A method, device and system for testing a wind turbine

Abstract

The application discloses a kind of wind turbine generator set test method, device and system, it is related to wind turbine test field, comprising: when the communication connection state of the variable pitch system of wind turbine generator set is connected, the initial pitch angle of each shaft is obtained;According to the initial pitch angle of each shaft, it is judged whether each shaft satisfies preset linkage test condition;When each shaft satisfies linkage test condition, linkage variable pitch instruction is synchronously sent to each shaft;The actual pitch angle generated based on linkage variable pitch instruction of each shaft is obtained;According to the consistency between the actual pitch angle of each shaft and the target pitch angle corresponding to linkage variable pitch instruction, linkage test result is generated.Through synchronously sending linkage variable pitch instruction to three shafts and simultaneously obtaining the response data of three shafts respectively, the real working condition of three blades cooperative variable pitch when wind turbine generator set operates can be simulated, and the working performance of wind turbine generator set under actual operating state can be more truly reflected.

Description

Technical Field

[0001] This invention relates to the field of wind turbine testing, and in particular to a testing method, apparatus and system for wind turbine generators. Background Technology

[0002] In existing workshop testing of wind turbine generators, the three shafts are often tested individually and sequentially. Each shaft undergoes pitch motor rotation verification, sensor position calibration, and pitch angle confirmation one by one. Once all three shafts are successfully tested sequentially, the test is considered complete, without involving the coordinated testing of the three shafts. However, in actual operation of a wind turbine generator, the three blades work simultaneously, with all three blades changing pitch at the same time. The current testing methods lack verification of the synchronicity and consistency of the three blades' coordinated movement, making it impossible to detect potential angle deviations or unresponsiveness issues under coordinated operating conditions in advance. Summary of the Invention

[0003] The purpose of this invention is to provide a testing method, device, and system for wind turbine generator sets. By synchronously sending linkage pitch control commands to three axes and simultaneously acquiring the response data of each of the three axes, it is possible to simulate the real operating condition of the three blades coordinating pitch control during the operation of a wind turbine generator set, and to more realistically reflect the working performance of the wind turbine generator set under actual operating conditions.

[0004] To address the aforementioned technical problems, this invention provides a testing method for wind turbine generator sets, comprising:

[0005] Obtain the communication connection status with the pitch system of the wind turbine generator;

[0006] When the communication connection status is connected, the initial pitch angle of each axis is obtained. The axis is used to drive the blade to perform pitch control. The initial pitch angle is the angle between the chord line of the blade and the plane of rotation in the initial state.

[0007] Based on the initial pitch angle of each shaft, determine whether each shaft meets the preset linkage test conditions;

[0008] When all the axes meet the linkage test conditions, a linkage pitch command is sent synchronously to each of the axes.

[0009] Obtain the actual pitch angle of each axis based on the linked pitch command;

[0010] Based on the consistency between the actual pitch angle of each axis and the target pitch angle corresponding to the linked pitch command, the linkage test results are generated.

[0011] On the other hand, it obtains the communication connection status of the wind turbine's pitch system, including:

[0012] The system sends a handshake request frame to the pitch system via the CAN communication protocol and receives a response frame returned by the pitch system based on the handshake request frame.

[0013] The communication connection status is confirmed as connected or disconnected based on whether the response frame is successfully received within a preset time.

[0014] On the other hand, synchronously sending coordinated pitch control commands to each of the axes includes:

[0015] Determine the test requirements for the blade to perform either a pitching or feathering action, and set the target test angle based on the test requirements;

[0016] The initial pitch angle of each axis is obtained, and according to the initial pitch angle and the target test angle, a pitch angle sequence data is generated from the initial pitch angle to the target test angle. There is a preset angle change step size and a preset change rate between adjacent angle values ​​in the pitch angle sequence data.

[0017] The propeller pitch angle sequence data is encapsulated into a synchronous data frame under the CAN communication protocol;

[0018] The synchronization data frame is simultaneously broadcast to the pitch driver of each of the axes.

[0019] On the other hand, based on the initial pitch angle of each shaft, it is determined whether each shaft meets the preset linkage test conditions, including:

[0020] Based on the initial pitch angle of each shaft, determine whether the initial pitch angle of each shaft is within the preset operable angle range.

[0021] Obtain the safety position arrival feedback signal of each axis, and determine whether the limit switch of each axis is in the normal trigger state based on the safety position arrival feedback signal;

[0022] Obtain the power-on status signal of each of the pitch drives of the axes, and determine whether each of the pitch drives has been powered on normally based on the power-on status signal.

[0023] When the initial pitch angles are all within the preset operable angle range, the limit switches are all in the normal trigger state, and the pitch drivers are all powered on normally, it is determined that each shaft meets the linkage test conditions.

[0024] On the other hand, after obtaining the actual pitch angle of each of the axes based on the linked pitch command, the process also includes:

[0025] The trigger status of the self-reset button on the control cabinet panel is obtained, and the control cabinet panel is used to receive user control information;

[0026] When the self-reset button is triggered, an emergency feathering command is sent to each of the axes;

[0027] Obtain feathering angle feedback data generated by each of the axes based on the emergency feathering command. The feathering angle feedback data includes the actual pitch angle and the safe position arrival feedback signal of each axis.

[0028] Based on the feedback data of the feathering angle, a safety chain function verification result is generated.

[0029] To address the aforementioned technical problems, the present invention also provides a testing device for wind turbine generator sets, comprising:

[0030] Memory, used to store computer programs;

[0031] A processor is used to execute the computer program to implement the steps of the above-described test method for wind turbine generator sets.

[0032] To address the aforementioned technical problems, the present invention also provides a testing system for wind turbine generator sets, comprising the aforementioned testing apparatus for wind turbine generator sets, and further comprising:

[0033] The connecting harness is located between the control cabinet and the pitch system of the wind turbine generator set and is used for data transmission;

[0034] The control cabinet is connected to the processor of the test device for the wind turbine generator set, and includes a power supply circuit and a switching power supply module.

[0035] The input end of the power supply circuit is connected to an external power source, and the output end is connected to the pitch system through the connecting harness to provide drive power to the pitch system.

[0036] The input terminal of the switching power supply module is connected to an AC power source, and the output terminal is connected to the testing device of the wind turbine generator set. It is used to convert the AC power source into DC power to power the testing device of the wind turbine generator set.

[0037] On the other hand, the connecting harness includes power cables and communication cables;

[0038] One end of the power supply cable is connected to the control cabinet, and the other end is plugged into the pitch system through the first heavy-duty plug for transmitting power signals;

[0039] The communication cable includes a CAN communication harness and a status feedback harness;

[0040] The first end of the CAN communication harness is connected to the test device, and the second end is connected to the pitch system. It is used to transmit the control commands generated by the test device to the pitch system and send the pitch angle collected by the pitch system to the test device.

[0041] The first end of the status feedback harness is connected to the test device, and the second end is connected to the pitch system. It includes a first signal sub-line for transmitting start confirmation signals for each shaft and a second signal sub-line for transmitting safety position arrival feedback signals for each blade.

[0042] On the other hand, the interface through which the test device communicates with the pitch system is a DB9 type plug-in interface;

[0043] A terminating resistor for impedance matching is provided between the CAN_H signal terminal and the CAN_L signal terminal of the DB9 type plug-in interface, and a toggle switch is provided on the DB9 type plug-in interface.

[0044] The toggle switch is used to connect or disconnect the terminating resistor from the transmission circuit of the CAN communication harness according to the physical location of the pitch system in the CAN bus network.

[0045] On the other hand, it also includes an emergency feathering simulation circuit;

[0046] The emergency feathering simulation circuit includes a self-reset button and a photoelectric prompt module located on the control cabinet panel.

[0047] The self-reset button is used to output a trigger signal to the pitch system through the connecting harness when it is pressed, and the photoelectric prompt module is used to provide a photoelectric prompt to the user when the self-reset button is pressed.

[0048] This application provides a testing method, apparatus, and system for wind turbine generator sets, relating to the field of wind turbine generator set testing. The method includes: acquiring the initial pitch angle of each shaft when the communication connection status of the wind turbine generator set's pitch system is connected; determining whether each shaft meets preset linkage test conditions based on the initial pitch angles of each shaft; synchronously sending linkage pitch commands to each shaft when all shafts meet the linkage test conditions; acquiring the actual pitch angle generated by each shaft based on the linkage pitch commands; and generating linkage test results based on the consistency between the actual pitch angles of each shaft and the target pitch angles corresponding to the linkage pitch commands. By synchronously sending linkage pitch commands to three shafts and simultaneously acquiring the response data of each of the three shafts, the actual operating condition of the three blades coordinating pitch control during wind turbine generator set operation can be simulated, more realistically reflecting the working performance of the wind turbine generator set under actual operating conditions. Attached Figure Description

[0049] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the prior art and embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0050] Figure 1 A flowchart of a testing method for a wind turbine generator set provided by the present invention;

[0051] Figure 2 A schematic diagram of the structure of a testing device for a wind turbine generator set provided by the present invention;

[0052] Figure 3 A control logic diagram provided by the present invention;

[0053] Figure 4 A schematic diagram illustrating a CAN communication connection method between a PLC main controller and a pitch system provided by the present invention;

[0054] Figure 5 A schematic diagram of a power supply circuit for a control cabinet provided by the present invention;

[0055] Figure 6 A schematic diagram of a control cabinet switching power supply circuit provided by the present invention;

[0056] Figure 7 A schematic diagram of a communication circuit for a control cabinet provided by the present invention;

[0057] Figure 8 A wiring diagram of the main control and pitch system of the control cabinet is provided for this invention;

[0058] Figure 9 A schematic diagram of a control cabinet signal feedback circuit provided by the present invention;

[0059] Figure 10 This invention provides a structural schematic diagram of a heavy-duty plug O;

[0060] Figure 11 This is a schematic diagram of the structure of a heavy-duty plug P provided by the present invention. Detailed Implementation

[0061] The core of this invention is to provide a testing method, device, and system for wind turbine generator sets. By synchronously sending linkage pitch control commands to three axes and simultaneously acquiring the response data of each of the three axes, it is possible to simulate the real working condition of the three blades coordinating pitch control during the operation of a wind turbine generator set, and to more realistically reflect the working performance of the wind turbine generator set under actual operating conditions.

[0062] To make the objectives, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be described clearly and completely below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by a person of ordinary skill in the art without making creative efforts fall within the scope of protection of the present invention.

[0063] Figure 1 is a flow chart of a test method for a wind turbine generator set provided by the present invention, the test method for a wind turbine generator set comprises:

[0064] S11: Acquire a communication connection state with a pitch system of the wind turbine generator set;

[0065] The method is applied to a processor in a test device for a wind turbine generator set. For the convenience of user operation, an intelligent control platform for displaying on a control cabinet panel is also provided, and a user can select or input instructions on the intelligent control platform. Before any linkage test operation is performed, it is firstly necessary to confirm whether a communication link between the intelligent control platform and the pitch system has been established, so as to ensure that all subsequent control instructions can be accurately transmitted to the pitch system, and at the same time ensure that pitch angle data, status signals and the like fed back by the pitch system can be correctly received by the processor. If a pitch instruction is blindly sent when the communication has not been established, potential safety hazards such as instruction loss and no response of an axis may be caused.

[0066] S12: When the communication connection state is connected, acquire the initial pitch angle of each axis, wherein the initial pitch angle is an angle between a chord line of a blade and a rotation plane in an initial state;

[0067] After confirming that the communication connection state is connected, a data reading request is sent to the pitch system through a CAN communication protocol to acquire the initial pitch angle of each axis. A pitch angle refers to an angle between a blade chord line and a wind wheel rotation plane, and is a core parameter that characterizes the wind-facing posture of a blade. Only on the premise of clarifying the current angular position of each axis can it be judged whether each axis has the condition for performing linked pitch variation, and the consistency between an actual pitch angle and a target pitch angle can also be accurately calculated in subsequent steps.

[0068] In addition, the initial pitch angles of the three axes can also be displayed on a debugging interface in real time, and a debugger can intuitively observe the current angle state of each axis through the interface, which is convenient for monitoring and judging the debugging process.

[0069] S13: According to the initial pitch angle of each axis, judge whether each axis all meets a preset linkage test condition;

[0070] After obtaining the initial pitch angle, it is necessary to determine whether each axis meets the preset linkage test conditions. The reason for setting this judgment step is that the linkage test requires all three axes to perform pitch control actions simultaneously. If an axis is currently in an abnormal working state, such as the pitch angle exceeding the operable range, the limit switch not triggering properly, or the pitch driver not being powered on, then sending the linkage command synchronously may cause that axis to fail to respond or produce abnormal actions, which will not only affect the accuracy of the test results, but may also damage the equipment.

[0071] S14: When all axes meet the linkage test conditions, send linkage pitch commands to each axis synchronously.

[0072] Once it is confirmed that all three axes meet the linkage test conditions, a linkage pitch command is synchronously sent to each axis. Synchronous sending means that within the same control cycle, the pitch command is simultaneously broadcast to the three pitch systems via the synchronization mechanism of the CAN communication protocol.

[0073] During actual operation of a wind turbine generator set, all three blades simultaneously perform pitch control to achieve coordinated regulation of wind energy capture. If there is a time difference or angular deviation in the actions of the three blades, it will lead to uneven force on the rotor, generating unbalanced loads, which will seriously affect the safe operation and service life of the unit.

[0074] S15: Obtain the actual pitch angle of each axis generated based on the linkage pitch command;

[0075] After sending the pitch control command, the actual pitch angle of each axis is read through the CAN communication protocol. The actual pitch angle is the actual angle value of the blade detected by the absolute encoder after the pitch driver responds to the command. The purpose of obtaining the actual pitch angle is to compare it with the target pitch angle, thereby verifying the response accuracy and consistency of each axis.

[0076] S16: Generate linkage test results based on the consistency between the actual pitch angle of each axis and the target pitch angle corresponding to the linkage pitch command.

[0077] The actual pitch angles of each axis are compared with the target pitch angles, and the linkage test results are generated based on the degree of consistency. The consistency judgment includes two dimensions: one is whether the deviation between the actual pitch angle reached by each axis and the target pitch angle is within the allowable error range; the other is whether the angle change curves of each axis during the pitch change process have good consistency, that is, whether the three axes reach the target angle synchronously with similar change rates.

[0078] If the actual pitch angles of all three axes match the target pitch angles, and the variation curves show good consistency, the linkage test result is qualified, indicating that the pitch systems of the three axes can work together and meet the actual operating requirements of the wind turbine generator. Conversely, if the actual pitch angle of a certain axis deviates too much from the target pitch angle, or if there are significant differences in the variation curves of the three axes, the linkage test result is unqualified, and further investigation is needed into potentially problematic components such as the pitch driver, encoder, and mechanical transmission chain of that axis.

[0079] This application provides a testing method for wind turbine generator sets, relating to the field of wind turbine generator set testing. The method includes: acquiring the initial pitch angle of each shaft when the communication connection status of the wind turbine generator set's pitch system is connected; determining whether each shaft meets preset linkage test conditions based on the initial pitch angles of each shaft; synchronously sending linkage pitch commands to each shaft when all shafts meet the linkage test conditions; acquiring the actual pitch angle generated by each shaft based on the linkage pitch commands; and generating linkage test results based on the consistency between the actual pitch angles of each shaft and the target pitch angles corresponding to the linkage pitch commands. By synchronously sending linkage pitch commands to three shafts and simultaneously acquiring the response data of each of the three shafts, the method can simulate the real operating condition of the three blades coordinating pitch control during wind turbine generator set operation, and can more realistically reflect the working performance of the wind turbine generator set under actual operating conditions.

[0080] Based on the above embodiments:

[0081] In some embodiments, obtaining the communication connection status of the pitch system of a wind turbine generator includes:

[0082] The system sends a handshake request frame to the pitch system via the CAN communication protocol and receives a response frame from the pitch system based on the handshake request frame.

[0083] The communication connection status is confirmed as connected or disconnected based on whether a response frame is successfully received within a preset time.

[0084] The master node sends handshake request frames to each shaft cabinet node of the pitch system via the CAN communication module. Upon receiving the request frame, if the communication function is normal and the node is in an operable state, the CAN communication module of each pitch system generates a corresponding response frame according to the CAN protocol specification and returns it to the processor via the CAN bus. The response frame carries the requested data content (e.g., device type code), indicating that the slave node has correctly identified and responded to the master's request.

[0085] After sending a handshake request frame, a preset waiting timer is started. If a response frame is successfully received from a certain axis cabinet node before the timer expires, the communication connection status of the axis cabinet is confirmed to be connected. If no response frame is received after the timer expires, the communication connection status of the axis cabinet is confirmed to be disconnected.

[0086] If the first handshake request does not receive a response, a handshake request frame is sent again, attempting three times consecutively. If no response is received after all three attempts, the communication connection is determined to be disconnected, and a corresponding fault message is displayed on the debugging interface to guide the debugging personnel in checking the physical connection. After confirming that the communication connection status of all three axis cabinets is connected, the subsequent linkage test process can proceed.

[0087] In some embodiments, synchronously sending coordinated pitch commands to each axis includes:

[0088] Determine the test requirements for the blades to perform either pitching or feathering actions, and set the target test angle based on the test requirements;

[0089] The initial pitch angle of each axis is obtained, and based on the initial pitch angle and the target test angle, a pitch angle sequence data is generated from the initial pitch angle to the target test angle. There is a preset angle change step size and a preset change rate between adjacent angle values ​​in the pitch angle sequence data.

[0090] Encapsulate the pitch angle sequence data into a synchronous data frame under the CAN communication protocol;

[0091] The synchronization data frames are broadcast simultaneously to the pitch drives of each axis.

[0092] The commissioning personnel select the pitch direction for this linkage test—open or feathering—through the interface software of the intelligent control platform connected to the processor. Opening the pitch involves adjusting the blade angle from a larger angle (close to 90°) to a smaller angle (close to 0°) to increase the blade's frontal area and capture more wind energy. Feathering involves adjusting the blade angle from a smaller angle to a larger angle to reduce the frontal area and decrease wind energy capture; this is typically used for safety protection under high wind conditions. After selecting the test direction on the interface, the commissioning personnel also need to set the target test angle. The target test angle can be a preset typical value or a custom angle value entered by the commissioning personnel according to actual needs. The interface software converts the commissioning personnel's selection and input into corresponding parameters.

[0093] After receiving the target test angle, the initial pitch angles of each axis are combined with the previously acquired initial pitch angles to generate a pitch angle sequence for each axis. The angle change step size refers to the angle increment between two adjacent angle updates, and its value affects the smoothness of the pitch process. An excessively large step size will cause abrupt angle changes, impacting the mechanical structure; an excessively small step size will result in an excessively large sequence data volume, increasing the communication burden.

[0094] The generated pitch angle sequence data is encapsulated into synchronization data frames according to the CAN protocol data format. These encapsulated synchronization data frames are simultaneously broadcast to the pitch drivers of the three pitch systems via the CAN bus. Upon receiving the synchronization data frame, each pitch driver parses the target pitch angle value and, combined with its current position feedback, drives the pitch motor to rotate towards the target angle.

[0095] In some embodiments, determining whether each axis meets preset linkage test conditions based on the initial pitch angle of each axis includes:

[0096] Based on the initial pitch angle of each axis, determine whether the initial pitch angle of each axis is within the preset operable angle range.

[0097] Obtain the safety position arrival feedback signal of each axis, and determine whether the limit switch of each axis is in the normal trigger state based on the safety position arrival feedback signal;

[0098] Acquire the power-on status signal of each axis pitch drive, and determine whether each pitch drive has been powered on normally based on the power-on status signal.

[0099] When the initial pitch angles are all within the preset operable angle range, the limit switches are all in the normal trigger state, and the pitch drives are all powered on normally, it is determined that each shaft meets the linkage test conditions.

[0100] The initial pitch angles of each axis are compared with the preset operable angle range. The operable angle range refers to the angle interval within which the pitch system can operate normally, typically set from 0° to 90°. This range is determined based on the mechanical design limits of the pitch system. When the pitch angle is 0°, the blades are at their open pitch limit position, with the largest frontal area; when the pitch angle is 90°, the blades are at their feathering limit position, with the smallest frontal area. If the initial pitch angle of a certain axis is less than 0° or greater than 90°, it indicates that the axis may have exceeded its mechanical limit range, or there may be a deviation in the zero-position setting of the angle sensor. In this case, the debugging interface will display a message indicating that the initial angle of axis X exceeds the operable range, instructing the debugging personnel to check the mechanical limit device and encoder settings of that axis. Testing can only continue after the problem is resolved.

[0101] The safe position arrival feedback signal is a digital signal generated by limit switches (proximity switches) installed within the pitch system. When the blade rotates to its 0° or 90° limit position, the trigger block installed at the tooth ring or blade root approaches the sensing surface of the limit switch, activating the internal circuitry and outputting a high-level or low-level signal to the processor, indicating that the blade has reached its safe limit position. Before the linkage test begins, the limit switches should be in an untriggered state (i.e., the blade is not in its limit position). This ensures that the limit switches can trigger normally when the blade reaches its limit position during the linkage pitch process, fulfilling their safety protection function. If a limit switch on a certain shaft is already in the triggered state, it indicates that the blade on that shaft may be stuck in its limit position, or that the installation position of the limit switch is incorrect, requiring adjustment before testing.

[0102] The power-on status signal of the pitch drive indicates whether the drive has been connected to the power supply and completed initialization. During workshop commissioning, the pitch drive is powered on by the commissioning personnel by closing the power supply switch of the pitch system. After confirming that the power supply connection is correct, the commissioning personnel close the power supply switch in the shaft cabinet, and the pitch drive begins its power-on self-test. After the self-test is completed, the drive sends a power-on success signal to the processor through the status output terminal. After receiving the power-on success signals from all three axes, it is confirmed that all pitch drives have been powered on normally. If a certain axis does not return a power-on success signal, the processor will indicate on the commissioning interface that the axis X drive is not powered on, guiding the commissioning personnel to check the power supply circuit of that axis cabinet.

[0103] When the initial pitch angles are all within the preset operable angle range, the limit switches are all in the normal trigger state, and the pitch drives are all powered on normally, it is determined that each axis meets the linkage test conditions. Only when all three conditions are met does the processor determine that each axis meets the linkage test conditions and allow the next step of linkage pitch operation. This multi-condition judgment mechanism fully ensures the safety of the test and avoids test failure or equipment damage due to abnormal equipment status.

[0104] In some embodiments, after obtaining the actual pitch angle of each axis generated based on the linked pitch command, the method further includes:

[0105] Obtain the trigger status of the self-reset button on the control cabinet panel, which is used to receive control information from the user.

[0106] When the self-reset button is triggered, an emergency feathering command is sent to each axis;

[0107] Acquire the feathering angle feedback data generated by each axis based on the emergency feathering command. The feathering angle feedback data includes the actual pitch angle and the safe position arrival feedback signal of each axis.

[0108] Based on the feedback data of the feathering angle, the safety chain function verification results are generated.

[0109] Emergency feathering is one of the most important safety features of wind turbine generators. When a serious malfunction causes the safety chain to break, the pitch system must be able to independently of the main control system and immediately execute an emergency feathering action, simultaneously rotating all three blades to a 90° safe position to minimize wind energy capture and ensure a safe shutdown of the generator. Verifying this critical safety feature during the workshop commissioning phase is a crucial step in ensuring the safe operation of wind turbine generators in the field.

[0110] The control panel of the intelligent control platform features a self-resetting illuminated metal button as an emergency feathering control button. This button is self-resetting, meaning that pressing it activates the circuit, and releasing it automatically disconnects the circuit, restoring it to its original state. The button has a built-in LED indicator that illuminates solid red when pressed, allowing operators to easily confirm the trigger status.

[0111] Upon detection of a self-reset button trigger, a safety chain disconnect signal is immediately sent to each pitch system. This signal is active low; it outputs a high level during normal operation and a low level when an emergency feathering command is triggered. The emergency feathering command has the highest priority and, once triggered, overrides all ongoing normal pitch operations. The pitch drive immediately propels the blades 90° at the maximum permissible speed until a safe position is reached or the 90° limit switch is triggered.

[0112] During the execution of the emergency feathering command, the actual pitch angle of each axis is read via the CAN communication protocol, and the safe position arrival feedback signal of each axis is read via the digital input module. These two sets of data together constitute the feathering angle feedback data. The feathering angle feedback data includes: the real-time pitch angle change curve of each axis during the emergency feathering process, the timestamp of each axis reaching the 90° safe position, and the trigger status of the safe position arrival feedback signal of each axis. This data comprehensively records the execution process of the emergency feathering function, providing sufficient basis for subsequent functional verification. If the pitch angle of a certain axis does not change significantly within a preset time (e.g., 10 seconds) or does not reach the 90° safe position, it indicates that the emergency feathering function of that axis is faulty.

[0113] Because the mechanical conditions and drive capabilities of the three shafts may differ, a certain degree of variation in arrival time is permissible. However, if the arrival time of one shaft is significantly longer than that of the others, it indicates a potential performance problem with the pitch system of that shaft.

[0114] Check whether the safety position arrival feedback signal of each axis is triggered normally after the blade reaches 90°. If the blade has reached the 90° position but the limit switch is not triggered, it indicates that there is a problem with the installation position or electrical connection of the limit switch.

[0115] When all three evaluation criteria are met, the safety chain function verification result is qualified; otherwise, it is unqualified, and specific fault information needs to be displayed on the interface to guide the debugging personnel to troubleshoot.

[0116] Figure 2 This is a schematic diagram of a testing device for a wind turbine generator set provided by the present invention. The testing device for the wind turbine generator set includes:

[0117] Memory 21 is used to store computer programs;

[0118] The processor 22 is used to execute computer programs to implement the steps of the above-described test method for wind turbine generator sets.

[0119] The description of the testing device for the wind turbine generator provided in this application is given in the above embodiments and will not be repeated here.

[0120] Figure 3 A control logic diagram provided by the present invention;

[0121] Figure 4 A schematic diagram illustrating a CAN communication connection method between a PLC main controller and a pitch system provided by the present invention;

[0122] Figure 5 A schematic diagram of a power supply circuit for a control cabinet provided by the present invention;

[0123] Figure 6 A schematic diagram of a control cabinet switching power supply circuit provided by the present invention;

[0124] Figure 7 A schematic diagram of a communication circuit for a control cabinet provided by the present invention;

[0125] Figure 8 A wiring diagram of the main control and pitch system of the control cabinet is provided for this invention;

[0126] Figure 9 A schematic diagram of a control cabinet signal feedback circuit provided by the present invention;

[0127] The present invention also provides a testing system for wind turbine generator sets, including the aforementioned testing apparatus for wind turbine generator sets, and further comprising:

[0128] The connecting harness is located between the control cabinet and the pitch system of the wind turbine generator set and is used for data transmission;

[0129] The control cabinet is connected to the processor of the wind turbine generator test device, and includes the power supply circuit and the switching power supply module;

[0130] The input end of the power supply circuit is connected to an external power source, and the output end is connected to the pitch system through a wiring harness to provide drive power to the pitch system.

[0131] The input terminal of the switching power supply module is connected to the AC power supply, and the output terminal is connected to the test device of the wind turbine generator set. It is used to convert the AC power supply to DC power to power the test device of the wind turbine generator set.

[0132] Figure 3 The control logic of the intelligent control platform was demonstrated. The intelligent control platform can translate the commands from the main control debugging interface of the engine room into the actions of the wheel hub, and can also feed back the pitch angle of the wheel hub to the debugging interface.

[0133] Figure 4 The CAN communication connection between the PLC main controller and the pitch system is demonstrated.

[0134] Figure 5 The power supply circuit of the control cabinet is shown. The workshop's own three-phase power input is connected to terminals 1, 2, 3, and 4 of X1, and output is connected to terminals 7, 8, 9, and 10 of X1. The heavy-duty plug O connects the control cabinet output to the hub pitch system, and the wiring harness is 5 meters long.

[0135] Figure 6 The control cabinet switching power supply circuit is shown. The input of the switching power supply is phase A of a three-phase power supply, and the output is 24V DC voltage, which is used to power the processor.

[0136] Figure 7 The communication circuitry of the control cabinet was demonstrated. The processor communicates with the hub pitch system via CANopen. The processor uses a DB9 connector with an internal 120Ω resistor to ensure communication quality. The communication cable, 5 meters long, connects to the hub pitch system via a heavy-duty P connector.

[0137] Figure 8 The wiring between the control cabinet processor and the hub pitch system is shown, and the power supply terminals of the processor and the EL1809 digital input module are also labeled.

[0138] Figure 9 The control cabinet signal feedback circuit is demonstrated. Terminals 4 and 5 of X1 correspond to the arrival of all blade safety positions, and the signal is input to the EL1809 module. Terminals 6 and 7 of X1 correspond to the start of the pitch controller, and the signal is input to the EL1809 module. Terminals 8 and 9 of X1 correspond to manual EFC control. A normally closed button SB1 is provided on the control cabinet panel; pressing it disconnects the EFC signal. The signal cable is connected to the hub pitch system via a heavy-duty connector P, and the cable harness length is 5 meters.

[0139] The connecting harness is located between the control cabinet and the pitch system of the wind turbine generator set, and is used to transmit electrical and communication signals. The connecting harness consists of two parts: a power supply cable (heavy-load plug O path) and a signal communication cable (heavy-load plug P path).

[0140] The power supply cable is a 4-core × 2.5mm² copper core flexible cable with a rated voltage of 450 / 750V and a temperature range of -40℃ to +105℃. One end connects to the female connector of the hub pitch system via the male connector O of the heavy-duty plug, and the other end connects to the output terminals and N terminal block of the three-phase circuit breaker in the control cabinet. The power supply cable provides three-phase 400V power to the pitch system, driving the pitch motor and the internal equipment of the shaft cabinet.

[0141] The signal communication cable is a combined shielded cable, consisting of a pair of CAN communication twisted-pair cables (2×2×0.75mm²) and four signal lines (8×0.75mm²). The outer layer is shielded with tinned copper wire braid, with a shielding density of not less than 85%. One end connects to the female connector of the hub pitch system via the male connector of the heavy-duty plug P. The other end splits into two paths: the CAN twisted-pair cable connects to the DB9 interface of the processor communication module, and the signal lines connect to the corresponding terminals of the digital input modules in the control cabinet.

[0142] The length of the connecting harness is 5 meters. Considering that the typical workshop distance between the control cabinet and the hub is 2 to 3 meters, the 5-meter length provides sufficient redundancy. The wiring path can be laid along the workshop floor to avoid being too tight or too droopy. The debugging personnel can move and operate freely within a 360° range around the hub without being hindered by the harness. The standard 5-meter length facilitates unified configuration at multiple workstations in the workshop, enabling the interchangeability and spare management of the harness.

[0143] The control cabinet is connected to the processor of the testing device, including the power supply circuit and the switching power supply module.

[0144] The control cabinet adopts a composite structure of high-strength engineering plastics and aluminum alloy frame. It has an embedded handle on the top and four wear-resistant rubber feet on the bottom, allowing for single-person movement and adjustment. The cabinet surface is coated with an anti-static and wear-resistant coating, achieving an IP54 protection rating, meeting the needs of frequent movement and wear resistance in the workshop.

[0145] The input of the power supply circuit is connected to an external power source in the workshop, and the output is connected to the pitch system via a wiring harness (heavy-load plug O path). The power supply circuit includes a circuit breaker and an isolation transformer. The circuit breaker (rated current 6A) provides dual overload and short-circuit protection. The isolation transformer is located between the switching power supply and the power circuit to prevent grid harmonic interference from affecting the control circuit.

[0146] The input terminal of the switching power supply module is connected to the AC power supply (phase A and neutral wire of a three-phase power supply), and the output terminal is connected to the testing device. The switching power supply module converts the input 230V AC power to DC 24V DC power, providing a stable and reliable DC power supply for low-voltage control circuits such as the processor, digital input module, and communication module. The output power of the switching power supply module is no less than 120W to meet the power requirements of various electrical modules within the control cabinet.

[0147] Figure 10 This invention provides a structural schematic diagram of a heavy-duty plug O;

[0148] Figure 11 This is a schematic diagram of the structure of a heavy-duty plug P provided by the present invention;

[0149] In some embodiments, the connecting harness includes power cables and communication cables;

[0150] One end of the power supply cable is connected to the control cabinet, and the other end is plugged into the pitch system through the first heavy-duty plug to transmit power signals;

[0151] Communication cables include CAN communication harnesses and status feedback harnesses;

[0152] The first end of the CAN communication harness is connected to the test device, and the second end is connected to the pitch system. It is used to transmit the control commands generated by the test device to the pitch system and send the pitch angle collected by the pitch system to the test device.

[0153] The first end of the status feedback harness is connected to the test device, and the second end is connected to the pitch system. It includes a first signal sub-line for transmitting start confirmation signals for each shaft and a second signal sub-line for transmitting safety position arrival feedback signals for each blade.

[0154] The first end of the CAN communication harness is connected to the test device, and the second end is connected to the pitch system. The CAN communication harness is used to transmit control commands generated by the test device to the pitch driver of the pitch system, and at the same time, to send data such as pitch angle and driver status collected by the pitch system to the test device.

[0155] One end of the power supply cable connects to the control cabinet, and the other end plugs into the pitch system via the first heavy-duty connector (i.e., heavy-duty connector O) for transmitting electrical signals. The power supply cable is a 4-core × 2.5mm² copper core flexible cable, with three cores corresponding to the three-phase power supply (L1, L2, L3) and one core as the neutral wire (N). The cable has a rated voltage of 450 / 750V, a temperature range of -40℃ to +105℃, and is wrapped in a flexible, oil-resistant PVC sheath, with a bending life of no less than 5 million cycles, suitable for frequent movement in workshops.

[0156] The heavy-duty plug O uses an industrial-grade heavy-duty connector, with the male end located at the cable end and the female end at the pitch system end. A snap-lock mechanism connects the plug and socket, automatically locking after insertion to ensure it won't loosen under vibration. The plug's metal housing provides excellent electromagnetic shielding, preventing electromagnetic fields generated during high-voltage transmission from interfering with nearby signal cables.

[0157] One end of the communication cable connects to the control cabinet, and the other end plugs into the pitch system via a second heavy-duty connector (i.e., heavy-duty connector P) for transmitting communication signals. The communication cable is a combined shielded cable, containing a pair of CAN communication twisted-pair wires and four signal lines.

[0158] The specifications of the CAN communication twisted-pair cable are 2×2×0.75mm², which means two pairs of twisted wires (one pair is used for CAN_H and CAN_L signal transmission, and the other pair is a spare). The twisted structure of the cable can effectively suppress common-mode interference, and the outer layer uses tinned copper wire braided shielding with a shielding density of not less than 85%, further enhancing the anti-electromagnetic interference capability.

[0159] The four signal cables are 8×0.75mm² (i.e., eight 0.75mm² wires), used for: pitch PLC start signal feedback (1 channel), independent safety position arrival feedback signals for the three blades (3 channels), EFC command downlink transmission (1 channel), and the remaining three channels are for backup. The signal cables are also wrapped with flexible, oil-resistant PVC sheaths, with a bending life of no less than 5 million cycles.

[0160] The communication cable also includes a shielded ground wire, which connects the shielding layers on the control cabinet side and the pitch system side to form a complete shielded loop, further improving anti-interference capabilities.

[0161] The structure of the heavy-duty plug P is similar to that of the heavy-duty plug O, both using industrial-grade heavy-duty connectors, but the pin definitions are different. The O plug is used for high-voltage transmission, while the P plug is used for low-voltage signal transmission. The two plugs use different key designs to prevent mis-insertion.

[0162] The CAN communication harness uses a twisted-pair cable structure, with two wires designated CAN_H and CAN_L. In the CAN bus network, CAN_H and CAN_L are a pair of differential signal lines, with the voltage difference between them representing logic 0 and logic 1. Differential transmission has strong common-mode interference suppression capabilities, making it suitable for use in complex electromagnetic environments such as industrial sites.

[0163] The communication rate of the CAN communication harness can be configured to 125kbps, 250kbps, or 500kbps. The choice of communication rate requires a trade-off between transmission distance and communication reliability: the higher the rate, the greater the amount of data transmitted per unit time, but the transmission distance is correspondingly shortened; the lower the rate, the greater the transmission distance, but the data throughput decreases.

[0164] The first end of the status feedback harness is connected to the test equipment, and the second end is connected to the pitch system. The status feedback harness contains multiple signal sub-wires, each transmitting different types of status signals.

[0165] The first signal sub-line is used to transmit the start confirmation signal (i.e., the pitch PLC start signal) for each axis. This signal is issued by the pitch driver in the pitch system after completing its power-on self-test and is transmitted to the processor via the status feedback harness. The processor uses this signal to determine whether the pitch driver of each axis has been powered on normally and completed initialization, which is one of the important bases for judging the linkage test conditions.

[0166] The second signal sub-line is used to transmit the safety position arrival feedback signal for each blade. Each of the three blades has an independent safety position arrival feedback signal, corresponding to the 90° limit switch status of each of the three axes. When a blade rotates to the 90° safety position, the corresponding limit switch is triggered, sending a high-level (or low-level) signal to the processor via the second signal sub-line. By detecting the trigger status of the three signals, the processor can determine whether all three blades have reached the safety position. This is a crucial basis for verifying the emergency feathering function and determining the results of the linkage test.

[0167] The status feedback harness uses 0.75mm² copper core wire, and the signal transmission uses a DC 24V level, matching the input voltage range (DC 11V to 30V) of the processor (such as EL1809). Each signal sub-line forms a loop with the common ground (0V), and the digital input module determines the presence or absence of a signal by detecting the voltage between the signal line and the ground line.

[0168] In some embodiments, the interface through which the test device communicates with the pitch system is a DB9 type plug-in interface;

[0169] The DB9 type plug-in interface has a terminating resistor for impedance matching between the CAN_H signal terminal and the CAN_L signal terminal, and the DB9 type plug-in interface is equipped with a toggle switch.

[0170] The toggle switch is used to connect or disconnect the terminating resistor from the transmission loop of the CAN communication harness, depending on the physical location of the pitch system in the CAN bus network.

[0171] In CAN bus communication networks, proper configuration of terminating resistors is a key factor in ensuring communication quality. When a signal propagates in the bus cable, if it encounters a point of impedance mismatch, signal reflection will occur. The reflected signal superimposed on the original signal may lead to signal waveform distortion, bit errors, or even complete communication failure. The role of the terminating resistor is to provide a load at both ends of the bus that matches the characteristic impedance of the cable, absorbing the signal energy reaching the end of the bus and thus suppressing signal reflection. A terminating resistor for impedance matching is provided between the CAN_H and CAN_L signal terminals of the DB9 connector. The resistance value of this terminating resistor matches the characteristic impedance of the CAN bus cable. The terminating resistor is pre-soldered inside the DB9 connector and includes a miniature toggle switch for connecting and disconnecting the resistor. The toggle switch simplifies the configuration of the terminating resistor; commissioning personnel do not need to disassemble the DB9 connector for soldering or wiring. They only need to switch the toggle switch to the ON or OFF position according to the position of the pitch system in the bus. During commissioning, simply toggling the DB9 connector switch automatically puts the system into standby mode, eliminating the need for complex parameter configuration. This design significantly lowers the operational threshold for commissioning and improves commissioning efficiency. When the toggle switch is in the ON position, the resistor is connected between CAN_H and CAN_L, ensuring proper impedance matching at the bus end and effectively suppressing signal reflections. When the toggle switch is in the OFF position, the resistor is disconnected from the loop, and this node no longer affects the bus impedance.

[0172] In some embodiments, an emergency feathering simulation circuit is also included;

[0173] The emergency feathering simulation circuit includes a self-reset button and a photoelectric indicator module located on the control cabinet panel.

[0174] The self-reset button is used to output a trigger signal to the pitch system via the connecting harness when it is pressed, and the photoelectric prompt module is used to provide a photoelectric prompt to the user when the self-reset button is pressed.

[0175] The emergency feathering simulation circuit includes a self-reset button located on the control cabinet panel. When pressed, the button outputs a trigger signal (safety chain disconnection signal, active low) to the pitch system via the connecting harness, simulating a safety chain interruption in the engine room. The button has a built-in LED indicator that illuminates solid red when pressed, providing a photoelectric indication to the user and facilitating confirmation of the trigger status by commissioning personnel.

[0176] The emergency feathering simulation circuit is designed independently of the CAN communication link. Even if communication is completely interrupted, this circuit can still trigger the emergency feathering function of the pitch system through the hardware signal path. This redundant design ensures the reliability of the emergency feathering function test and also realistically simulates the field conditions—in actual operation, the safety chain signal is also a hardware protection path independent of the communication link.

[0177] It should also be noted that, in this specification, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0178] Those skilled in the art will further recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.

[0179] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A testing method for wind turbine generator sets, characterized in that, include: Obtain the communication connection status with the pitch system of the wind turbine generator; When the communication connection status is connected, the initial pitch angle of each shaft is obtained. The initial pitch angle is the angle between the chord line of the blade of each shaft and the plane of rotation in the initial state. Based on the initial pitch angle of each shaft, determine whether each shaft meets the preset linkage test conditions; When all the axes meet the linkage test conditions, a linkage pitch command is sent synchronously to each of the axes. Obtain the actual pitch angle of each axis based on the linked pitch command; Based on the consistency between the actual pitch angle of each axis and the target pitch angle corresponding to the linked pitch command, the linkage test results are generated.

2. The test method for wind turbine generator sets as described in claim 1, characterized in that, Obtain the communication connection status of the wind turbine's pitch system, including: The system sends a handshake request frame to the pitch system via the CAN communication protocol and receives a response frame returned by the pitch system based on the handshake request frame. The communication connection status is confirmed as connected or disconnected based on whether the response frame is successfully received within a preset time.

3. The test method for wind turbine generator sets as described in claim 1, characterized in that, Synchronously send coordinated pitch control commands to each of the aforementioned axes, including: Determine the test requirements for the blade to perform either a pitching or feathering action, and set the target test angle based on the test requirements; The initial pitch angle of each axis is obtained, and according to the initial pitch angle and the target test angle, a pitch angle sequence data is generated from the initial pitch angle to the target test angle. There is a preset angle change step size and a preset change rate between adjacent angle values ​​in the pitch angle sequence data. The propeller pitch angle sequence data is encapsulated into a synchronous data frame under the CAN communication protocol; The synchronization data frame is simultaneously broadcast to the pitch driver of each of the axes.

4. The test method for wind turbine generator sets as described in claim 1, characterized in that, Based on the initial pitch angle of each shaft, determine whether each shaft meets the preset linkage test conditions, including: Based on the initial pitch angle of each shaft, determine whether the initial pitch angle of each shaft is within the preset operable angle range. Obtain the safety position arrival feedback signal of each axis, and determine whether the limit switch of each axis is in the normal trigger state based on the safety position arrival feedback signal; Obtain the power-on status signal of each of the pitch drives of the axes, and determine whether each of the pitch drives has been powered on normally based on the power-on status signal. When the initial pitch angles are all within the preset operable angle range, the limit switches are all in the normal trigger state, and the pitch drivers are all powered on normally, it is determined that each shaft meets the linkage test conditions.

5. The test method for wind turbine generator sets as described in any one of claims 1 to 4, characterized in that, After obtaining the actual pitch angle of each of the axes based on the linked pitch command, the method further includes: The trigger status of the self-reset button on the control cabinet panel is obtained, and the control cabinet panel is used to receive user control information; When the self-reset button is triggered, an emergency feathering command is sent to each of the axes; Obtain the feathering angle feedback data generated by each of the axes based on the emergency feathering command. The feathering angle feedback data includes the actual pitch angle and the safe position arrival feedback signal of each axis. Based on the feedback data of the feathering angle, a safety chain function verification result is generated.

6. A testing device for a wind turbine generator set, characterized in that, include: Memory, used to store computer programs; A processor for executing the computer program to implement the steps of the test method for a wind turbine generator set as described in any one of claims 1 to 5.

7. A testing system for a wind turbine generator set, characterized in that, The testing apparatus for wind turbine generator sets as described in claim 6 further includes: The connecting harness is located between the control cabinet and the pitch system of the wind turbine generator set and is used for data transmission; The control cabinet is connected to the processor of the test device for the wind turbine generator set, and includes a power supply circuit and a switching power supply module. The input end of the power supply circuit is connected to an external power source, and the output end is connected to the pitch system through the connecting harness to provide drive power to the pitch system. The input terminal of the switching power supply module is connected to an AC power source, and the output terminal is connected to the testing device of the wind turbine generator set. It is used to convert the AC power source into DC power to power the testing device of the wind turbine generator set.

8. The testing system for wind turbine generator sets as described in claim 7, characterized in that, The connecting harness includes power cables and communication cables; One end of the power supply cable is connected to the control cabinet, and the other end is plugged into the pitch system through the first heavy-duty plug for transmitting power signals; The communication cable includes a CAN communication harness and a status feedback harness; The first end of the CAN communication harness is connected to the test device, and the second end is connected to the pitch system. It is used to transmit the control commands generated by the test device to the pitch system and send the pitch angle collected by the pitch system to the test device. The first end of the status feedback harness is connected to the test device, and the second end is connected to the pitch system. It includes a first signal sub-line for transmitting start confirmation signals for each shaft and a second signal sub-line for transmitting safety position arrival feedback signals for each blade.

9. The testing system for wind turbine generator sets as described in claim 8, characterized in that, The interface for communication between the test device and the pitch system is a DB9 type plug-in interface; A terminating resistor for impedance matching is provided between the CAN_H signal terminal and the CAN_L signal terminal of the DB9 type plug-in interface, and a toggle switch is provided on the DB9 type plug-in interface. The toggle switch is used to connect or disconnect the terminating resistor from the transmission circuit of the CAN communication harness according to the physical location of the pitch system in the CAN bus network.

10. The test system for wind turbine generator sets as described in any one of claims 7 to 9, characterized in that, It also includes an emergency feathering simulation circuit; The emergency feathering simulation circuit includes a self-reset button and a photoelectric prompt module located on the control cabinet panel. The self-reset button is used to output a trigger signal to the pitch system through the connecting harness when it is pressed, and the photoelectric prompt module is used to provide a photoelectric prompt to the user when the self-reset button is pressed.

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