A wind turbine generator transmission system instantaneous angular acceleration testing device and method

Abstract

The application discloses a kind of wind turbine drive system instantaneous angular acceleration testing devices in the field of wind power device detection, comprising: high-speed shaft acquisition component, be located on the high-speed output shaft of wind power gear box;Low-speed shaft acquisition component, be located on the low-speed input shaft of wind power gear box;Acquisition controller is electrically connected with high-speed shaft acquisition component, low-speed shaft acquisition component respectively;And a kind of testing method;The beneficial effects of the application are that: by simultaneously setting up magnetic grid sensor and eddy current sensor on the same shaft, form double-channel data, the data of two channels can be verified each other, can effectively improve the precision of instantaneous speed data, to obtain more accurate angular acceleration of shaft, and high-speed shaft high-frequency instantaneous speed synchronous acquisition, eliminate the phase error introduced by asynchronous sampling or according to transmission ratio conversion interpolation alignment, can more accurately judge the fault inside gear box and carry out real-time monitoring to the non-fault operation state of gear box.

Description

Technical Field

[0001] This invention relates to the field of wind power equipment testing, specifically to a device and method for testing the instantaneous angular acceleration of a wind turbine transmission system. Background Technology

[0002] my country boasts abundant wind energy resources, and wind power generation has become an important component of the country's renewable energy system. Driven by the construction of new power systems, the entire wind power industry chain has developed rapidly, now forming a complete manufacturing and operation and maintenance system covering wind turbines, blades, bearings, gearboxes, generators, and converters. As wind turbine units become increasingly larger, their structures more flexible, and their actual operating conditions more complex, load fluctuations and fatigue accumulation issues in key wind power components are becoming increasingly prominent, directly affecting the reliability of unit operation and driving up maintenance costs. The wind turbine gear transmission system is the core component for energy transmission in wind turbine units, operating under harsh conditions of variable speed and load. The dynamic response and instantaneous speed evolution of its planetary gear meshing pairs are key factors determining the operational stability and service life of the transmission system.

[0003] The angular velocity signal of a gearbox contains a wealth of dynamic characteristic information and is a direct physical quantity characterizing the torque impact and torsional vibration of the transmission system. It is extremely sensitive to the early fault characteristics of rotating components such as gears and bearings. Simultaneously, angular velocity is also a core input parameter for conducting torsional vibration characteristic analysis and dynamic load assessment of the transmission system, providing data support for unit structure optimization and control strategy iteration. High-precision angular acceleration signals can be calculated from the high-frequency acquired velocity signals. When defects such as local pitting or broken teeth occur in gears, or when bearing raceways peel off, transient impacts are generated during component meshing and rolling. These impacts are reflected in the angular acceleration signal as high-frequency abrupt changes. Based on this characteristic, early fault warning and precise fault location can be achieved. Furthermore, the measured angular acceleration data can be used for transmission system dynamic parameter identification, completing model calibration of key parameters such as bearing stiffness, damping, and gear meshing stiffness, ensuring a high degree of matching between the simulation model and the characteristics of the actual equipment.

[0004] To address this, we propose a device and method for testing the instantaneous angular acceleration of a wind turbine transmission system. Summary of the Invention

[0005] To address the aforementioned shortcomings of the prior art, this invention provides a device and method for testing the instantaneous angular acceleration of a wind turbine transmission system.

[0006] To achieve the above-mentioned objectives, the technical solution adopted by this invention is as follows: A device for testing the instantaneous angular acceleration of a wind turbine transmission system includes: a high-speed shaft acquisition component, mounted on the high-speed output shaft of the wind turbine gearbox, which acquires instantaneous rotational speed data of the high-speed output shaft through magnetic and inductive signals; a low-speed shaft acquisition component, mounted on the low-speed input shaft of the wind turbine gearbox, which acquires instantaneous rotational speed data of the low-speed input shaft through magnetic and inductive signals; and an acquisition controller, which is electrically connected to the high-speed shaft acquisition component and the low-speed shaft acquisition component respectively.

[0007] By setting up high-speed and low-speed shaft acquisition components, and simultaneously acquiring instantaneous speed data of each shaft using two signals within the acquisition component, the two signals can be mutually verified, improving the accuracy of instantaneous speed data detection. The controller processes the signals acquired by the high-speed and low-speed shaft acquisition components to output the angular acceleration of the corresponding shaft. More accurate instantaneous speed data input can yield more accurate angular acceleration of the corresponding shaft, enabling more accurate detection of faults inside the wind turbine gearbox.

[0008] Further defining, the high-speed shaft acquisition component includes a first mounting base, a first magnetic grating sensor, a first eddy current sensor, and a first gear disk; The first gear is connected to the high-speed output shaft of the wind turbine gearbox via the first flange. The first mounting base is located on a platform directly below the high-speed output shaft of the wind turbine gearbox. The first mounting base includes a first vertical plate and a second vertical plate spaced apart along the axial direction of the high-speed output shaft. A first magnetic grating sensor is fixedly mounted on the first vertical plate to collect instantaneous rotational speed data of the high-speed output shaft. A first eddy current sensor is fixedly mounted on the second vertical plate, and the acquisition probe is located directly below the teeth of the first gear.

[0009] The high-speed shaft of the wind turbine gearbox extends out of the gearbox, so the first magnetic grating sensor can directly collect the instantaneous rotational speed data of the high-speed output shaft. The first gear disk is connected to the high-speed output shaft and rotates synchronously with the high-speed output shaft. The instantaneous rotational speed data of the first gear disk is collected by the first eddy current sensor. The data from both can form dual-channel data, which can be used to verify each other and improve the accuracy of the data.

[0010] Further defined, the first magnetic grating sensor includes a first magnetic strip, a first reading head, and a first processor; the first magnetic strip is sleeved on the high-speed output shaft, the back of the housing of the first processor extends upward with a first fixing plate, two first reading heads are provided and symmetrically arranged on the first fixing plate about the axis of the high-speed output shaft, the two first reading heads are electrically connected to the first processor through wires, the first fixing plate is fixedly connected to the first upright plate by bolts, the through hole through which the bolts pass on the first fixing plate is a vertical waist-shaped hole, the through hole through which the bolts pass on the first upright plate is a horizontal waist-shaped hole, and the through hole through which the bolts pass on the first reading head is an inclined arc-shaped waist-shaped hole; the first eddy current sensor is fixedly connected to the second upright plate through the first mounting plate, the first mounting plate is L-shaped, and the first eddy current sensor is fixedly connected to the horizontal plate of the first mounting plate.

[0011] The first magnetic strip is directly fitted onto the high-speed output shaft and rotates synchronously with it. Two first reading heads are symmetrically arranged, and the two reading heads collect the instantaneous rotational speed data of the first magnetic strip. The two reading heads can serve as backups for each other. The collected data is input into the first processor for signal conversion into data that can be processed by the acquisition controller. The first processor is fixed to the first vertical plate by the first fixing plate. The through holes through which the bolts pass have vertical and horizontal oblong holes, allowing the first processor to be adjusted in height and horizontal position on the first vertical plate. The arc-shaped oblong holes on the first reading head allow the first reading head to be rotated and adjusted, making it more versatile.

[0012] Further specifying, the low-speed shaft acquisition component includes a second mounting base, a second magnetic grating sensor, a second eddy current sensor, an extension shaft, and a second gear disk; The extension shaft is connected to the low-speed input shaft via a flange. The second gear is fixedly mounted on the end of the extension shaft. Both the extension shaft and the second gear are hollow. The second mounting base is located on the platform directly below the extension shaft. The second mounting base includes a vertical third plate. The second magnetic grating sensor is fixedly mounted on the front of the third plate to collect the instantaneous rotational speed data of the extension shaft. The second eddy current sensor is fixedly mounted on the back of the third plate, and the acquisition probe is located directly below the teeth of the second gear.

[0013] Since the low-speed input shaft does not extend out of the wind turbine gearbox, an extension shaft that rotates synchronously with the low-speed input shaft is added. Both the second gear and the extension shaft are hollow to avoid affecting the wiring inside the originally hollow low-speed input shaft. The second magnetic grating sensor collects the instantaneous rotational speed data of the extension shaft, and the second eddy current sensor collects the instantaneous rotational speed data of the second gear. The dual-channel data can be mutually verified to improve the accuracy of the data.

[0014] Further defining the second magnetic grating sensor, it includes a second magnetic strip, a second reading head, and a second processor. The second magnetic strip is sleeved on the high-speed output shaft. A second fixing plate extends upward from the back of the housing of the second processor. Two second reading heads are symmetrically arranged on the second fixing plate about the axis of the extension shaft. The two second reading heads are electrically connected to the second processor via wires. The second fixing plate is fixedly connected to the third vertical plate by bolts. The through holes through which the bolts pass on the second fixing plate are vertical oblong holes. The through holes through which the bolts pass on the third vertical plate are horizontal oblong holes. The through holes through which the bolts pass on the second reading heads are inclined arc-shaped oblong holes. The second eddy current sensor is fixedly connected to the second vertical plate via a second mounting plate. The second mounting plate is L-shaped, and the second eddy current sensor is fixedly connected to the horizontal plate of the second mounting plate.

[0015] The second magnetic strip is directly fitted onto the extension shaft and rotates synchronously with it. Two second reading heads are symmetrically arranged, and the two reading heads collect the instantaneous rotational speed data of the second magnetic strip. The two reading heads can serve as backups for each other. The collected data is input into the second processor for signal conversion into data that can be processed by the acquisition controller. The second processor is fixed to the third vertical plate by the second fixing plate. The through holes through which the bolts pass have vertical and horizontal oblong holes, allowing the second processor to be adjusted in height and horizontal position on the third vertical plate. The arc-shaped oblong holes on the second reading heads allow the second reading heads to be rotated and adjusted, making them more versatile.

[0016] Furthermore, the acquisition controller is electrically connected to both the first processor and the second processor.

[0017] A testing method, using the aforementioned instantaneous angular acceleration testing device for wind turbine transmission systems to test the instantaneous angular acceleration of the high-speed and low-speed shafts of a wind turbine gearbox, includes the following steps: S1. Sensor Adaptor Installation: Corresponding magnetic grating sensors and eddy current sensors are evenly deployed at monitoring positions on the high-speed output shaft and / or extension shaft of the wind turbine gearbox. The magnetic grating sensors and eddy current sensors on the same shaft form a dual-channel independent acquisition link, with the magnetic grating sensor channel designated as Channel 1 and the eddy current sensor channel as Channel 2. The preset effective angle division per revolution of the extension shaft is [number of graduations]. The effective angle division per revolution of the high-speed output shaft is as follows: The theoretical angular displacement corresponding to two adjacent effective edges of a single axis is defined as follows: , N To divide the effective angle per revolution of the extension shaft or high-speed output shaft into several graduations, take the following values ​​when testing the extension shaft: When testing the high-speed output shaft, take ; S2. Dual-channel synchronous sampling from the same source: By synchronously outputting a common sampling clock and synchronous trigger signal to channels one and two on the same axis through the acquisition controller, a unified sampling time reference for the two channels is established, and the sampling frequencies of the magnetic grating sensor and the eddy current sensor are set to [value missing]. Initial sampling time Then the first Each sampling time Obtain the original signal sequence of the two channels. n The sampling point number: ; in, , These are the original sampled signals from channel one and channel two, respectively. , These are the effective measurement components of the rotating shaft motion for Channel 1 and Channel 2, respectively. , These are the interference components for channel one and channel two, respectively. S3. Feature event extraction and timestamp sequence generation: Extraction of the original sampled signals from channel one and channel two. , Zero-crossing detection, peak extraction, and Schmitt shaping are employed for shaping filtering and threshold discrimination to eliminate signal clutter and invalid interference. Simultaneously, linear interpolation is used to calculate the subsampling-level edge time as the valid edge time. ; ; in, For the time of two adjacent sampling points during linear interpolation, ... The time of the two sampling points The corresponding sampling signal amplitude, The threshold value for the amplitude of the sampled signal; The effective edge time series of the original sampled signals acquired by channel one and channel two on the extended axis were obtained respectively. , And the effective edge time series of the original sampled signals acquired by Channel 1 and Channel 2 on the high-speed output shaft. , ; Calculate the time interval between two adjacent valid edge moments in the valid edge time series. , k The edge timestamps of the valid edge time series are used to obtain the general time interval series. , Effective edge sampling time; S4. Instantaneous rotational speed parameter calculation: based on theoretical angular displacement and time interval Calculate the instantaneous angular velocities of channel one and channel two corresponding to the extended axis, respectively. and instantaneous speed The instantaneous angular velocities of channels one and two corresponding to the high-speed output shaft. and instantaneous speed ; instantaneous angular velocity of the extended axis and instantaneous speed for: ; ; Instantaneous angular velocity of high-speed output shaft and instantaneous speed for: ; ; in, The first time series acquired within the effective edge time series corresponding to the extended axis k One valid edge time, The first time series acquired within the effective edge time series corresponding to the extended axis k +1 valid edge time, The first time sequence acquired within the effective edge time series corresponding to the high-speed output shaft k One valid edge time, The first time sequence acquired within the effective edge time series corresponding to the high-speed output shaft k +1 valid edge time; For general time interval sequences Outlier removal and smoothing are performed to obtain the noise-corrected time interval. instantaneous angular velocity about the extended axis and the instantaneous angular velocity of the high-speed output shaft After correction, the instantaneous angular velocities of channel one and channel two corresponding to the corrected extended axis are obtained. The instantaneous angular velocities of channels one and two corresponding to the corrected high-speed output shaft. ; ; in, These are the noise-corrected time intervals for the extended axis and the high-speed output axis, respectively. Take the sampling time of two adjacent valid edges The midpoint is taken as the instantaneous angular velocity. Instantaneous angular velocity Corresponding timing mark and marked with time sequence As the corresponding timing moments of the instantaneous angular velocity, the corrected instantaneous angular velocity sequences corresponding to the extended axis and the high-speed output axis are obtained; S5. Instantaneous Angular Acceleration Calculation and Dual-Channel Timing Alignment Calibration: Discrete instantaneous angular acceleration is calculated using the finite difference method based on the corrected instantaneous angular velocity sequence. ; in, , The time step corresponding to the corrected instantaneous angular velocity; Under high sampling density conditions, instantaneous angular acceleration is equivalent to the first derivative of angular velocity with respect to time, satisfying the definition of the continuous domain. Based on the same physical angle mark on the axis, Calculate the dual-channel edge time difference based on the two valid edge timestamps with the same edge time series. , to obtain K Two-channel edge time difference sequence, For the first channel Each edge timestamp corresponds to a valid edge time. For the second channel Each edge timestamp corresponds to a valid edge moment; Pick The dual-channel edge time difference corresponding to each edge timestamp The average value is used to obtain the fixed delay deviation of the dual-channel acquisition link. Using delay deviation For all valid edge times of channel two Perform translation compensation and alignment; the effective edge time of channel two after compensation and alignment is... , This is the timestamp of the complete edge time sequence in Channel 2. , This represents the total number of timestamps for the edge moments collected by Channel 2. The effective edge time of channel 2 after compensation and alignment As a unified verification time sequence for Channel 1 and Channel 2 And based on the verification time series The instantaneous angular velocities corrected for Channel 1 and Channel 2 are resampled to obtain the resampled instantaneous angular velocities for Channel 1 and Channel 2. , ; For verifying time series The verification time in the middle, q The timestamp for the verification time; The angular velocity sequences of channels 1 and 2 corresponding to the extended axis and channels 1 and 2 corresponding to the high-speed output axis were aligned and resampled into the same verification time sequence. , , The total number of samples for consistency verification; S6. Dual-channel signal fusion and consistency verification: Weighting coefficients are set based on the signal-to-noise ratio and calibration accuracy of channel one and channel two, respectively. Instantaneous angular velocity , Weighted fusion is performed to obtain a unified verification time. Fusion instantaneous angular velocity : ; Based on fused instantaneous angular velocity Calculate the final fusion instantaneous angular acceleration : ; The final fused instantaneous angular velocity of the extended axis is obtained. The final fusion instantaneous angular velocity with the high-speed output shaft And the final fusion instantaneous angular acceleration of the extended axis. The final fusion instantaneous angular acceleration with the high-speed output shaft ; Calculate the same verification time again Instantaneous error of angular velocity consistency in lower dual channels The root mean square error (RMSE) was used to quantify and evaluate the synchronization consistency coefficient of the dual channels. ; ; A preset root mean square error threshold is set when the calculated value is... When the preset threshold is exceeded, it is determined that there is a sensor malfunction, shaft installation deviation, code disk contamination or signal pulse loss problem, and the abnormal signal rejection and sensor recalibration process is automatically triggered. At the same time, the rated transmission ratio of the wind turbine gearbox is set as follows: The actual operating transmission ratio is defined as The fluctuation deviation of the instantaneous transmission ratio relative to the rated value Through fluctuation deviation The dynamic stability of the transmission chain is evaluated; the final output is the instantaneous speed and instantaneous angular acceleration test results of the tested shaft after time alignment, weighted fusion and consistency verification.

[0018] This method enables synchronous acquisition of high-frequency instantaneous rotational speeds of the high and low speed shafts of wind turbine gearboxes, eliminating phase errors introduced by asynchronous sampling or interpolation alignment based on transmission ratio. It can more accurately acquire dynamic fluctuations of dynamic errors, significantly improving the signal-to-noise ratio of weak fault characteristics such as gear meshing stiffness changes, micro-deceleration impacts caused by local defects, and tooth profile error modulation. It can reliably identify early faults and accurately monitor the operating status of wind turbine transmission systems. Even under non-stationary operating conditions such as variable speed and variable load, it can still perform accurate order tracking and angular domain resampling, which is particularly important for testing that simulates the variable wind speed operating conditions of real wind farms. This invention is not only suitable for bench tests but can also be extended to online monitoring in wind farms.

[0019] The beneficial effects of this invention are as follows: by simultaneously setting a magnetic grating sensor and an eddy current sensor on the same shaft, dual-channel data is formed. The data from the two channels can be mutually verified, which can effectively improve the accuracy of instantaneous speed data, thereby obtaining a more accurate angular acceleration of the shaft. Furthermore, the high-frequency instantaneous speed of the high and low speed shafts is collected synchronously, eliminating the phase error introduced by asynchronous sampling or interpolation alignment based on the transmission ratio. This enables more accurate judgment of internal faults in the gearbox and real-time monitoring of the non-faulty operating status of the gearbox. Attached Figure Description

[0020] Figure 1 This is a three-dimensional schematic diagram of the present invention; Figure 2 A three-dimensional schematic diagram of the front view of the low-speed axis acquisition component; Figure 3 A 3D schematic diagram of the back view of the low-speed axis acquisition component; Figure 4 This is a diagram showing the connection relationships of the electrical components in this invention.

[0021] The symbols for each component are as follows: High-speed shaft acquisition assembly 1, first mounting base 11, first vertical plate 111, second vertical plate 112, first magnetic grating sensor 12, first magnetic strip 121, first reading head 122, first processor 123, first fixing plate 124, first eddy current sensor 13, first mounting plate 131, first gear 14; Low-speed shaft acquisition assembly 2, second mounting base 21, third vertical plate 211, second magnetic grating sensor 22, second magnetic strip 221, second reading head 222, second processor 223, second fixing plate 224, second eddy current sensor 23, second mounting plate 231, extension shaft 24, second gear 25, acquisition controller 3. Detailed Implementation

[0022] The specific embodiments of the present invention are described below to enable those skilled in the art to understand the present invention. However, it should be understood that the present invention is not limited to the scope of the specific embodiments. For those skilled in the art, various changes are obvious as long as they are within the spirit and scope of the present invention as defined and determined by the appended claims. All inventions utilizing the concept of the present invention are protected.

[0023] Example: like Figures 1-4 As shown, a wind turbine transmission system instantaneous angular acceleration testing device includes a high-speed shaft acquisition component 1, a low-speed shaft acquisition component 2, and an acquisition controller 3. The high-speed shaft acquisition component 1 acquires instantaneous rotational speed data of the high-speed output shaft through magnetic signals and inductive signals. The high-speed shaft acquisition component 1 includes a first mounting base 11, a first magnetic grating sensor 12, a first eddy current sensor 13, and a first gear disk 14. The first gear disk 14 is connected to the high-speed output shaft of the wind turbine gearbox through a first flange. The first mounting base 11 is located on a platform directly below the high-speed output shaft of the wind turbine gearbox. The first mounting base 11 includes a first vertical plate 111 and a second vertical plate 112 spaced apart along the axial direction of the high-speed output shaft. The first eddy current sensor 13 is fixedly mounted on the second vertical plate 112, and the acquisition probe is located directly below the teeth of the first gear disk 14. The first magnetic grating sensor 12 includes a first magnetic strip 121, a first reading head 122, and a first processor 123. The first magnetic strip 121 is sleeved on the high-speed output shaft. The back of the housing of the first processor 123 extends upward with a first fixing plate 124. Two first reading heads 122 are provided and symmetrically arranged on the first fixing plate 124 about the axis of the high-speed output shaft. The two first reading heads 122 are electrically connected to the first processor 123 through wires. The first fixing plate 124 is fixedly connected to the first vertical plate 111 by bolts. The through holes through which the bolts pass on the first fixing plate 124 are vertical waist-shaped holes. The through holes through which the bolts pass on the first vertical plate 111 are horizontal waist-shaped holes. The through holes through which the bolts pass on the first reading head 122 are inclined arc-shaped waist-shaped holes. The first eddy current sensor 13 is fixedly connected to the second vertical plate 112 through a first mounting plate 131. The first mounting plate 131 is L-shaped, and the first eddy current sensor 13 is fixedly connected to the horizontal plate of the first mounting plate 131. The low-speed shaft acquisition component 2 acquires instantaneous rotational speed data of the low-speed input shaft through magnetic and inductive signals. The low-speed shaft acquisition component 2 includes a second mounting base 21, a second magnetic grating sensor 22, a second eddy current sensor 23, an extension shaft 24, and a second gear disk 25. The extension shaft 24 is connected to the low-speed input shaft through a flange, and the second gear disk 25 is fixedly installed at the end of the extension shaft 24. Both the extension shaft 24 and the gear disk 25 are hollow. The second mounting base 21 is located on a platform directly below the extension shaft 24. The second mounting base 21 includes a vertical third plate 211. The second eddy current sensor 23 is fixedly installed on the back of the third plate 211, and the acquisition probe is located directly below the teeth of the second gear disk 25. The second magnetic grating sensor 22 includes a second magnetic strip 221, a second reading head 222, and a second processor 223. The second magnetic strip 221 is sleeved on the high-speed output shaft. The back of the housing of the second processor 223 extends upward with a second fixing plate 224. Two second reading heads 222 are symmetrically arranged on the second fixing plate 224 about the axis of the extension shaft 24. The two second reading heads 222 are electrically connected to the second processor 223 through wires. The second fixing plate 224 is fixedly connected to the third vertical plate 211 by bolts. The through hole through which the bolts pass on the second fixing plate 224 is a vertical waist-shaped hole. The through hole through which the bolts pass on the third vertical plate 211 is a horizontal waist-shaped hole. The through hole through which the bolts pass on the second reading head 222 is an inclined arc-shaped waist-shaped hole. The second eddy current sensor 23 is fixedly connected to the second vertical plate 112 through a second mounting plate 231. The second mounting plate 231 is L-shaped, and the second eddy current sensor 23 is fixedly connected to the horizontal plate of the second mounting plate 231.

[0024] The data acquisition controller 3 is electrically connected to the first processor 123 and the second processor 223.

[0025] By setting up a high-speed shaft acquisition component 1 and a low-speed shaft acquisition component 2, and simultaneously acquiring instantaneous speed data of each shaft through two signals within the acquisition component, the two signals can be mutually verified, improving the accuracy of instantaneous speed data detection. The controller processes the signals acquired by the high-speed shaft acquisition component 1 and the low-speed shaft acquisition component 2 to output the angular acceleration of the corresponding shaft. More accurate instantaneous speed data input can yield more accurate angular acceleration of the corresponding shaft, enabling more accurate detection of faults inside the wind turbine gearbox. The high-speed shaft of the wind turbine gearbox extends out of the gearbox, so the first magnetic grating sensor 12 can directly acquire the instantaneous speed data of the high-speed output shaft. A first gear disk 14 is connected to the high-speed output shaft. The gear disk 14 rotates synchronously with the high-speed output shaft. The instantaneous rotational speed data of the first gear disk 14 is collected by the first eddy current sensor 13. The data from both can form dual-channel data, which can be used to verify each other and improve the accuracy of the data. The first magnetic strip 121 is directly sleeved on the high-speed output shaft and rotates synchronously with the high-speed output shaft. Two first reading heads 122 are symmetrically arranged. The two reading heads collect the instantaneous rotational speed data of the first magnetic strip 121. The two reading heads can serve as backups for each other. The collected data is input into the first processor 123 for signal conversion into data that can be processed by the acquisition controller 3. The first processor 123 is fixed to the first vertical plate 111 by the first fixing plate 124. The through hole through which the bolt passes has a vertical waist shape. The horizontal oblong hole allows the first processor 123 to be adjusted horizontally on the first vertical plate 111. The arc-shaped oblong hole on the first reading head 122 allows the first reading head 122 to be rotated and adjusted, making it more versatile. The low-speed input shaft does not extend out of the wind turbine gearbox, so an extension shaft 24 that rotates synchronously with the low-speed input shaft is added. The second gear disk 25 and the extension shaft 24 are both hollow to avoid affecting the wiring inside the originally hollow low-speed input shaft. The second magnetic grating sensor 22 collects the instantaneous speed data of the extension shaft 24, and the second eddy current sensor 23 collects the instantaneous speed data of the second gear disk 25. The dual-channel data can be mutually verified to improve the accuracy of the data. The strip 221 is directly fitted onto the extension shaft 24 and rotates synchronously with the extension shaft 24. Two second reading heads 222 are symmetrically arranged. The two reading heads collect the instantaneous rotational speed data of the second magnetic strip 221. The two reading heads can serve as backups for each other. The collected data is input into the second processor 223 for signal conversion into data that can be processed by the acquisition controller 3. The second processor 223 is fixed to the third vertical plate 211 through the second fixing plate 224. The through holes through which the bolts pass have vertical and horizontal oblong holes, allowing the second processor 223 to be adjusted in height and horizontal position on the third vertical plate 211. The arc-shaped oblong holes on the second reading head 222 allow the second reading head 222 to be rotated and adjusted, making it more versatile.

[0026] A testing method, using the aforementioned instantaneous angular acceleration testing device for wind turbine transmission systems to test the instantaneous angular acceleration of the high-speed and low-speed shafts of a wind turbine gearbox, includes the following steps: S1. Sensor Adaptor Installation: Corresponding magnetic grating sensors and eddy current sensors are evenly deployed at the monitoring positions on the high-speed output shaft and / or extension shaft 24 of the wind turbine gearbox. The magnetic grating sensors and eddy current sensors on the same shaft form a dual-channel independent acquisition link, with the magnetic grating sensor channel designated as Channel 1 and the eddy current sensor channel as Channel 2. The preset effective angle division per revolution of the extension shaft 24 is [number missing]. The effective angle division per revolution of the high-speed output shaft is as follows: The theoretical angular displacement corresponding to two adjacent effective edges of a single axis is defined as follows: , N To divide the effective angle per revolution of the extension shaft 24 or the high-speed output shaft into graduations, the following values ​​are used when testing the extension shaft 24: When testing the high-speed output shaft, take ; S2. Dual-channel synchronous sampling from the same source: By synchronously outputting a common sampling clock and synchronous trigger signal to channels one and two on the same axis through the acquisition controller 3, a unified sampling time reference for the two channels is established, and the sampling frequencies of the magnetic grating sensor and the eddy current sensor are set to [value missing]. Initial sampling time Then the first Each sampling time Obtain the original signal sequence of the two channels. n The sampling point number: ; in, , These are the original sampled signals from channel one and channel two, respectively. , These are the effective measurement components of the rotating shaft motion for Channel 1 and Channel 2, respectively. , These are the interference components for channel one and channel two, respectively. S3. Feature event extraction and timestamp sequence generation: Extraction of the original sampled signals from channel one and channel two. , Zero-crossing detection, peak extraction, and Schmitt shaping are employed for shaping filtering and threshold discrimination to eliminate signal clutter and invalid interference. Simultaneously, linear interpolation is used to calculate the subsampling-level edge time as the valid edge time. ; ; in, For the time of two adjacent sampling points during linear interpolation, ... The time of the two sampling points The corresponding sampling signal amplitude, The threshold value for the amplitude of the sampled signal; The effective edge time series of the original sampled signals acquired by channel one and channel two on the extended axis 24 were obtained respectively. , And the effective edge time series of the original sampled signals acquired by Channel 1 and Channel 2 on the high-speed output shaft. , ; Calculate the time interval between two adjacent valid edge moments in the valid edge time series. , k The edge timestamps of the valid edge time series are used to obtain the general time interval series. , Effective edge sampling time; S4. Instantaneous rotational speed parameter calculation: based on theoretical angular displacement and time interval Calculate the instantaneous angular velocities of channel one and channel two corresponding to the extended axis 24, respectively. and instantaneous speed The instantaneous angular velocities of channels one and two corresponding to the high-speed output shaft. and instantaneous speed ; Instantaneous angular velocity of extension axis 24 and instantaneous speed for: ; ; Instantaneous angular velocity of high-speed output shaft and instantaneous speed for: ; ; in, The first time series acquired within the effective edge time series corresponding to extended axis 24 k One valid edge time, The first time series acquired within the effective edge time series corresponding to extended axis 24 k +1 valid edge time, The first time sequence acquired within the effective edge time series corresponding to the high-speed output shaft k One valid edge time, The first time sequence acquired within the effective edge time series corresponding to the high-speed output shaft k+1 valid edge time; For general time interval sequences Outlier removal and smoothing are performed to obtain the noise-corrected time interval. The instantaneous angular velocity about the extension axis 24 and the instantaneous angular velocity of the high-speed output shaft After correction, the instantaneous angular velocities of channels one and two corresponding to the corrected extended axis 24 are obtained. The instantaneous angular velocities of channels one and two corresponding to the corrected high-speed output shaft. ; ; in, These are the noise-reduced time intervals corresponding to the extension axis 24 and the high-speed output axis, respectively. Take the sampling time of two adjacent valid edges The midpoint is taken as the instantaneous angular velocity. Instantaneous angular velocity Corresponding timing mark and marked with time sequence As the corresponding timing moments of the instantaneous angular velocity, the corrected instantaneous angular velocity sequences corresponding to the extended axis 24 and the high-speed output axis are obtained; S5. Instantaneous Angular Acceleration Calculation and Dual-Channel Timing Alignment Calibration: Discrete instantaneous angular acceleration is calculated using the finite difference method based on the corrected instantaneous angular velocity sequence. ; in, , The time step corresponding to the corrected instantaneous angular velocity; Under high sampling density conditions, instantaneous angular acceleration is equivalent to the first derivative of angular velocity with respect to time, satisfying the definition of the continuous domain. Based on the same physical angle mark on the axis, Calculate the dual-channel edge time difference based on the two valid edge timestamps with the same edge time series. , to obtain K Two-channel edge time difference sequence, For the first channel Each edge timestamp corresponds to a valid edge time. For the second channel Each edge timestamp corresponds to a valid edge moment; Pick The dual-channel edge time difference corresponding to each edge timestamp The average value is used to obtain the fixed delay deviation of the dual-channel acquisition link. Using delay deviation For all valid edge times of channel two Perform translation compensation and alignment; the effective edge time of channel two after compensation and alignment is... , This is the timestamp of the complete edge time sequence in Channel 2. , This represents the total number of timestamps for the edge moments collected by Channel 2. The effective edge time of channel 2 after compensation and alignment As a unified verification time sequence for Channel 1 and Channel 2 And based on the verification time series The instantaneous angular velocities corrected for Channel 1 and Channel 2 are resampled to obtain the resampled instantaneous angular velocities for Channel 1 and Channel 2. , ; For verifying time series The verification time in the middle, q The timestamp for the verification time; The angular velocity sequences of channels 1 and 2 corresponding to the extension axis 24 and channels 1 and 2 corresponding to the high-speed output axis are uniformly resampled into the same verification time sequence. , , The total number of samples for consistency verification; S6. Dual-channel signal fusion and consistency verification: Weighting coefficients are set based on the signal-to-noise ratio and calibration accuracy of channel one and channel two, respectively. Instantaneous angular velocity , Weighted fusion is performed to obtain a unified verification time. Fusion instantaneous angular velocity : ; Based on fused instantaneous angular velocity Calculate the final fusion instantaneous angular acceleration : ; The final fusion instantaneous angular velocity of the extended axis 24 is obtained. The final fusion instantaneous angular velocity with the high-speed output shaft and the final fusion instantaneous angular acceleration of the extended axis 24. The final fusion instantaneous angular acceleration with the high-speed output shaft ; Calculate the same verification time again Instantaneous error of angular velocity consistency in lower dual channels The root mean square error (RMSE) was used to quantify and evaluate the synchronization consistency coefficient of the dual channels. ; ; A preset root mean square error threshold is set when the calculated value is... When the preset threshold is exceeded, it is determined that there is a sensor malfunction, shaft installation deviation, code disk contamination or signal pulse loss problem, and the abnormal signal rejection and sensor recalibration process is automatically triggered. At the same time, the rated transmission ratio of the wind turbine gearbox is set as follows: The actual operating transmission ratio is defined as The fluctuation deviation of the instantaneous transmission ratio relative to the rated value Through fluctuation deviation The dynamic stability of the transmission chain is evaluated; the final output is the instantaneous speed and instantaneous angular acceleration test results of the tested shaft after time alignment, weighted fusion and consistency verification.

[0027] This method enables synchronous acquisition of high-frequency instantaneous rotational speeds of the high and low speed shafts of wind turbine gearboxes, eliminating phase errors introduced by asynchronous sampling or interpolation alignment based on transmission ratio. It can more accurately acquire dynamic fluctuations of dynamic errors, significantly improving the signal-to-noise ratio of weak fault characteristics such as gear meshing stiffness changes, micro-deceleration impacts caused by local defects, and tooth profile error modulation. It can reliably identify early faults and accurately monitor the operating status of wind turbine transmission systems. Even under non-stationary operating conditions such as variable speed and variable load, it can still perform accurate order tracking and angular domain resampling, which is particularly important for testing that simulates the variable wind speed operating conditions of real wind farms. This invention is not only suitable for bench tests but can also be extended to online monitoring in wind farms.

Claims

1. A device for testing the instantaneous angular acceleration of a wind turbine transmission system, characterized in that, include: The high-speed shaft acquisition component (1) is installed on the high-speed output shaft of the wind turbine gearbox and acquires the instantaneous speed data of the high-speed output shaft through magnetic signals and inductive signals. The low-speed shaft acquisition component (2) is installed on the low-speed input shaft of the wind turbine gearbox and acquires the instantaneous speed data of the low-speed input shaft through magnetic signals and inductive signals. The acquisition controller (3) is electrically connected to the high-speed axis acquisition component (1) and the low-speed axis acquisition component (2), respectively.

2. The instantaneous angular acceleration testing device for wind turbine transmission system according to claim 1, characterized in that, The high-speed shaft acquisition component (1) includes a first mounting base (11), a first magnetic grating sensor (12), a first eddy current sensor (13), and a first gear disk (14). The first gear (14) is connected to the high-speed output shaft of the wind turbine gearbox via the first flange. The first mounting base (11) is located on the platform directly below the high-speed output shaft of the wind turbine gearbox. The first mounting base (11) includes a first vertical plate (111) and a second vertical plate (112) spaced apart along the axial direction of the high-speed output shaft. The first magnetic grating sensor (12) is fixedly mounted on the first vertical plate (111) to collect the instantaneous rotational speed data of the high-speed output shaft. The first eddy current sensor (13) is fixedly mounted on the second vertical plate (112), and the acquisition probe is located directly below the teeth of the first gear (14).

3. The instantaneous angular acceleration testing device for wind turbine transmission system according to claim 2, characterized in that, The first magnetic grating sensor (12) includes a first magnetic strip (121), a first reading head (122), and a first processor (123). The first magnetic strip (121) is sleeved on the high-speed output shaft. A first fixing plate (124) extends upward from the back of the housing of the first processor (123). Two first reading heads (122) are provided and symmetrically arranged on the first fixing plate (124) about the axis of the high-speed output shaft. The two first reading heads (122) are electrically connected to the first processor (123) through wires. The first fixing plate (124) is connected by screws. The bolt is fixedly connected to the first upright plate (111). The through hole through which the bolt passes on the first fixed plate (124) is a vertical waist-shaped hole. The through hole through which the bolt passes on the first upright plate (111) is a horizontal waist-shaped hole. The through hole through which the bolt passes on the first reading head (122) is an inclined arc-shaped waist-shaped hole. The first eddy current sensor (13) is fixedly connected to the second upright plate (112) through the first mounting plate (131). The first mounting plate (131) is L-shaped. The first eddy current sensor (13) is fixedly connected to the horizontal plate of the first mounting plate (131).

4. The instantaneous angular acceleration testing device for wind turbine transmission system according to claim 3, characterized in that, The low-speed shaft acquisition assembly (2) includes a second mounting base (21), a second magnetic grating sensor (22), a second eddy current sensor (23), an extension shaft (24), and a second gear disk (25). The extension shaft (24) is connected to the low-speed input shaft via a flange. The second gear (25) is fixedly mounted on the end of the extension shaft (24). Both the extension shaft (24) and the second gear (25) are hollow. The second mounting base (21) is mounted on a platform directly below the extension shaft (24). The second mounting base (21) includes a vertical third plate (211). The second magnetic grating sensor (22) is fixedly mounted on the front of the third plate (211) to collect the instantaneous rotational speed data of the extension shaft (24). The second eddy current sensor (23) is fixedly mounted on the back of the third plate (211), and the acquisition probe is located directly below the teeth of the second gear (25).

5. The instantaneous angular acceleration testing device for wind turbine transmission system according to claim 4, characterized in that, The second magnetic grating sensor (22) includes a second magnetic strip (221), a second reading head (222), and a second processor (223). The second magnetic strip (221) is sleeved on the high-speed output shaft. A second fixing plate (224) extends upward from the back of the housing of the second processor (223). Two second reading heads (222) are provided and symmetrically arranged on the second fixing plate (224) about the axis of the extension shaft (24). The two second reading heads (222) are electrically connected to the second processor (223) through wires. The second fixing plate (224) is connected to the second processor (223) through wires. The bolts are fixedly connected to the third upright plate (211). The through hole through which the bolts pass on the second fixed plate (224) is a vertical waist-shaped hole. The through hole through which the bolts pass on the third upright plate (211) is a horizontal waist-shaped hole. The through hole through which the bolts pass on the second reading head (222) is an inclined arc-shaped waist-shaped hole. The second eddy current sensor (23) is fixedly connected to the second upright plate (112) through the second mounting plate (231). The second mounting plate (231) is L-shaped. The second eddy current sensor (23) is fixedly connected to the horizontal plate of the second mounting plate (231).

6. The instantaneous angular acceleration testing device for wind turbine transmission system according to claim 5, characterized in that, The acquisition controller (3) is electrically connected to the first processor (123) and the second processor (223).

7. A testing method, comprising using the instantaneous angular acceleration testing device for wind turbine transmission systems as described in claim 6 to test the instantaneous angular acceleration of the high-speed shaft and low-speed shaft of a wind turbine gearbox, characterized in that, Includes the following steps: S1. Sensor Adaptor Installation: Corresponding magnetic grating sensors and eddy current sensors are evenly distributed at the monitoring positions on the high-speed output shaft and / or extension shaft (24) of the wind turbine gearbox. The magnetic grating sensors and eddy current sensors on the same shaft form a dual-channel independent acquisition link, with the magnetic grating sensor channel being Channel 1 and the eddy current sensor channel being Channel 2. The preset effective angle division per revolution of the extension shaft (24) is: The effective angle division per revolution of the high-speed output shaft is as follows: The theoretical angular displacement corresponding to two adjacent effective edges of a single axis is defined as follows: , N To divide the effective angle per revolution of the extension shaft (24) or high-speed output shaft into graduations, when testing the extension shaft (24), take... When testing the high-speed output shaft, take ; S2. Dual-channel synchronous sampling from the same source: By synchronously outputting a common sampling clock and synchronous trigger signal to channels one and two on the same axis through the acquisition controller (3), a unified sampling time reference for the two channels is established, and the sampling frequency of the magnetic grating sensor and the eddy current sensor is set to [value missing]. Initial sampling time Then the first Each sampling time Obtain the original signal sequence of the two channels. n The sampling point number: ； in, , These are the original sampled signals from channel one and channel two, respectively. , These are the effective measurement components of the rotating shaft motion for Channel 1 and Channel 2, respectively. , These are the interference components for channel one and channel two, respectively. S3. Feature event extraction and timestamp sequence generation: Extraction of the original sampled signals from channel one and channel two. , Zero-crossing detection, peak extraction, and Schmitt shaping are employed for shaping filtering and threshold discrimination to eliminate signal clutter and invalid interference. Simultaneously, linear interpolation is used to calculate the subsampling-level edge time as the valid edge time. ; ； in, For the time of two adjacent sampling points during linear interpolation, ... The time of the two sampling points The corresponding sampling signal amplitude, The threshold value for the amplitude of the sampled signal; The effective edge time series of the original sampled signals acquired by channel one and channel two on the extended axis (24) are obtained respectively. , And the effective edge time series of the original sampled signals acquired by Channel 1 and Channel 2 on the high-speed output shaft. , ; Calculate the time interval between two adjacent valid edge moments in the valid edge time series. , k The edge timestamps of the valid edge time series are used to obtain the general time interval series. , This is the effective edge sampling time; S4. Instantaneous rotational speed parameter calculation: based on theoretical angular displacement and time interval Calculate the instantaneous angular velocities of channel one and channel two corresponding to the extended axis (24), respectively. and instantaneous speed The instantaneous angular velocities of channels one and two corresponding to the high-speed output shaft. and instantaneous speed ; Instantaneous angular velocity of extended axis (24) and instantaneous speed for: ； ； Instantaneous angular velocity of high-speed output shaft and instantaneous speed for: ； ； in, The first time sequence acquired within the effective edge time series corresponding to the extended axis (24) k One valid edge time, The first time sequence acquired within the effective edge time series corresponding to the extended axis (24) k +1 valid edge time, The first time sequence acquired within the effective edge time series corresponding to the high-speed output shaft k One valid edge time, The first time sequence acquired within the effective edge time series corresponding to the high-speed output shaft k +1 valid edge time; For general time interval sequences Outlier removal and smoothing are performed to obtain the noise-corrected time interval. The instantaneous angular velocity about the extended axis (24) and the instantaneous angular velocity of the high-speed output shaft After correction, the instantaneous angular velocities of channel one and channel two corresponding to the corrected extended axis (24) are obtained. The instantaneous angular velocities of channels one and two corresponding to the corrected high-speed output shaft. ; ； in, These are the noise-reduced time intervals corresponding to the extended axis (24) and the high-speed output axis, respectively. Take the sampling time of two adjacent valid edges The midpoint is taken as the instantaneous angular velocity. Instantaneous angular velocity Corresponding timing mark and marked with time sequence As the corresponding timing moments of the instantaneous angular velocity, the corrected instantaneous angular velocity sequences corresponding to the extended axis (24) and the high-speed output axis are obtained; S5. Instantaneous Angular Acceleration Calculation and Dual-Channel Timing Alignment Calibration: Discrete instantaneous angular acceleration is calculated using the finite difference method based on the corrected instantaneous angular velocity sequence. ； in, , The time step corresponding to the corrected instantaneous angular velocity; Under high sampling density conditions, instantaneous angular acceleration is equivalent to the first derivative of angular velocity with respect to time, satisfying the definition of the continuous domain. Based on the same physical angle mark on the axis, Calculate the dual-channel edge time difference based on the two valid edge timestamps with the same edge time series. , to obtain K Two-channel edge time difference sequence, For the first channel Each edge timestamp corresponds to a valid edge time. For the second channel Each edge timestamp corresponds to a valid edge moment; Pick The dual-channel edge time difference corresponding to each edge timestamp The average value is used to obtain the fixed delay deviation of the dual-channel acquisition link. Using delay deviation For all valid edge times of channel two Perform translation compensation and alignment; the effective edge time of channel two after compensation and alignment is... , This is the timestamp of the complete edge time sequence in Channel 2. , This represents the total number of timestamps for the edge moments collected by Channel 2. The effective edge time of channel 2 after compensation and alignment As a unified verification time sequence for Channel 1 and Channel 2 And based on the verification time series The instantaneous angular velocities corrected for Channel 1 and Channel 2 are resampled to obtain the resampled instantaneous angular velocities for Channel 1 and Channel 2. , ; For verifying time series The verification time in the middle, q The timestamp for the verification time; The angular velocity sequences of channels 1 and 2 corresponding to the extended axis (24) and channels 1 and 2 corresponding to the high-speed output axis are uniformly resampled into the same verification time sequence. , , The total number of samples is used for consistency verification; S6. Dual-channel signal fusion and consistency verification: Weighting coefficients are set based on the signal-to-noise ratio and calibration accuracy of channel one and channel two, respectively. Instantaneous angular velocity , Weighted fusion is performed to obtain a unified verification time. Fusion instantaneous angular velocity : ； Based on fused instantaneous angular velocity Calculate the final fusion instantaneous angular acceleration : ； The final fusion instantaneous angular velocity of the extended axis (24) is obtained. The final fusion instantaneous angular velocity with the high-speed output shaft , and the final fusion instantaneous angular acceleration of the extended axis (24) The final fusion instantaneous angular acceleration with the high-speed output shaft ; Calculate the same verification time again Instantaneous error of angular velocity consistency in lower dual channels The root mean square error (RMSE) was used to quantify and evaluate the synchronization consistency coefficient of the dual channels. ; ； A preset root mean square error threshold is set when the calculated value is... When the preset threshold is exceeded, it is determined that there is a sensor malfunction, shaft installation deviation, code disk contamination or signal pulse loss problem, and the abnormal signal rejection and sensor recalibration process is automatically triggered. At the same time, the rated transmission ratio of the wind turbine gearbox is set as follows: The actual operating transmission ratio is defined as The fluctuation deviation of the instantaneous transmission ratio relative to the rated value Through fluctuation deviation The dynamic stability of the transmission chain is evaluated; the final output is the instantaneous speed and instantaneous angular acceleration test results of the tested shaft after time alignment, weighted fusion and consistency verification.

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