rigid main transmission path.

[0015] The data processing and transmission module has a built-in signal filtering unit, a data noise reduction unit, a fault feature extraction unit, and a wireless transmission unit. It is used to perform noise reduction, filtering, and feature extraction processing on the collected raw state data, remove noise interference data, extract effective fault feature signals, and upload the processed effective data to the background monitoring platform through wireless transmission.

[0016] The local storage module is used to store raw monitoring data and processed feature data in real time, avoiding data loss due to network interruption and ensuring the integrity and continuity of monitoring data.

[0017] A wind turbine attachment-based condition monitoring method based on rigid bolt main transmission path and multi-source energy optimization, applied to the aforementioned monitoring device, includes the following steps:

[0018] S1. Device Attachment and Installation and Path Construction: The attachable integrated monitoring housing is attached and fixed to the key parts of the fan to be monitored. The mating sleeve of the rigid bolt transmission component is rigidly locked to the original fixing bolts of the fan to construct a gapless rigid main signal transmission path, thus completing the device positioning, installation and initial calibration.

[0019] S2. Synchronous collection of multi-source energy: The vibration energy collection unit, wind energy collection unit, and solar energy collection unit are used to simultaneously collect three types of micro-energy: wind turbine vibration mechanical energy, ambient wind energy, and solar energy, thus completing the initial collection and conversion of multi-source energy.

[0020] S3. Multi-source energy optimization scheduling: The energy optimization scheduling module rectifies and stabilizes the collected multi-source electrical energy, monitors the current environmental energy supply intensity and device operating power consumption in real time, and dynamically adjusts the output ratio of various types of energy through an adaptive energy allocation algorithm; when there is sufficient sunlight, solar power is given priority; when there is wind, wind power is superimposed; when the wind turbine is in high vibration condition, the mechanical energy of vibration is enhanced; when there is no external energy, energy storage is activated to assist in power supply, so as to achieve dynamic matching of energy supply and demand.

[0021] S4. Rigid Path Signal Precision Acquisition: Relying on the main transmission path of rigid bolts, the physical signals such as vibration, stress, deformation, and temperature during the operation of the wind turbine equipment are transmitted to each sensor without attenuation. The sensing and acquisition module collects multi-dimensional raw data of equipment status in real time.

[0022] S5. Data Preprocessing and Feature Extraction: The data processing and transmission module performs noise reduction, filtering, and outlier removal on the raw monitoring data to eliminate environmental interference and conducted noise, and extracts fault characteristic parameters such as equipment fatigue damage, bolt loosening, and structural deformation.

[0023] S6. Data storage and remote transmission: The pre-processed valid data and fault characteristic data are synchronously stored in the local storage module, and simultaneously uploaded to the background monitoring platform through the wireless transmission unit, so that maintenance personnel can monitor, analyze and predict faults in real time.

[0024] S7. Cyclic Monitoring and Dynamic Adaptation: The device continuously repeats steps S2-S6, dynamically adapting the energy dispatch strategy and data acquisition frequency according to the fan operating conditions and environmental conditions, to achieve uninterrupted status monitoring around the clock.

[0025] Beneficial effects

[0026] Compared with the prior art, the present invention has the following significant advantages:

[0027] 1. This invention innovatively adopts a rigid bolt main transmission path design, relying on the original fixing bolts of the wind turbine to build a gapless rigid signal transmission channel, completely eliminating the signal attenuation and noise interference defects of traditional flexible attached media, realizing the lossless and efficient transmission of subtle fault signals such as vibration, stress, and deformation of wind turbine equipment, greatly improving the accuracy and reliability of monitoring data, and accurately capturing early hidden fault characteristics.

[0028] 2. This invention adopts multi-source energy collaborative acquisition and optimized scheduling technology, integrating three types of renewable micro-energy: vibration mechanical energy, wind energy, and solar energy. Through an adaptive energy allocation algorithm, it achieves efficient utilization of various types of energy, solving the problems of single power supply, insufficient battery life, and poor adaptability to operating conditions in traditional monitoring devices. It eliminates the need for frequent battery replacements, significantly reduces operation and maintenance costs, and enables the device to operate autonomously with power supply around the clock.

[0029] 3. The present invention adopts an integrated adhesive structure, which is convenient to install and does not require modification of the main equipment of the fan. It is suitable for monitoring the key parts of various fans. The rigid locking structure can effectively avoid the problem of sensor displacement and falling off caused by long-term vibration, and greatly improve the operational stability and service life of the device.

[0030] 4. This invention has multi-dimensional data acquisition and intelligent preprocessing capabilities. It can simultaneously collect multi-dimensional state data such as vibration, stress, deformation, and temperature. Through data noise reduction and feature extraction technology, it removes interference data, greatly improving the accuracy of fault identification. It can provide accurate data support for intelligent operation and maintenance, fault prediction, and life assessment of wind turbines.

[0031] 5. This invention combines local storage and remote wireless transmission functions, ensuring the continuity and real-time nature of monitoring data. It can be adapted to various complex wind power conditions on land and at sea, and has strong versatility and practicality. Detailed Implementation

[0032] The present invention will now be described in further detail and in complete detail with reference to specific embodiments. These embodiments are implemented based on the technical solution of the present invention, providing detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0033] Example 1: Specific Implementation Structure of the Device

[0034] This invention discloses a wind turbine attached condition monitoring device based on the main transmission path of rigid bolts and multi-source energy optimization. The device employs an integrated sealed attachment structure, adaptable to core monitoring components such as wind turbine blade roots, tower flanges, and bolted connection nodes. The attached integrated monitoring housing is made of high-strength, lightweight ABS sealing material, possessing IP67 waterproof and dustproof properties, high and low temperature resistance, and wind erosion resistance, allowing for long-term adaptation to extreme outdoor operating conditions ranging from -40℃ to 85℃.

[0035] The rigid bolt transmission assembly serves as the core signal transmission carrier. The docking sleeve is made of high-strength alloy material, and its inner diameter is precisely matched with the outer diameter of the standard fixing bolt of the fan, with the gap controlled within 0.02mm. The built-in elastic positioning locking ring achieves a gapless rigid fit, eliminating transmission loosening and signal attenuation. The rigid transmission rod adopts an integrated solid structure, with both ends rigidly pressed and docked with the docking sleeve and sensor probe, respectively, forming a complete rigid force transmission and signal transmission link, ensuring 1:1 lossless transmission of subtle deformation and vibration signals of the equipment.

[0036] In the multi-source energy harvesting module, the vibration energy harvesting unit uses a piezoelectric vibration harvesting chip, which is attached to the rigid transmission rod to accurately capture the high-frequency vibration mechanical energy of the equipment and complete the electromechanical conversion; the wind energy harvesting unit uses a miniature flexible wind energy harvesting film, which is deployed on the windward side of the shell to adapt to the harvesting of low-speed micro-wind energy; the solar energy harvesting unit uses a high-efficiency monocrystalline solar film, which is embedded on the outer surface of the shell to balance light transmission and protection performance. The three types of harvesting units work independently and do not interfere with each other, and can simultaneously realize multi-dimensional micro-energy harvesting.

[0037] The energy optimization scheduling module uses a built-in low-power microcontroller as its core control unit, integrating rectifier circuits, voltage regulator circuits, power detection circuits, and adaptive energy allocation algorithms. It can collect the output power of three types of energy sources in real time, and dynamically allocate power supply priorities based on the device's real-time power consumption monitoring. The specific scheduling logic is as follows: under strong light conditions, priority is given to solar power supply, and surplus energy is stored in the built-in energy storage capacitor; under windy and weak light conditions, wind power and vibration mechanical energy are used for combined power supply; under static conditions with no wind and no light, power is supplied by the energy storage capacitor, while maximizing the collection of vibration mechanical energy from the equipment to supplement energy, achieving a dynamic balance between energy supply and demand. The overall energy utilization rate is more than 40% higher than that of traditional single power supply solutions.

[0038] The sensing and acquisition module uses high-precision, low-power sensors, including a vibration sensor with a sampling accuracy of 0.001g, a stress sensor with a measurement accuracy of 0.1MPa, a deformation sensor that can capture micron-level structural deformation, and a temperature sensor with a temperature measurement accuracy of 0.1℃. The collaboration of multiple sensors enables comprehensive and accurate acquisition of the operating status of the wind turbine equipment.

[0039] The data processing and transmission module incorporates a second-order filtering noise reduction algorithm, which can effectively filter out outdoor wind noise, electromagnetic interference and other noise signals, and accurately extract fault characteristics such as loose bolts, structural cracks and fatigue deformation; the wireless transmission unit adopts LoRa low-power wireless transmission technology, which has a long transmission distance and strong anti-interference ability, and is suitable for the long-distance data transmission needs of wind farms; the local storage module uses a large-capacity Flash storage chip, which can store massive amounts of monitoring data for a long time and ensure data traceability.

[0040] Example 2: Specific Implementation Process of Monitoring Method

[0041] In practical applications, the monitoring method of the present invention first completes the installation and calibration of the device: the integrated monitoring housing is attached to the position of the flange bolt group of the wind turbine tower, the mating sleeve of the rigid bolt transmission component is fitted onto the outside of the original fixing bolts of the wind turbine, and rigid locking is completed by the positioning and locking structure to ensure a gapless fit, thereby completing the device fixation and initial signal calibration and eliminating the monitoring error caused by installation stress.

[0042] After the device is started, the multi-source energy acquisition module simultaneously activates its working mode. The piezoelectric vibration acquisition unit captures the vibration energy of the wind turbine, while the wind and solar energy acquisition units simultaneously collect ambient micro-energy, completing the real-time conversion and output of multi-source energy. The energy optimization and scheduling module monitors the output power of each energy source and the device's operating power consumption in real time, dynamically adjusting the power supply strategy to achieve optimal energy allocation and minimize the device's static power consumption and dynamic energy consumption.

[0043] During wind turbine operation, physical signals such as vibration, stress, and micro-deformation generated by the equipment are directly transmitted to each sensor through the rigid main path of the rigid bolt transmission component. The sensor collects multi-dimensional raw state data in real time at a sampling frequency of 100Hz. There is no signal attenuation or phase shift during the acquisition process, and the data is highly authentic.

[0044] The data processing and transmission module performs real-time preprocessing on the raw data, removes environmental interference noise through filtering algorithms, removes random error data through outlier removal algorithms, and further extracts fault characteristic parameters of equipment operation, including core fault indicators such as vibration main frequency deviation, stress amplitude mutation, and excessive structural deformation.

[0045] The pre-processed valid data is stored in the local storage module in real time to form a local data ledger; on the other hand, it is uploaded to the background monitoring platform through the LoRa wireless transmission unit. The operation and maintenance personnel can view the operating status of each monitoring part of the wind turbine in real time through the platform. The system can automatically realize abnormal warnings based on the fault characteristic parameter thresholds and predict potential equipment failure risks in advance.

[0046] The device performs a complete cycle of data acquisition, scheduling, monitoring, and transmission. It can dynamically adjust the data acquisition frequency and energy acquisition priority according to the wind turbine's operating load. When the wind turbine is under high load, the acquisition frequency is increased, and when it is under low load and static operation, the power consumption is reduced, achieving the optimal balance between monitoring accuracy and energy consumption, and meeting the routine monitoring needs of the wind turbine throughout its entire life cycle.

Claims

1. A wind turbine attached condition monitoring device based on rigid bolt main transmission path and multi-source energy optimization, characterized in that: The system includes an attached integrated monitoring housing, a rigid bolt transmission assembly, a multi-source energy acquisition module, an energy optimization scheduling module, a sensor acquisition module, a data processing and transmission module, and a local storage module. The attached integrated monitoring housing is a sealed and lightweight structure that is attached to key monitoring parts of the wind turbine. The rigid bolt transmission assembly is installed inside the attached integrated monitoring housing and rigidly connects to the existing fixing bolts of the wind turbine to establish a rigid main signal transmission and force transmission path. The multi-source energy acquisition module, energy optimization scheduling module, sensor acquisition module, data processing and transmission module, and local storage module are all integrated inside the attached integrated monitoring housing. The multi-source energy acquisition module and the sensor acquisition module are electrically connected to the energy optimization scheduling module, and the sensor acquisition module and the local storage module are both electrically connected to the data processing and transmission module.

2. The wind turbine attached condition monitoring device based on rigid bolt main transmission path and multi-source energy optimization according to claim 1, characterized in that: The rigid bolt transmission assembly includes a docking sleeve, a rigid transmission rod, and a positioning and locking structure. The docking sleeve is fitted onto the outside of the original fixing bolts of the fan, and the positioning and locking structure achieves a gapless rigid fit. One end of the rigid transmission rod is fixedly connected to the docking sleeve, and the other end is rigidly docked with the sensing probe of the sensing acquisition module, which is used to transmit the vibration, stress, and micro-deformation physical signals of the fan equipment without attenuation.

3. The wind turbine attached condition monitoring device based on rigid bolt main transmission path and multi-source energy optimization according to claim 1, characterized in that: The multi-source energy acquisition module includes a vibration energy acquisition unit, a wind energy acquisition unit, and a solar energy acquisition unit. The vibration energy acquisition unit is attached to the rigid transmission rod and is used to acquire the mechanical energy of the wind turbine's vibration. The wind energy acquisition unit is located on the windward side of the attached integrated monitoring housing and is used to acquire ambient wind energy. The solar energy acquisition unit is embedded in the outer surface of the attached integrated monitoring housing and is used to acquire solar energy.

4. The wind turbine attached condition monitoring device based on rigid bolt main transmission path and multi-source energy optimization according to claim 1, characterized in that: The energy optimization scheduling module incorporates an energy voltage stabilization unit, an energy allocation algorithm unit, and a power consumption matching unit. The energy voltage stabilization unit is used to rectify, stabilize, and filter multi-source collected power. The energy allocation algorithm unit is used to dynamically adjust the output ratio of various energy types based on the environmental energy supply status and the real-time operating power consumption of the device. The power consumption matching unit is used to achieve dynamic matching between energy supply and monitored power consumption.

5. The wind turbine attached condition monitoring device based on rigid bolt main transmission path and multi-source energy optimization according to claim 1, characterized in that: The sensing and acquisition module includes vibration sensors, stress sensors, deformation sensors, and temperature sensors. All sensor probes are rigidly attached to the rigid transmission rod to synchronously acquire multi-dimensional status data of the fan equipment, including vibration amplitude, stress changes, structural deformation, and operating temperature.

6. The wind turbine attached condition monitoring device based on rigid bolt main transmission path and multi-source energy optimization according to claim 1, characterized in that: The data processing and transmission module has a built-in signal filtering unit, data noise reduction unit, fault feature extraction unit and wireless transmission unit, which are used to perform noise reduction filtering, outlier removal and fault feature extraction on the original monitoring data, and remotely upload the processed valid data to the background monitoring platform.