Method for on-line replacement of generator slip ring carbon brush and synchronous calibration adjustment of coaxiality

Abstract

The present application relates to the field of generator, discloses a method for online replacement and coaxiality synchronous calibration adjustment of generator slip ring carbon brush, which comprises the following steps: positioning the new carbon brush to the working position based on offline calibration when the generator is running; controlling the contact operation of the carbon brush and the slip ring, collecting position information to generate a trajectory, and calculating the actual rotation center; adjusting the installation position according to the position deviation; establishing a feedforward compensation relationship for dynamic fine adjustment; verifying the calibration effect, monitoring key indicators, and triggering a safety process when unqualified; processing the trajectory data and optimizing the planned motion path. The present application realizes the safe and accurate replacement of the carbon brush and the precise calibration of the coaxiality under the running state of the generator, thereby ensuring the stable operation of the generator.

Description

Technical Field

[0001] This invention relates to the field of generators, and more particularly to a method for online replacement of generator slip ring carbon brushes and synchronous calibration and adjustment of coaxiality. Background Technology

[0002] During the operation of thermal power generating units, slip ring carbon brushes, as key conductive components of the excitation system, bear the important task of leading out the rotor current and transmitting it to the external circuit. Their working condition directly affects the operational stability and reliability of the generator. As thermal power units develop towards higher parameters and larger capacities, more stringent requirements are placed on the installation accuracy and operational stability of slip ring carbon brushes.

[0003] Traditionally, slip ring carbon brush replacement usually requires the generator to be shut down. This not only leads to power generation interruption, causing direct power and economic losses, but also, in scenarios where thermal power plants require continuous operation under conditions of deep peak shaving and high load, replacing carbon brushes during shutdown will seriously affect the power grid's reliability and the unit's availability. Therefore, online slip ring carbon brush replacement technology has become a hot research topic in the industry.

[0004] During operation, slip rings can develop coaxiality deviations due to various factors, causing the slip ring's rotation center to deviate from its theoretical center. This deviation leads to uneven contact pressure distribution between the carbon brush and the slip ring, accelerating carbon brush wear, generating electrical sparks, and even causing carbon brush overheating and sparking, seriously threatening the safe and stable operation of thermal power units. Therefore, during online carbon brush replacement, synchronously calibrating and adjusting the slip ring's coaxiality to ensure good contact between the carbon brush and the slip ring is crucial for improving generator operational reliability and extending carbon brush lifespan.

[0005] In terms of slip ring coaxiality calibration, existing technologies typically employ static measurement methods, measuring the slip ring coaxiality while the generator is off. However, during operation, thermal power units experience dynamic deformation of the slip ring due to factors such as temperature, speed, and vibration. Static measurement results cannot accurately reflect the actual coaxiality of the slip ring under operating conditions, resulting in unsatisfactory contact between the calibrated carbon brush and the slip ring, and failing to effectively address carbon brush wear and electrical sparking issues.

[0006] After completing carbon brush replacement and coaxiality calibration, existing technologies lack effective methods to verify the calibration effect. It is impossible to accurately determine whether the contact state between the calibrated carbon brush and slip ring meets the requirements for safe operation, and potential problems cannot be detected and addressed in a timely manner, increasing the safety risks of thermal power unit operation.

[0007] Therefore, we propose a method for online replacement of generator slip ring carbon brushes and synchronous calibration and adjustment of coaxiality to solve the above problems. Summary of the Invention

[0008] This invention provides a method for online replacement of generator slip ring carbon brushes and synchronous calibration and adjustment of coaxiality, which is used to achieve synchronous calibration and adjustment.

[0009] The first aspect of this invention provides a method for online replacement and synchronous coaxiality calibration of generator slip ring carbon brushes. This method includes: based on offline calibration results, positioning a new carbon brush close to the working position of the slip ring while the generator is running; controlling the new carbon brush to maintain contact with the rotating slip ring surface and perform driven operation, synchronously collecting its position information to generate a spatial motion trajectory; calculating the actual rotation center of the slip ring in the running state based on the spatial motion trajectory; performing compensation adjustment on the installation position of the new carbon brush according to the positional deviation between the actual rotation center and the theoretical center; after compensation adjustment, establishing a feedforward compensation relationship based on real-time collected rotation angle and contact force data, and calibrating and adjusting the new carbon brush accordingly.

[0010] Optionally, in a first implementation of the first aspect of the present invention, the method includes: Measure the spatial coordinates of multiple points on the outer cylindrical surface of the slip ring while the generator is stationary. Based on the aforementioned spatial coordinates, the theoretical axis equation of the slip ring in a static state is calculated and determined. Adjust the orientation and position of the pre-positioning fixture used to support the new carbon brush, and calibrate the reference surface of the fixture to obtain the spatial equation of the fixture reference surface. Based on the theoretical axis equation and the space equation of the fixture reference surface, calculate and record the position and attitude correlation parameters between the two that meet the preset installation requirements; When the generator is running and the carbon brushes need to be replaced, the replacement mechanism is controlled according to the associated parameters to move the pre-positioned fixture carrying the new carbon brushes to the working position.

[0011] Optionally, in a second implementation of the first aspect of the present invention, the method includes: By applying a preset contact force through a replacement mechanism, the new carbon brush forms a stable contact with the outer cylindrical surface of the rotating slip ring; While maintaining stable contact, the replacement mechanism is controlled to enter position driven mode, so that the new carbon brush follows the slip ring surface for at least one revolution; The new carbon brush continuously acquires multi-dimensional displacement data in a set coordinate system using at least one non-contact displacement sensor. The multi-dimensional displacement data collected over at least one week and synchronized with the rotation angle of the slip ring are combined to generate composite trajectory data.

[0012] Optionally, in a third implementation of the first aspect of the present invention, the method includes: Multiple spatial location points are extracted at equal angular intervals from the spatial motion trajectory to form a trajectory sampling point set; Based on the set of trajectory sampling points, the geometric parameters characterizing the outer contour of the slip ring rotation are calculated; Based on the geometric parameters, the actual rotation center data of the slip ring in operation is calculated analytically.

[0013] Optionally, in a fourth implementation of the first aspect of the present invention, the method includes: The actual rotation center data is subtracted from the pre-stored theoretical center position data by a three-dimensional spatial vector subtraction operation to generate position deviation vector data; Based on the position deviation vector data, combined with the kinematic model and motion constraint parameters of the replacement mechanism, a multi-degree-of-freedom motion path is planned to move the new carbon brush from its current position to the target position. The replacement mechanism is controlled to drive the new carbon brush to move along the multi-degree-of-freedom motion path until it reaches the installation target position determined based on the theoretical center position.

[0014] Optionally, in the fifth implementation of the first aspect of the present invention, the new carbon brush is controlled to maintain contact with the slip ring surface and perform driven operation again, and its position information is collected synchronously to generate a verification space motion trajectory. Based on the verified spatial motion trajectory, the updated actual rotation center data of the slip ring in the running state are calculated again; The updated actual rotation center data is compared with the theoretical center position data again to calculate and generate residual position deviation data. Determine whether the residual position deviation data is less than the preset static compensation accuracy threshold, and decide whether to perform iterative compensation adjustment based on the determination result.

[0015] Optionally, in a sixth implementation of the first aspect of the present invention, the method includes: Synchronously acquire the real-time rotation angle sequence and the corresponding contact force fluctuation sequence during one or more rotations of the slip ring; The contact force fluctuation sequence is periodically decomposed to extract the harmonic amplitude and phase information related to the fundamental frequency and its integer multiples. Based on the harmonic amplitude and phase information, an angle-compensation mapping relationship is constructed that maps the rotation angle to the feedforward compensation amount; Based on the real-time monitored rotation angle, the corresponding real-time feedforward compensation amount is obtained by querying the angle-compensation amount mapping relationship; The real-time feedforward compensation is superimposed on the basic position command of the replacement mechanism to drive the new carbon brush to dynamically shift its position.

[0016] Optionally, in a seventh implementation of the first aspect of the present invention, it further includes: After performing the continuous dynamic position fine-tuning, the calibration effect verification stage begins. Real-time monitoring of the fluctuation amplitude of the contact force between the new carbon brush and the slip ring, and the intensity of the electrical spark signal; Compare the key indicators obtained from monitoring with the preset safe operation thresholds; When the comparison result is qualified, the control replacement mechanism and the measurement system are removed from the working area; When the comparison result is unqualified, the corresponding safety processing procedure is triggered.

[0017] Beneficial effects: By controlling the contact operation between the new carbon brush and the rotating slip ring, position information is simultaneously collected to generate a spatial motion trajectory, thereby calculating the actual rotation center under operating conditions. This accurately reflects the actual coaxiality of the slip ring under high-speed rotation and various influences, making the calibration results more consistent with actual operating requirements. It effectively solves problems such as carbon brush wear and electrical sparks caused by coaxiality deviation, and improves the operational stability of the generator. It fully considers the dynamic changes of the slip ring and the fluctuations of the contact force between the carbon brush and the slip ring during generator operation, and can adjust the position of the carbon brush in a timely manner to ensure that it always maintains good contact with the slip ring, extend the service life of the carbon brush, and reduce maintenance costs. It can accurately determine whether the contact state between the calibrated carbon brush and the slip ring meets the standard, promptly identify potential problems and trigger safety procedures, such as reducing contact pressure and moving the carbon brush position, effectively reducing generator operation risks and ensuring equipment and personnel safety. The collected trajectory data is cleaned and fitted, and iterative optimization algorithms are used to solve for the cylindrical surface parameters. Multi-degree-of-freedom motion paths are planned based on position deviation vector data and kinematic models. This improves the accuracy of data processing and the scientific nature of motion path planning, making the compensation adjustment and movement of the new carbon brush more precise, and further enhancing the quality and efficiency of the entire calibration and adjustment process. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of an embodiment of the generator slip ring carbon brush online replacement and coaxiality synchronous calibration and adjustment method in this invention; Figure 2 This is a schematic diagram of an embodiment of the generator slip ring carbon brush online replacement and coaxiality synchronous calibration and adjustment device in this invention. Detailed Implementation

[0019] This invention provides a method for online replacement of generator slip ring carbon brushes and synchronous calibration and adjustment of coaxiality, used to achieve synchronous calibration and adjustment. The terms "first," "second," "third," "fourth," etc. (if present) in the specification, claims, and accompanying drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments described herein can be implemented in a sequence other than that illustrated or described herein. Furthermore, the terms "comprising" or "having" and any variations thereof are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or device that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or devices.

[0020] For ease of understanding, the specific process of the embodiments of the present invention is described below. Please refer to [link / reference]. Figure 1 One embodiment of the generator slip ring carbon brush online replacement and coaxiality synchronous calibration and adjustment method in this invention includes: 101. Based on the offline calibration results, position the new carbon brushes close to the slip rings while the generator is running.

[0021] It is understood that the executing entity of this invention can be a generator slip ring carbon brush online replacement and coaxiality synchronous calibration adjustment device, or it can be a terminal or a server; the specific implementation is not limited here. This embodiment of the invention will be described using a server as an example.

[0022] Specifically, with the generator stationary, the spatial coordinates of multiple points on the outer cylindrical surface of the slip ring are measured; Based on spatial coordinates, the theoretical axis equation of the slip ring in a static state is determined by geometric fitting calculation; the attitude and position of the pre-positioning fixture used to carry the new carbon brush are adjusted, and the reference surface of the fixture is calibrated to obtain the spatial equation of the fixture reference surface; according to the theoretical axis equation and the spatial equation of the fixture reference surface, the position and attitude correlation parameters between the two that meet the preset installation requirements are calculated and recorded; when the generator is running and the carbon brush needs to be replaced, the replacement mechanism is controlled according to the correlation parameters to move the pre-positioning fixture carrying the new carbon brush to the working position.

[0023] It should be noted that this is an example of a large steam turbine generator with a rated speed of 3000 rpm (i.e., a frequency of 50 Hz) and a nominal slip ring diameter of 500 mm (i.e., a nominal radius of 250 mm).

[0024] With the generator in a completely static state during shutdown and maintenance, a high-precision laser tracker was used to establish a three-dimensional global coordinate system. Three cross-sections (front, middle, and rear) were selected on the outer cylindrical surface of the slip ring, with 12 points evenly collected at each cross-section, resulting in the acquisition of the three-dimensional spatial coordinates of 36 surface feature points. Measurement data showed that, due to manufacturing tolerances, the actual measured radius of the slip ring's outer surface fluctuated slightly between 249.95 mm and 250.05 mm.

[0025] The system receives the spatial coordinate data of these 36 points and performs calculations using a spatial cylindrical surface geometric fitting algorithm. This calculation eliminates the interference of minor surface undulations and accurately fits the theoretical principal axis of the slip ring in its static state. The fitting results show that the theoretical axis has a slight deflection of 0.02 degrees relative to the horizontal plane of the global coordinate system, and the system also records the precise spatial position of the center point of the slip ring's principal axis.

[0026] The pre-positioning fixture installed at the end of the automatic changing robotic arm is calibrated, with a new carbon brush with a cross-section of 32 mm × 40 mm securely clamped inside. The system establishes the spatial attitude equation of the fixture's reference plane and sets the robotic arm to stop in a safe standby position. At this time, the lateral straight-line distance from the center of the working end face of the new carbon brush inside the fixture to the center point of the slip ring spindle is exactly 800 mm.

[0027] Spatial correlation calculations were performed based on the theoretical axis equation and the fixture reference surface equation. To meet the installation requirements of ensuring absolute parallelism between the new carbon brush end face and the slip ring surface, and reserving a 2 mm safety working clearance (i.e., the carbon brush end face is suspended at a position 252 mm from the spindle center), it was calculated that the robotic arm needs to be translated laterally 548 mm towards the slip ring, with a tilt angle compensation of 0.02 degrees. This parameter was accurately stored in the database.

[0028] When the generator resumes full speed operation (3000 rpm) and the carbon brushes need to be replaced, the server retrieves the aforementioned saved associated parameters. The replacement mechanism translates the pre-positioned fixture carrying the new carbon brush 548 mm from its standby position, simultaneously performing a 0.02-degree spatial attitude fine-tuning. Ultimately, the new carbon brush is precisely suspended at its predetermined working position, only 2 mm from the surface of the high-speed rotating slip ring.

[0029] 102. Control the new carbon brush to maintain contact with the rotating slip ring surface and perform driven operation, and synchronously collect its position information to generate a spatial motion trajectory.

[0030] Specifically, a preset contact force is applied by the replacement mechanism to make the new carbon brush make stable contact with the outer cylindrical surface of the rotating slip ring; while maintaining stable contact, the replacement mechanism is controlled to enter the position driven mode, so that the new carbon brush follows the slip ring surface for at least one revolution; multi-dimensional displacement data of the new carbon brush in a set coordinate system is continuously collected by at least one non-contact displacement sensor; the multi-dimensional displacement data collected within at least one revolution and synchronized with the rotation angle of the slip ring are combined to generate composite trajectory data characterizing the periodic change of the spatial position of the center point of the end of the new carbon brush with the angle.

[0031] It should be noted that after receiving the command, the replacement mechanism controls the miniature pneumatic servo system within the end effector to slowly push the new carbon brush across the reserved 2mm safety gap, ensuring its end face makes smooth contact with the outer surface of the slip ring rotating at 3000 rpm. At the moment of contact, the closed-loop force control system intervenes, applying and maintaining a constant radial contact pressure of 18 Newtons. This pressure effectively penetrates the surface airflow layer generated by high-speed rotation, ensuring electromechanical fit. The corresponding contact pressure is approximately 14 kPa, within the industrial standard safety range.

[0032] Once the contact pressure is confirmed to be stable, the radial feed axis of the replacement mechanism automatically releases its rigid lock and enters a low-damping position driven mode. At this time, the carbon brush is allowed to fully conform to the true dynamic contour of the slip ring surface under the guidance of a constant contact force, and undergo high-frequency radial micro-amplitude expansion and contraction as the rotor rotates.

[0033] In the servo-floating state, a high-precision non-contact laser displacement sensor mounted on the side of the fixture begins high-speed data acquisition. To capture sufficiently fine dynamic features, the system sets the sensor's sampling frequency to 50,000 Hz. With the generator rotating at 50 revolutions per second, the sensor can densely acquire 1000 radial displacement data points per revolution of the slip ring (taking 20 milliseconds). Simultaneously, the system reads the key phase signal of the generator spindle and synchronously acquires the corresponding precise rotation angle.

[0034] The new carbon brush was controlled to run continuously for 50 cycles in driven mode, with a total time of 1 second, accumulating 50,000 sets of synchronous data including timestamps, radial displacement, and absolute rotation angle. Monitoring showed that, affected by machining tolerances and thermal expansion, the new carbon brush exhibited periodic radial reciprocating motion, with a single-turn displacement fluctuation difference of approximately 0.08 mm. The server superimposed and fitted these 50,000 sets of data in a three-dimensional coordinate system to generate a composite three-dimensional spatial motion trajectory characterizing the undulation state of the actual rotating outer surface of the slip ring.

[0035] 103. Calculate the actual rotation center of the slip ring in operation based on the spatial motion trajectory.

[0036] Specifically, multiple spatial position points are extracted at equal angular intervals from the spatial motion trajectory to form a trajectory sampling point set; based on the trajectory sampling point set, geometric parameters characterizing the outer contour of the slip ring rotation are calculated using a geometric fitting algorithm; and based on the geometric parameters, the actual rotation center data of the slip ring in operation is calculated analytically.

[0037] Furthermore, the trajectory sampling point set is cleaned to identify and remove abnormal data points that deviate from the main spatial distribution characteristics. The cleaned trajectory sampling point set is then input into a preset geometric constraint model, which defines the geometric condition that the outer contour of the slip ring is an ideal cylindrical surface. An iterative optimization algorithm is used to solve for the cylindrical surface parameters that minimize the spatial error between the cleaned trajectory sampling point set and the geometric constraint model. The solved cylindrical surface parameters are then verified to ensure that they meet the preset thresholds for cylindricity and radius variation range.

[0038] It should be noted that a total of 50,000 sets of spatial motion trajectory data generated in step 102 are received. In order to balance computational efficiency and analytical accuracy, the system is set to resample at equal angular intervals of 1.8 degrees, that is, 200 spatial position points are evenly extracted from 1,000 data points per lap, and a total of 10,000 points are extracted for 50 laps to form the initial trajectory sampling point set.

[0039] Statistical filtering algorithms were used to clean the data and remove anomalous jump points caused by electromagnetic interference. The cleaning threshold was set to 0.1 mm deviation from the main distribution. After cleaning, a total of 85 anomalous jump points were identified and removed, and 9915 valid and smooth spatial location points were retained.

[0040] The 9915 cleaned data points were input into a preset 3D geometric constraint model, which defined the outer contour of the slip ring in operation as an ideal dynamic cylindrical surface. Due to the high-speed centrifugal force of 3000 rpm and the thermal expansion caused by a temperature rise of approximately 50 degrees Celsius during operation, the actual contour will change. The background process uses iterative optimization algorithms such as the least squares method to find the best-fit surface that minimizes the overall spatial error with these 9915 spatial points. The fitting results show that the actual working radius of the slip ring at this cross-section increases to 250.15 mm in operation.

[0041] Based on the parameters of the optimally fitted cylindrical surface, the system directly parses the equation of the actual principal axis under the current operating state, obtaining the precise three-dimensional coordinates of the actual rotation center. Compared with the "theoretical center in static state" in step 101, the actual rotation center under the operating state has undergone a slight dynamic shift: it has shifted by +0.04 mm in the horizontal X-axis direction and sunk by -0.03 mm in the vertical Y-axis direction.

[0042] After compliance verification, the cylindricity error of the currently fitted cylindrical surface is 0.035 mm, and the maximum local variation in radius is 0.06 mm, both of which are strictly within the preset safety threshold of 0.1 mm, proving that the data is reliable.

[0043] 104. Based on the positional deviation between the actual rotation center and the theoretical center, perform compensatory adjustments to the installation position of the new carbon brush.

[0044] Specifically, the actual rotation center data is subtracted from the pre-stored theoretical center position data using a three-dimensional spatial vector subtraction operation to generate position deviation vector data. Based on the position deviation vector data, combined with the kinematic model and motion constraint parameters of the replacement mechanism, a multi-degree-of-freedom motion path is planned to move the new carbon brush from its current position to the target position. The replacement mechanism is then controlled to drive the new carbon brush to move along the multi-degree-of-freedom motion path until it reaches the installation target position determined based on the theoretical center position.

[0045] Furthermore, the new carbon brush is controlled to maintain contact with the slip ring surface and operate in a driven manner, while its position information is collected synchronously to generate a verification space motion trajectory. Based on the verification space motion trajectory, the updated actual rotation center data of the slip ring in the running state is calculated again. The updated actual rotation center data is compared with the theoretical center position data again to calculate and generate residual position deviation data. It is determined whether the residual position deviation data is less than the preset static compensation accuracy threshold, and it is decided whether to perform iterative compensation adjustment based on the judgment result.

[0046] It should be noted that the actual rotation center of the slip ring calculated in step 103 is extracted and then subtracted from the theoretical center of the stationary state stored in step 101 using a three-dimensional spatial vector. The results show that the actual rotation center of the slip ring is offset by 0.04 mm in the positive X-axis direction and 0.03 mm in the negative Y-axis direction relative to the theoretical center.

[0047] Input this deviation vector into the underlying kinematic model to plan a smooth micron-level multi-degree-of-freedom compensation path: the end effector of the robotic arm is required to drive the pre-positioning fixture to accurately translate 0.04 mm to the X-axis and 0.03 mm to the Y-axis from the current spatial hovering position.

[0048] The servo drive unit of the replacement mechanism activates the high-precision reducer and lead screw module, driving the fixture carrying the new carbon brush to smoothly complete the aforementioned micron-level displacement. After adjustment, the center of the arc surface of the new carbon brush is precisely aligned with the actual rotation center of the slip ring at 3000 rpm, completing the initial macroscopic eccentricity compensation.

[0049] The system controls the new carbon brush to re-engage with the slip ring using a contact force of 18 Newtons, entering the driven operation mode. The non-contact displacement sensor then synchronously acquires displacement data over 50 generator rotation cycles at a frequency of 50,000 Hz, generating a new verification space motion trajectory.

[0050] Based on the verification trajectory, geometric fitting calculations are performed again to obtain the updated actual rotation center. After a second comparison operation, residual position deviation data is generated: at this point, the residual deviation on the X-axis is only +0.003 mm, and the residual deviation on the Y-axis is -0.002 mm. The system's preset static compensation accuracy threshold is an absolute error of no more than 0.01 mm. Determining that the current residual deviation (maximum 0.003 mm) has met the standard, it is decided not to trigger iterative compensation and directly lock the current spatial coordinates as the final static installation reference position for the new carbon brush.

[0051] 105. After compensation and adjustment, a feedforward compensation relationship is established based on the real-time collected rotation angle and contact force data, and the new carbon brush is continuously and dynamically fine-tuned accordingly.

[0052] Specifically, the real-time rotation angle sequence and corresponding contact force fluctuation sequence during one or more rotations of the slip ring are simultaneously acquired; the contact force fluctuation sequence is periodically decomposed to extract the harmonic amplitude and phase information related to the fundamental frequency and its integer multiples; based on the harmonic amplitude and phase information, an angle-compensation mapping relationship is constructed that maps the rotation angle to the feedforward compensation amount; according to the real-time monitored rotation angle, the corresponding real-time feedforward compensation amount is obtained by querying the angle-compensation mapping relationship; the real-time feedforward compensation amount is superimposed on the basic position command of the replacement mechanism to drive the new carbon brush to perform dynamic position offset.

[0053] It should be noted that after static center alignment is completed, the new carbon brush maintains contact with the slip ring at a reference pressure of 18 Newtons. The system triggers the high-speed data acquisition module to continuously record dynamic data during 100 generator revolutions (taking 2 seconds) at a sampling rate of 20,000 Hz. Monitoring shows that although the macroscopic eccentricity has been eliminated, the actual contact force exhibits periodic pulsations between 17.2 Newtons and 18.8 Newtons due to the microscopic ellipticity of the slip ring itself.

[0054] The contact force fluctuation sequence is periodically decomposed. Stray noise is accurately removed, and harmonic features related to the fundamental frequency and its second harmonic are extracted to obtain the amplitude of the force peaks and valleys and the corresponding angular phase information.

[0055] To eliminate periodic force pulsations, the system utilizes the aforementioned harmonic characteristics to derive a mapping table from "rotation angle" to "radial position feedforward compensation amount," thus achieving a symmetrical and linear feedforward compensation mechanism. Some typical mapping data are shown in Table 1 below: Table 1 Note: Positive values ​​indicate that the carbon brush retracts, while negative values ​​indicate that the carbon brush protrudes.

[0056] The control system reads the real-time angle with sub-millisecond latency. When the rotor reaches 90 degrees, the system looks up the required +0.015 mm compensation from the table and instantly adds it to the base position command, driving the high-frequency piezoelectric ceramic actuator in the fixture to shrink the carbon brush by 0.015 mm. Through this feedforward dynamic adjustment, true "flexible" fit is achieved, eliminating the risk of electrical sparks.

[0057] 106. After continuous dynamic position fine-tuning, the calibration effect verification stage is entered; the amplitude of the contact force fluctuation and the intensity of the electric spark signal between the new carbon brush and the slip ring are monitored in real time; the key indicators obtained by monitoring are compared with the preset safe operation thresholds; when the comparison result is qualified, the replacement mechanism and the measurement system are controlled to exit the working area; when the comparison result is unqualified, the corresponding safety handling procedure is triggered.

[0058] Furthermore, the control actuator reduces the contact pressure between the new carbon brush and the slip ring surface to a preset minimum maintenance value; the control replacement mechanism moves the new carbon brush a preset safe distance away from the slip ring surface; the control replacement mechanism moves to the initial standby position completely away from the slip ring working area; and an alarm report containing an anomaly type identifier and handling process record is sent to the remote monitoring system.

[0059] It should be noted that after the dynamic position fine-tuning is initiated, the system controls the new carbon brush to run continuously and stably in the working position for 10 seconds (500 rotations of the slip ring). During this period, the high-frequency force sensor and ultraviolet spark detector built into the pre-positioning fixture are activated simultaneously to monitor the amplitude of contact force fluctuations and electromagnetic radiation intensity in real time at a frequency of 1000 Hz.

[0060] The data within 10 seconds was smoothed, the peak value was extracted, and compared with the preset safe operating threshold, as shown in Table 2 below: Table 2 The comparison results showed that the key indicators after fine-tuning all decreased significantly and remained strictly within the safety threshold, and the system determined the calibration to be "qualified". The system control fixture released the physical clamp and smoothly transferred the carbon brush to the generator's original constant pressure brush holder spring assembly. After confirming that everything was correct, the replacement mechanism smoothly moved laterally at a speed of 50 mm / s, exited the working area, and returned to the initial standby position, successfully completing the online replacement.

[0061] If, during the verification phase, a defect in the carbon brush material causes the electrical spark signal to spike to 25.0mV (determined as unqualified), the system will trigger a safety procedure within milliseconds: the micro servo system will quickly reduce the contact pressure to a minimum maintenance value of 5 Newtons to prevent arc erosion; then, the replacement mechanism will move the carbon brush radially backward by 20 mm to cut off the contact; subsequently, it will return to the standby position; finally, it will automatically send an alarm report with the "0x04 - Electrical Spark Signal Exceeds Limit" label and handling record to the remote control center for manual intervention.

[0062] Figure 2 This is a schematic diagram of a generator slip ring carbon brush online replacement and coaxiality synchronous calibration and adjustment device 200 provided in an embodiment of the present invention. The device 200 can vary considerably due to differences in configuration or performance. The device 200 includes a transmitter 201, a receiver 202, and a processor 203. The processor 203 can also be a controller. Figure 2 The device is referred to as "controller / processor 203". Optionally, the device 200 may also include a modem processor 205, wherein the modem processor 205 may include an encoder 206, a modulator 207, a decoder 208, and a demodulator 209.

[0063] In one example, transmitter 201 modulates (e.g., analog-to-analog conversion, filtering, amplification, and up-conversion, etc.) the output sample and generates an uplink signal, which is transmitted via an antenna to an access network device. On the downlink, the antenna receives the downlink signal transmitted by the access network device. Receiver 202 modulates (e.g., filtering, amplification, down-conversion, and digitization, etc.) the signal received from the antenna and provides an input sample. In modem processor 205, encoder 206 receives traffic data and signaling messages to be transmitted on the uplink and processes (e.g., formatting, encoding, and interleaving) the traffic data and signaling messages. Modulator 207 further processes (e.g., symbol mapping and modulation) the encoded traffic data and signaling messages and provides an output sample. Demodulator 209 processes (e.g., demodulates) the input sample and provides a symbol estimate. Decoder 208 processes (e.g., deinterleaving and decoding) the symbol estimate and provides decoded data and signaling messages to device 200. Encoder 206, modulator 207, demodulator 209, and decoder 208 can be implemented by a combined modem processor 205. These units process data according to the radio access technology used by the radio access network (e.g., LTE and other evolved systems access technologies). It should be noted that when device 200 does not include modem processor 205, the aforementioned functions of modem processor 205 can also be performed by processor 203.

[0064] The processor 203 controls and manages the operation of the device 200, and is used to execute the processing procedures performed by the device 200 in the above embodiments of this disclosure. For example, the processor 203 is also used to execute various steps of the transmitting or receiving device in the above method embodiments, and / or other steps of the technical solutions described in the embodiments of this disclosure.

[0065] Furthermore, the device 200 may also include a memory 204 for storing program code and data for the device 200.

[0066] Understandable, Figure 2 Only a simplified design of device 200 is shown. In practical applications, device 200 can include any number of transmitters, receivers, processors, modem processors, memory, etc., and all devices that can implement the embodiments of this disclosure are within the protection scope of the embodiments of this disclosure.

[0067] The present invention also provides a generator slip ring carbon brush online replacement and coaxiality synchronous calibration and adjustment device. The generator slip ring carbon brush online replacement and coaxiality synchronous calibration and adjustment device includes a memory and a processor. The memory stores computer-readable instructions. When the computer-readable instructions are executed by the processor, the processor performs the steps of the generator slip ring carbon brush online replacement and coaxiality synchronous calibration and adjustment method in the above embodiments.

[0068] The present invention also provides a computer-readable storage medium, which can be a non-volatile computer-readable storage medium or a volatile computer-readable storage medium, wherein the computer-readable storage medium stores instructions that, when the instructions are executed on a computer, cause the computer to perform the steps of the generator slip ring carbon brush online replacement and coaxiality synchronous calibration adjustment method.

[0069] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0070] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0071] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for online replacement and coaxiality synchronous calibration and adjustment of generator slip ring carbon brushes, characterized in that, Includes the following steps: Based on the offline calibration results, the new carbon brush is positioned close to the slip ring while the generator is running. The new carbon brush is controlled to maintain contact with the rotating slip ring surface and perform driven operation, while its position information is collected synchronously to generate a spatial motion trajectory; Calculate the actual rotation center of the slip ring in operation based on the described spatial motion trajectory; Based on the positional deviation between the actual rotation center and the theoretical center, the installation position of the new carbon brush is adjusted to compensate for the deviation. After compensation adjustment, a feedforward compensation relationship is established based on the real-time collected rotation angle and contact force data, and the new carbon brush is calibrated and adjusted accordingly.

2. The method for online replacement and coaxiality synchronous calibration and adjustment of generator slip ring carbon brushes according to claim 1, characterized in that, include: Measure the spatial coordinates of multiple points on the outer cylindrical surface of the slip ring while the generator is stationary. Based on the aforementioned spatial coordinates, the theoretical axis equation of the slip ring in a static state is calculated and determined. Adjust the orientation and position of the pre-positioning fixture used to support the new carbon brush, and calibrate the reference surface of the fixture to obtain the spatial equation of the fixture reference surface. Based on the theoretical axis equation and the space equation of the fixture reference surface, calculate and record the position and attitude correlation parameters between the two that meet the preset installation requirements; When the generator is running and the carbon brushes need to be replaced, the replacement mechanism is controlled according to the associated parameters to move the pre-positioned fixture carrying the new carbon brushes to the working position.

3. The method for online replacement and coaxiality synchronous calibration and adjustment of generator slip ring carbon brushes according to claim 1, characterized in that, include: By applying a preset contact force through a replacement mechanism, the new carbon brush forms a stable contact with the outer cylindrical surface of the rotating slip ring; While maintaining stable contact, the replacement mechanism is controlled to enter position driven mode, so that the new carbon brush follows the slip ring surface for at least one revolution; The new carbon brush continuously acquires multi-dimensional displacement data in a set coordinate system using at least one non-contact displacement sensor. The multi-dimensional displacement data collected over at least one week and synchronized with the rotation angle of the slip ring are combined to generate composite trajectory data.

4. The method for online replacement and coaxiality synchronous calibration and adjustment of generator slip ring carbon brushes according to claim 1, characterized in that, include: Multiple spatial location points are extracted at equal angular intervals from the spatial motion trajectory to form a trajectory sampling point set; Based on the set of trajectory sampling points, the geometric parameters characterizing the outer contour of the slip ring rotation are calculated; Based on the geometric parameters, the actual rotation center data of the slip ring in operation is calculated analytically.

5. The method for online replacement and coaxiality synchronous calibration and adjustment of generator slip ring carbon brushes according to claim 1, characterized in that, include: The actual rotation center data is subtracted from the pre-stored theoretical center position data by a three-dimensional spatial vector subtraction operation to generate position deviation vector data; Based on the position deviation vector data, combined with the kinematic model and motion constraint parameters of the replacement mechanism, a multi-degree-of-freedom motion path is planned to move the new carbon brush from its current position to the target position. The replacement mechanism is controlled to drive the new carbon brush to move along the multi-degree-of-freedom motion path until it reaches the installation target position determined based on the theoretical center position.

6. The method for online replacement and coaxiality synchronous calibration and adjustment of generator slip ring carbon brushes according to claim 5, characterized in that, The new carbon brush is controlled to maintain contact with the slip ring surface and run in a driven manner, while its position information is collected synchronously to generate a verification spatial motion trajectory. Based on the verified spatial motion trajectory, the updated actual rotation center data of the slip ring in the running state are calculated again; The updated actual rotation center data is compared with the theoretical center position data again to calculate and generate residual position deviation data. Determine whether the residual position deviation data is less than the preset static compensation accuracy threshold, and decide whether to perform iterative compensation adjustment based on the determination result.

7. The method for online replacement and coaxiality synchronous calibration and adjustment of generator slip ring carbon brushes according to claim 1, characterized in that, include: Synchronously acquire the real-time rotation angle sequence and the corresponding contact force fluctuation sequence during one or more rotations of the slip ring; The contact force fluctuation sequence is periodically decomposed to extract the harmonic amplitude and phase information related to the fundamental frequency and its integer multiples. Based on the harmonic amplitude and phase information, an angle-compensation mapping relationship is constructed that maps the rotation angle to the feedforward compensation amount; Based on the real-time monitored rotation angle, the corresponding real-time feedforward compensation amount is obtained by querying the angle-compensation amount mapping relationship; The real-time feedforward compensation is superimposed on the basic position command of the replacement mechanism to drive the new carbon brush to dynamically shift its position.

8. The method for online replacement and coaxiality synchronous calibration and adjustment of generator slip ring carbon brushes according to any one of claims 1-7, characterized in that, Also includes: After performing the continuous dynamic position fine-tuning, the calibration effect verification stage begins. Real-time monitoring of the fluctuation amplitude of the contact force between the new carbon brush and the slip ring, and the intensity of the electrical spark signal; Compare the key indicators obtained from monitoring with the preset safe operation thresholds; When the comparison result is qualified, the control replacement mechanism and the measurement system are removed from the working area; When the comparison result is unqualified, the corresponding safety processing procedure is triggered.

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