A method for detecting a generator rotor inter-pole connection wire

Abstract

The application provides a generator rotor inter-pole connecting wire detection method, which is suitable for a generator rotor inter-pole connecting wire detection device and comprises the following steps: installing an auxiliary tool on a generator main shaft by using a mounting mechanism; inserting a second end of a probe rod into a to-be-detected area from a gap between the generator main shaft and a generator rotor; adjusting the height of a probe mounting seat by using a height adjusting assembly, and installing a first end of the probe rod on the probe mounting seat; adjusting the included angle between a detection end and the probe rod by using an angle adjusting assembly, so that the detection surface of an eddy current sensor faces the rotor inter-pole connecting wire; driving the detection probe to rotate around the circumference of the generator main shaft by using the auxiliary tool, so that the eddy current sensor rotates and scans detection around the generator main shaft by 360°; and analyzing the scanning information of the eddy current sensor to determine the defect position. The method can realize the detection of the rotor inter-pole connecting wire without disassembling the generator, and is helpful to improve the efficiency and safety of wind power operation and maintenance.

Description

Technical Field

[0001] This application relates to the field of generator testing technology, and more specifically, to a method for testing the inter-pole connection wires of a generator rotor. Background Technology

[0002] As a core component of renewable energy generation, the operational stability of wind turbines directly impacts the reliability and power quality of the power system. Among them, doubly-fed asynchronous wind turbines have become the mainstream model in the wind power industry due to their advantages such as low cost, small power converter capacity, and good operational performance. However, during long-term operation, the inter-pole connecting wires of the generator rotor are highly susceptible to cracking, burning, and breakage due to the combined effects of centrifugal force generated by high-speed rotation, periodic vibration, temperature rise, and alternating electromagnetic forces.

[0003] Currently, the inspection of rotor inter-pole connections mainly relies on visual inspection or contact testing methods after shutdown and disassembly. During operation and maintenance, a significant amount of time is often required for disassembly, cleaning, and reassembly, leading not only to long maintenance cycles and high costs but also the potential introduction of new safety hazards.

[0004] Therefore, there is an urgent need to develop an eddy current detection method for the inter-pole connection wires of in-service wind turbine rotors, which can achieve high-precision and high-reliability defect detection without disassembly, so as to improve the efficiency and safety of wind power operation and maintenance. Summary of the Invention

[0005] This application provides at least one method for detecting the inter-pole connection wires of a generator rotor. This method can detect the inter-pole connection wires of the rotor without disassembling the generator, which helps to improve the efficiency and safety of wind power operation and maintenance.

[0006] This application provides a method for detecting generator rotor inter-pole connection wires, applicable to generator rotor inter-pole connection wire detection devices. The generator rotor inter-pole connection wire detection device includes auxiliary fixtures and a detection probe. The auxiliary fixture includes a base, a mounting mechanism, a probe mounting seat, and a height adjustment component. The base is mounted on the generator main shaft via the mounting mechanism and can rotate circumferentially around the generator main shaft. The probe mounting seat is disposed on the base. The height adjustment component is disposed between the probe mounting seat and the base and can adjust the height of the probe mounting seat relative to the base. The detection probe includes a probe rod, a detection end, an angle adjustment mechanism, and an eddy current sensor. The probe rod is conformally bendable and has a first end and a second end. The first end is detachably mounted on the auxiliary fixture, and the detection end is hinged to the second end. The angle adjustment mechanism is disposed on the probe rod and can adjust the angle between the detection end and the probe rod. The eddy current sensor is disposed on the detection end. The method includes: The auxiliary tooling is installed on the generator main shaft using the installation mechanism; Insert the second end of the probe into the area to be tested through the gap between the generator main shaft and the generator rotor; The height of the probe mounting base is adjusted using the height adjustment component, and the first end of the probe rod is mounted on the probe mounting base. The angle between the detection end and the probe is adjusted using an angle adjustment component so that the detection surface of the eddy current sensor faces the rotor inter-pole connection line. The auxiliary tooling is used to drive the detection probe to rotate circumferentially around the generator main shaft, so that the eddy current sensor can rotate 360° around the generator main shaft for scanning and detection; The scanning information from the eddy current sensor is analyzed to determine the location of the defect.

[0007] In one optional embodiment, the mounting mechanism includes a first chain, a second chain, a first connecting part, and a second connecting part; One end of the first chain is connected to the base, and the other end is connected to the first connecting part; One end of the second chain is connected to the base, and the other end is connected to the second connecting part; The first connecting part and the second connecting part are configured to engage to mount the base onto the generator main shaft.

[0008] In one alternative embodiment, the height adjustment assembly includes a guide post, a stud, and a rotary handle; The guide post is disposed on the base and passes through the probe mounting seat, and the guide post can guide the probe mounting seat to move along the axial direction of the guide post; The stud is rotatably mounted on the base and parallel to the guide post, and the stud is threadedly engaged with the probe mounting seat; The rotating handle is connected to the stud, and the rotating handle is used to drive the stud to rotate circumferentially so that the probe mounting base can move axially along the guide post.

[0009] In one optional embodiment, the auxiliary tooling further includes an angle encoder disposed on the base. The angle encoder is used to detect the angle of rotation of the base relative to the generator main shaft to ensure that the detection probe completes 360° rotational scanning detection.

[0010] In one alternative embodiment, the angle adjustment mechanism includes a first elastic element and a driving element; The first elastic element is disposed between the probe and the detection end, and the first elastic element is configured to maintain a 90° angle between the detection end and the probe when no external force is applied; The driving member is connected to the detection end, and the driving member is configured to overcome the elastic force of the first elastic member and drive the detection end to rotate relative to the probe rod, so as to reduce the included angle between the detection end and the probe rod.

[0011] In one alternative implementation, the driving element is a pull rope.

[0012] In one alternative embodiment, the angle adjustment mechanism further includes a second elastic element and a push button; The second elastic element is disposed at the first end of the probe and connected to the driving element. The second elastic element has a free state and a compressed state. In the free state, the second elastic element pulls the driving element to drive the detection end to rotate relative to the probe to reduce the angle between the detection end and the probe. In the compressed state, the second elastic element releases the driving element to maintain a 90° angle between the detection end and the probe. The push button is located at the first end of the probe rod, and the push button is configured to move relative to the probe rod to change the state of the second elastic element.

[0013] In one optional embodiment, the detection probe further includes a spring-loaded mechanism disposed at the second end of the probe rod, the spring-loaded mechanism including a guide tube, a connecting end, and an elastic support member; The catheter is disposed at the second end of the probe, and the axis of the catheter coincides with the axis of the probe; The connecting end is movably disposed on the conduit, the detection end is disposed on the connecting end, and the connecting end is capable of moving along the axial direction of the conduit when the eddy current sensor squeezes the rotor interpole connecting line; The elastic support is sleeved on the conduit and located between the probe and the connecting end. The elastic support can stretch / contract when the connecting end moves, so that the eddy current sensor fits against the part to be measured under the elastic force of the elastic support.

[0014] In one optional embodiment, the detection probe further includes a vision sensor disposed at the second end, the vision sensor being used to acquire image information of the rotor inter-pole connection line, the image information being used to verify defects in the rotor inter-pole connection line.

[0015] In one optional embodiment, the detection probe further includes a steering mechanism disposed at the second end of the probe rod, the steering mechanism including a base plate and a rotating part; The substrate is disposed on the probe; The rotating part is rotatably disposed on the substrate, and the vision sensor is disposed on the rotating part. The rotating part can rotate relative to the substrate to adjust the shooting angle of the vision sensor.

[0016] The above-mentioned technical solution of this application has the following beneficial technical effects: The generator rotor pole connection wire detection method of this application embodiment can detect the rotor pole connection wire without disassembling the generator, which helps to improve the efficiency and safety of wind power operation and maintenance.

[0017] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly described below. These drawings are incorporated in and constitute a part of this specification. They illustrate embodiments conforming to this application and, together with the specification, serve to explain the technical solutions of this application. It should be understood that the following drawings only show some embodiments of this application and should not be considered as limiting the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0019] Figure 1 This paper shows a schematic diagram of the structure of a generator rotor pole connection detection device provided in an embodiment of this application; Figure 2 It shows Figure 1 A schematic diagram of the auxiliary tooling in the process; Figure 3 It shows Figure 2 A front view of the auxiliary tooling in the process; Figure 4 It shows Figure 3 A schematic diagram of the installation mechanism in the diagram; Figure 5 It shows Figure 1 A schematic diagram of the detection probe in the diagram; Figure 6 It shows Figure 5 A schematic diagram showing the angle between the detection end and the probe rod is 0°. Figure 7 It shows Figure 5A schematic diagram showing the angle between the detection end and the probe rod is 90°. Figure 8 It shows Figure 5 A schematic diagram of the installation of the vision sensor in the image; Figure 9 It shows Figure 1 A schematic diagram of the detection device for the inter-pole connection wire of the generator rotor in the diagram; Figure 10 It shows Figure 9 A sectional view; In the picture: 1. Generator main shaft; 2. Generator rotor; 1000. Auxiliary tooling; 1100. Base; 1200. Mounting mechanism; 1210. First chain; 1220. Second chain; 1230. First connecting part; 1231. Threaded hole; 1240. Second connecting part; 1241. Screw; 1250. Wheel set; 1260. Arc hook; 1270. Auxiliary handle; 1300. Probe mounting base; 1310. Mounting hole; 1320. Limit screw; 1400. Height adjustment assembly; 1410. Guide column ; 1420, Stud; 1430, Nut; 1440, Rotary Handle; 2000, Detection Probe; 2100, Probe Rod; 2110, First Rod Section; 2120, Second Rod Section; 2200, Eddy Current Sensor; 2300, Operating Handle; 2400, Detection End; 2500, Angle Adjustment Mechanism; 2510, Drive Component; 2520, Second Elastic Component; 2530, Push Button; 2600, Vision Sensor; 2700, Steering Mechanism; 2710, Base Plate; 2720, Rotating Part; 2730, Silicone Sleeve. Detailed Implementation

[0020] Various exemplary embodiments of the present application will now be described in detail with reference to the accompanying drawings. It should be noted that, unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the present application.

[0021] The embodiments of this application will now be described in detail. Examples of these embodiments are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0022] The terms "first" and "second" in the specification and claims of this application may explicitly or implicitly include one or more of the features. In the description of this application, unless otherwise stated, "multiple" means two or more. Furthermore, "and / or" in the specification and claims indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0023] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0024] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0025] refer to Figures 1 to 10 This application provides a generator rotor 2 inter-pole connection wire detection device, including an auxiliary fixture 1000 and a detection probe 2000. The auxiliary fixture 1000 is mounted on the generator main shaft 1 and is rotatable around the generator main shaft 1. The detection probe 2000 is mounted on the auxiliary fixture 1000 and includes a probe rod 2100 and a detection device. The probe rod 2100 has a first end connected to the auxiliary fixture 1000 and a second end away from the auxiliary fixture 1000. The detection device is mounted on the second end. The probe rod 2100 is configured to insert the second end into the area to be tested from the gap between the generator main shaft 1 and the generator rotor 2, so that the detection device can detect defects in the inter-pole connection wire.

[0026] Optionally, such as Figure 2As shown, the auxiliary fixture 1000 includes a base 1100 and a mounting mechanism 1200. The base 1100 is used to mount the detection probe 2000. The mounting mechanism 1200 is disposed on the base 1100 and is used to mount the base 1100 to the generator main shaft 1 and allow the base 1100 to rotate circumferentially relative to the generator main shaft 1.

[0027] Optionally, such as Figure 3 and Figure 4 As shown, the mounting mechanism 1200 includes a first chain 1210, a second chain 1220, a first connecting part 1230, and a second connecting part 1240. One end of the first chain 1210 is connected to the base 1100, and the other end is connected to the first connecting part 1230. One end of the second chain 1220 is connected to the base 1100, and the other end is connected to the second connecting part 1240. The first connecting part 1230 and the second connecting part 1240 are configured to engage. During installation, the first chain 1210 and the second chain 1220 wrap around the back side of the generator main shaft 1 from both sides, and then engage through the first connecting part 1230 and the second connecting part 1240. Specifically, the first chain 1210 and the second chain 1220 (and the base 1100) are assembled into a loop during installation to fit the base 1100 onto the generator main shaft 1. In a specific configuration, the side of the base 1100 facing the generator main shaft 1 may have an arc surface conforming to the shape of the generator main shaft 1.

[0028] Optionally, both the first chain 1210 and the second chain 1220 include multiple chain links and multiple shafts, with the chain links arranged sequentially and adjacent chain links connected by shafts. In specific configurations, the chain links can be configured to conform to the generator main shaft 1.

[0029] Optionally, such as Figure 3 and Figure 4 As shown, both the first chain 1210 and the second chain 1220 are provided with wheel sets 1250 on both sides of their width direction. That is, each end of the shaft of the first chain 1210 and the second chain 1220 can be provided with a sliding wheel, which can reduce the friction when the base 1100 rotates around the generator main shaft 1.

[0030] Optionally, the first connecting portion 1230 and the second connecting portion 1240 are joined by a threaded connection. For example... Figure 4 As shown in the example, the first connecting part 1230 is provided with a threaded hole 1231, and the second connecting part 1240 is rotatably provided with a screw 1241, which can be threadedly engaged with the threaded hole 1231.

[0031] Optionally, the first connecting portion 1230 is hinged to the first chain 1210, and the first connecting portion 1230 and the second connecting portion 1240 can engage tangentially along the generator main shaft 1. This arrangement allows the mounting mechanism 1200 to mount the base 1100 onto generator main shafts 1 of different diameters. Specifically, the greater the engagement length of the first connecting portion 1230 and the second connecting portion 1240, the smaller the diameter of the annular structure formed by the first chain 1210 and the second chain 1220 (and the base 1100), allowing the mounting mechanism 1200 to mount the base 1100 onto generator main shafts 1 with smaller diameters. Conversely, the smaller the engagement length of the first connecting portion 1230 and the second connecting portion 1240, the larger the diameter of the annular structure formed by the first chain 1210 and the second chain 1220 (and the base 1100), allowing the mounting mechanism 1200 to mount the base 1100 onto generator main shafts 1 with larger diameters.

[0032] Optionally, such as Figure 3 and Figure 4 As shown, the mounting mechanism 1200 also includes an arc-shaped hook 1260, which has a first end and a second end opposite to each other along the bending direction. The first end is hinged to the first chain 1210, and the first connecting part 1230 is hinged to the second end and located inside the arc-shaped hook 1260. Specifically, the arc-shaped hook 1260 bends outward and is used to extend the length of the first chain 1210, so that the first connecting part 1230 and the second connecting part 1240 can be engaged when applicable to spindles of different diameters. At the same time, it avoids interference between the first chain 1210 and the second chain 1220 due to excessive length, which would prevent the mounting mechanism 1200 from being installed.

[0033] Optionally, such as Figure 3 and Figure 4 As shown, the mounting mechanism 1200 also includes an auxiliary handle 1270, which is hinged to the end of the arc-shaped hook 1260 away from the first chain 1210 and located on the outside of the arc-shaped hook 1260. A first connecting portion 1230 is disposed on (or hinged to) the auxiliary handle 1270. This arrangement facilitates adjustment of the angle of the first connecting portion 1230 to engage the first connecting portion 1230 and the second connecting portion 1240. Specifically, during installation, the operator can manipulate the auxiliary handle 1270 to adjust the angle of the first connecting portion 1230, thereby aligning the threaded hole 1231 with the screw 1241 to engage the first connecting portion 1230 and the second connecting portion 1240.

[0034] In other embodiments, the base 1100 may also be mounted on the generator spindle 1 using other mechanisms, such as using a magnetic structure to attach the base 1100 to the surface of the generator spindle 1.

[0035] Optionally, such as Figure 2 and Figure 3 As shown, the auxiliary fixture 1000 also includes a probe mounting base 1300 and a height adjustment assembly 1400. The probe mounting base 1300 is disposed on the base 1100, and the detection probe 2000 is mounted on the base 1100 via the probe mounting base 1300. The height adjustment assembly 1400 is disposed between the probe mounting base 1300 and the base 1100, and is configured to adjust the height of the probe mounting base 1300 relative to the base 1100. In use, by adjusting the height of the probe mounting base 1300 via the height adjustment assembly 1400, the installation height of the probe rod 2100 can be matched with that of the probe mounting base 1300.

[0036] For example, such as Figure 2 and Figure 3 As shown, the height adjustment assembly 1400 includes a guide post 1410, a stud 1420, and a rotary handle 1440. The guide post 1410 is disposed on the base 1100 and passes through the probe mounting base 1300. The guide post 1410 can guide the probe mounting base 1300 to move along the axial direction of the guide post 1410. The stud 1420 is rotatably disposed on the base 1100 and parallel to the guide post 1410. The stud 1420 is threadedly engaged with the probe mounting base 1300 (or the nut 1430 connected to the probe mounting base 1300). The rotary handle 1440 is connected to the stud 1420 and is used to drive the stud 1420 to rotate circumferentially so that the probe mounting base 1300 moves along the axial direction of the guide post 1410. In use, the operator can rotate the rotary handle 1440 to drive the stud 1420 to rotate circumferentially, thereby moving the probe mounting base 1300 along the axial direction of the guide post 1410 to adjust the height of the probe mounting base 1300 relative to the base 1100, thus satisfying the installation height of the first end of the probe rod 2100.

[0037] Optionally, such as Figure 3 As shown, the probe mounting base 1300 is provided with a mounting hole 1310, and the first end of the probe rod 2100 is inserted into the mounting hole 1310. Furthermore, to ensure installation stability, the probe mounting base 1300 can be provided with a limiting screw 1320. After the probe rod 2100 is inserted into the mounting hole 1310, the limiting screw 1320 is tightened to compress the probe rod 2100, preventing it from moving freely. Of course, the probe mounting base 1300 can also use other structures to fix the probe rod 2100, such as clips.

[0038] Optionally, the auxiliary tooling 1000 also includes an angle encoder (not shown in the figure), which is mounted on the base 1100 and is used to detect the angle of rotation of the base 1100 relative to the generator main shaft 1. In actual use, the angle encoder records the real-time angle of probe rotation (such as the cross-sectional detection position every 15°), and combines it with the Z-axis (axial position) and R-axis (radial distance) to construct a three-dimensional defect location model in a polar coordinate system (Z-θ-R).

[0039] Optionally, the probe 2100 has a hollow tubular structure, and the power lines, signal lines, etc. of the detection device can be led out through the inside of the probe 2100.

[0040] Optionally, the probe 2100 can be conformally bent to insert its second end from the gap between the generator main shaft 1 and the generator rotor 2 into the area to be measured. For example... Figure 5 As shown in this embodiment, the probe 2100 includes a first segment 2110 and a second segment 2120 connected from the first end to the second end. The second segment 2120 is bendable, and the detection device is located at the end of the second segment 2120 away from the first segment 2110. During the insertion of the second end into the gap between the generator main shaft 1 and the generator rotor 2, the operator can bend the second segment 2120 to allow it to reach the area to be tested smoothly.

[0041] Optionally, the first segment 2110 includes a nickel-titanium alloy skeleton (e.g., Φ8mm in diameter) and a lightweight aluminum alloy outer layer (e.g., 6061-T6). This ensures structural rigidity while reducing structural weight.

[0042] Optionally, the second segment 2120 is made of nickel-titanium alloy superelastic tube (outer diameter Φ6mm, wall thickness 0.5mm), with a pre-bending angle of 30°~60° (adjustable by manual plasticity). Furthermore, a wear-resistant and insulating polyurethane sheath (Shore hardness 80A) can be installed on the outside of the nickel-titanium alloy superelastic tube.

[0043] Optionally, such as Figure 1 and Figure 5 As shown, the detection device includes an eddy current sensor 2200, which is used to detect defects in the rotor pole connection wire. Specifically, when the auxiliary tooling 1000 drives the detection probe 2000 to rotate circumferentially around the generator main shaft 1, the eddy current sensor 2200 rotates 1360° around the generator main shaft 1 to scan and detect defects. The location of the defects is then determined by analyzing the scanning information of the eddy current sensor 2200.

[0044] Optionally, the eddy current sensor 2200 can be a 16-channel array eddy current sensor 2200 with a frequency greater than 1MHz, which can improve detection efficiency. For example, the eddy current sensor 2200 can be a 4×4 rectangular array, with a single probe size of 2mm×2mm, a spacing of 0.5mm, and a coverage area of ​​10mm×10mm. Of course, the eddy current sensor 2200 can also be an 8-channel array eddy current sensor 2200 or a 32-channel array eddy current sensor 2200, etc.

[0045] Optionally, such as Figure 1 , Figure 5 , Figure 6 and Figure 7 As shown, the detection probe 2000 also includes an operating handle 2300, which is located at the first end of the probe rod 2100. In use, the operator can insert the second end of the probe rod 2100 into the area to be measured by holding the operating handle 2300. Alternatively, the operating handle 2300 can be installed in place of the probe rod 2100 on the auxiliary fixture 1000.

[0046] Optionally, such as Figure 1 , Figure 5 , Figure 6 and Figure 7 As shown, the detection probe 2000 also includes a detection end 2400 and an angle adjustment mechanism 2500. The detection end 2400 is hinged to the second end of the probe rod 2100, and the eddy current sensor 2200 is disposed on the detection end 2400. The angle adjustment mechanism 2500 is disposed on the probe rod 2100 and is configured to drive the detection end 2400 to rotate relative to the probe rod 2100 to adjust the angle between the detection end 2400 and the probe rod 2100. In use, during insertion, a small angle (0°) can be maintained between the detection end 2400 and the probe rod 2100. When the second end of the probe rod 2100 reaches the area to be measured, the angle between the detection end 2400 and the probe rod 2100 can be adjusted so that the detection surface of the eddy current sensor 2200 faces the rotor inter-pole connection line. This configuration facilitates the insertion of the second end of the probe rod 2100 into the area to be measured and reduces interference.

[0047] Optionally, such as Figure 6 and Figure 7As shown, the angle adjustment mechanism 2500 includes a first elastic element (not shown) and a driving element 2510. The first elastic element is disposed between the probe 2100 and the detection end 2400, and is configured to maintain a 90° angle between the detection end 2400 and the probe 2100 when no external force is applied. The driving element 2510 is connected to the detection end 2400, and is configured to overcome the elastic force of the first elastic element and drive the detection end 2400 to rotate relative to the probe 2100, thereby reducing the angle between the detection end 2400 and the probe 2100. When in use, if the driving component 2510 is not applied to the detection end 2400, the detection end 2400 maintains a 90° angle with the probe rod 2100 under the action of the first elastic element. When the operator operates the driving component 2510 to rotate the detection end 2400 relative to the probe rod 2100, the angle between the detection end 2400 and the probe rod 2100 can be reduced. After installation, when the operator stops operating the driving component 2510, the effect of the driving component 2510 on the detection end 2400 disappears, and the detection end 2400 can return to its initial angle under the action of the first elastic element.

[0048] Optionally, the first elastic element may consist of a hinge and a spring. For example, the hinge may be formed by three joints connected in series via miniature needle roller bearings, with the spring positioned between each pair of adjacent joints. When no external force is applied, the spring can bend the hinge (each joint can deflect by 30°, allowing the hinge as a whole to bend by 90°), thereby driving the detection end 2400 to rotate relative to the probe 2100, maintaining a 90° angle between the detection end 2400 and the probe 2100. When a 0° angle is maintained between the detection end 2400 and the probe 2100, the hinge is in a straight state and the spring is compressed.

[0049] Optionally, the drive unit 2510 is a pull rope, which can be led out from inside the probe 2100 to facilitate the operation of the pull rope by the operator.

[0050] Optionally, such as Figure 6 and Figure 7As shown, the angle adjustment mechanism 2500 also includes a second elastic element 2520 and a push button 2530. The second elastic element 2520 is disposed at the first end of the probe 2100 (or the operating handle 2300) and connected to the drive element 2510. The second elastic element 2520 has a free state and a compressed state. In the free state, the second elastic element 2520 pulls the drive element 2510 to drive the detection end 2400 to rotate relative to the probe 2100, thereby reducing the angle between the detection end 2400 and the probe 2100. In the compressed state, the second elastic element 2520 releases the drive element 2510 to maintain a 90° angle between the detection end 2400 and the probe 2100. The push button 2530 is disposed at the first end of the probe 2100 (or the operating handle 2300) and is configured to move relative to the probe 2100 (or the operating handle 2300) to change the state of the second elastic element 2520. This embodiment exemplarily illustrates that the push button 2530 is disposed on the operating handle 2300, and the moving direction of the push button 2530 is consistent with the axial direction of the operating handle 2300. In use, while the operator holds the operating handle 2300, they can push the push button 2530 forward with their thumb to compress the second elastic element 2520. When the thumb releases the push button 2530, the second elastic element 2520 returns to its free state under its own elastic force, thus resetting the push button 2530.

[0051] Optionally, the first end of the probe 2100 (or the operating handle 2300) is provided with a scale mark, which is used to indicate the sliding stroke of the push button 2530. In specific settings, the operator can determine the angle between the detection end 2400 and the probe 2100 by using different scale marks. For example, when the push button 2530 is at the 0mm position, it can be determined that there is a 90° angle between the detection end 2400 and the probe 2100. For every 5mm that the push button 2530 advances, the corresponding detection end 2400 rotates 15°.

[0052] Optionally, the angle adjustment structure also includes a locking component (not shown in the figure). The locking component is disposed on the operating handle 2300 and is used to lock the push button 2530, so that the second elastic element 2520 is kept in a compressed state. This locks the push button 2530 and prevents the reaction force of the second elastic element 2520 from continuously acting on the thumb and causing damage. In specific settings, the locking component can be a mechanical snap-locking mechanism, a spring-loaded locking mechanism, etc.

[0053] Optionally, the detection probe 2000 also includes a spring-loaded mechanism (not shown in the figure), which is disposed at the second end of the probe rod 2100. The eddy current sensor 2200 (or detection end 2400) is disposed on the spring-loaded mechanism. The spring-loaded mechanism is configured to be able to elastically deform when the eddy current sensor 2200 squeezes the rotor inter-pole connecting line, so that the eddy current sensor 2200 fits against the rotor inter-pole connecting line under the elastic force of the spring-loaded mechanism.

[0054] Optionally, the spring-loaded mechanism includes a conduit, a connecting end, and an elastic support. The conduit is disposed at the second end of the probe 2100, and the axis of the conduit coincides with the axis of the probe 2100. The connecting end is movably disposed on the conduit, and the eddy current sensor 2200 (or detection end 2400) is disposed on the connecting end. The connecting end can move axially along the conduit when the eddy current sensor 2200 compresses the rotor inter-pole connecting wire. The elastic support is sleeved on the conduit and located between the probe 2100 and the connecting end. The elastic support can stretch / contract when the connecting end moves, so that the eddy current sensor 2200 fits against the part to be measured under the elastic force of the elastic support.

[0055] Optionally, such as Figure 5 and Figure 8 As shown, the detection device also includes a vision sensor 2600, which is used to acquire image information of the rotor inter-pole connection line. The image information is used to verify defects in the rotor inter-pole connection line. It should be understood that, in specific implementations, the vision sensor 2600 can also capture images of the area between the spindle and the rotor to assist the probe 2100 in avoiding interference objects during insertion.

[0056] Alternatively, the vision sensor 2600 can be a camera, specifically an OV2740 CMOS sensor (1 / 4-inch, 2-megapixel) paired with a 60° wide-angle lens (2.8mm focal length). Additionally, the camera can be equipped with illumination, such as integrated four LEDs (5600K color temperature, adjustable brightness) arranged in a ring around the camera.

[0057] Optionally, such as Figure 5 and Figure 8 As shown, the detection probe 2000 also includes a steering mechanism 2700, which is disposed at the second end of the probe rod 2100. The vision sensor 2600 is disposed on the probe rod 2100 via the steering mechanism 2700. The steering mechanism 2700 is configured to adjust the shooting angle of the vision sensor 2600. In use, the operator can operate the steering mechanism 2700 to adjust the shooting angle of the vision sensor 2600 so that the vision sensor 2600 can capture image information of the rotor pole connection line.

[0058] Optionally, such as Figure 8As shown, the steering mechanism 2700 includes a base plate 2710 and a rotating part 2720. The base plate 2710 is disposed (e.g., welded) on the probe rod 2100 (the side of the second rod segment 2120). The rotating part 2720 is rotatably disposed on the base plate 2710, and a vision sensor 2600 is disposed on the rotating part 2720. The rotating part 2720 can rotate relative to the base plate 2710 to adjust the shooting angle of the vision sensor 2600. This embodiment exemplarily shows that the rotating part 2720 is a threaded post, and the vision sensor 2600 is disposed at one end of the threaded post. In use, the operator can adjust the shooting angle of the vision sensor 2600 by screwing the threaded post, so that the vision sensor 2600 can accurately acquire image information of the rotor inter-pole connection line.

[0059] Optionally, the steering mechanism 2700 further includes a positioning component (not shown in the figure), which is disposed between the base plate 2710 and the rotating part 2720 to position the rotation angle of the rotating part 2720 relative to the base plate 2710. For example, the positioning component can be a magnetic positioning component, which includes a magnet and a Hall sensor. When the magnet rotates with the rotating part 2720, its magnetic field distribution changes with the angle. The Hall sensor detects the change in magnetic field and outputs an electrical signal. The electrical signal is converted into an angle value by an algorithm to achieve non-contact positioning.

[0060] Optionally, a shock-absorbing material is provided between the visual sensor 2600 and the rotating part 2720 to improve camera stability and prevent image blurring due to camera shake. For example, as Figure 8 As shown, a silicone sleeve 2730 is provided at one end of the rotating part 2720, and the vision sensor 2600 is inserted into the silicone sleeve 2730, which enables the installation and vibration reduction of the vision sensor 2600.

[0061] This application also provides a method for detecting the connection wire between the two poles of a generator rotor, including the following steps: 1. A device for detecting the connection wire between the two poles of a generator rotor includes an auxiliary fixture 1000 and a detection probe 2000. The auxiliary fixture 1000 includes a base 1100, a mounting mechanism 1200, a probe mounting seat 1300, and a height adjustment component 1400. The base 1100 is mounted on the generator main shaft 1 via the mounting mechanism 1200 and can rotate around the circumference of the generator main shaft 1. The probe mounting seat 1300 is disposed on the base 1100. The height adjustment component 1400 is disposed between the probe mounting seat 1300 and the base 1100 and can adjust the probe mounting seat 1300. Relative to the height of the base 1100, the detection probe 2000 includes a probe rod 2100, a detection end 2400, an angle adjustment mechanism 2500, and an eddy current sensor 2200. The probe rod 2100 is conformally bendable and has a first end and a second end. The first end is detachably mounted on the auxiliary tooling 1000, and the detection end 2400 is hinged to the second end. The angle adjustment mechanism is provided on the probe rod 2100 and can adjust the angle between the detection end 2400 and the probe rod 2100. The eddy current sensor 2200 is provided on the detection end 2400.

[0062] 2. Use the mounting mechanism 1200 to install the auxiliary tooling 1000 onto the generator main shaft 1; 3. Insert the second end of the probe 2100 into the area to be measured through the gap between the generator main shaft 1 and the generator rotor 2; 4. Adjust the height of the probe mounting base 1300 using the height adjustment component 1400, and install the first end of the probe rod 2100 onto the probe mounting base 1300. 5. Adjust the angle between the detection end 2400 and the probe 2100 using the angle adjustment component so that the detection surface of the eddy current sensor 2200 faces the rotor inter-pole connection line; 6. Use auxiliary tooling 1000 to drive the detection probe 2000 to rotate around the generator main shaft 1 in a circumferential direction, so that the eddy current sensor 2200 can rotate around the generator main shaft 1360° to scan and detect. 7. Analyze the scanning information of the eddy current sensor 2200 to determine the location of the defect.

[0063] Furthermore, during the testing process, a cross-sectional inspection is performed every 15° rotation, covering the entire connecting line area.

[0064] Furthermore, during the detection process, each channel of the eddy current sensor 2200 is independently excited and received. By calculating the impedance amplitude / phase i of each channel, a C-scan image is generated and mapped using polar coordinates Z-θ-R.

[0065] Furthermore, during the detection process, an adaptive wavelet denoising algorithm is used to suppress electromagnetic interference.

[0066] Furthermore, during the inspection process, the visual sensor 2600 is used to acquire image information of the rotor inter-pole connection lines, and the defects in the rotor inter-pole connection lines are verified based on the image information. Specifically, eddy current signals and video images are fused to achieve defect localization, quantification, and cross-verification.

[0067] Furthermore, during the detection process, the data from the eddy current sensor 2200 and the video sensor are transmitted in real time to the terminal device via a wireless transmission module for analysis and storage.

[0068] The generator rotor pole connection wire detection device of this application embodiment can detect the rotor pole connection wire without disassembling the generator, which helps to improve the efficiency and safety of wind power operation and maintenance.

[0069] One or more embodiments in this specification are intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of one or more embodiments in this specification should be included within the protection scope of this application.

[0070] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A method for detecting the inter-pole connection wires of a generator rotor, characterized in that, A generator rotor inter-pole connection wire detection device is applicable. The device includes auxiliary fixtures and a detection probe. The auxiliary fixture includes a base, a mounting mechanism, a probe mounting seat, and a height adjustment assembly. The base is mounted on the generator main shaft via the mounting mechanism and can rotate circumferentially around the generator main shaft. The probe mounting seat is disposed on the base. The height adjustment assembly is disposed between the probe mounting seat and the base and can adjust the height of the probe mounting seat relative to the base. The detection probe includes a probe rod, a detection end, an angle adjustment mechanism, and an eddy current sensor. The probe rod is conformally bendable and has a first end and a second end. The first end is detachably mounted on the auxiliary fixture, and the detection end is hinged to the second end. The angle adjustment mechanism is disposed on the probe rod and can adjust the angle between the detection end and the probe rod. The eddy current sensor is disposed on the detection end. The method includes: The auxiliary tooling is installed on the generator main shaft using the installation mechanism; Insert the second end of the probe into the area to be tested through the gap between the generator main shaft and the generator rotor; The height of the probe mounting base is adjusted using the height adjustment component, and the first end of the probe rod is mounted on the probe mounting base. The angle between the detection end and the probe is adjusted using an angle adjustment component so that the detection surface of the eddy current sensor faces the rotor inter-pole connection line. The auxiliary tooling is used to drive the detection probe to rotate circumferentially around the generator main shaft, so that the eddy current sensor can rotate 360° around the generator main shaft for scanning and detection; The scanning information from the eddy current sensor is analyzed to determine the location of the defect.

2. The method according to claim 1, characterized in that, The installation mechanism includes a first chain, a second chain, a first connecting part, and a second connecting part; One end of the first chain is connected to the base, and the other end is connected to the first connecting part; One end of the second chain is connected to the base, and the other end is connected to the second connecting part; The first connecting part and the second connecting part are configured to engage to mount the base onto the generator main shaft.

3. The method according to claim 1, characterized in that, The height adjustment assembly includes a guide post, a stud, and a rotary handle; The guide post is disposed on the base and passes through the probe mounting seat, and the guide post can guide the probe mounting seat to move along the axial direction of the guide post; The stud is rotatably mounted on the base and parallel to the guide post, and the stud is threadedly engaged with the probe mounting seat; The rotating handle is connected to the stud, and the rotating handle is used to drive the stud to rotate circumferentially so that the probe mounting base can move axially along the guide post.

4. The method according to claim 1, characterized in that, The auxiliary tooling also includes an angle encoder, which is mounted on the base and is used to detect the angle of rotation of the base relative to the generator main shaft, so as to ensure that the detection probe completes 360° rotational scanning detection.

5. The method according to claim 1, characterized in that, The angle adjustment mechanism includes a first elastic element and a driving element; The first elastic element is disposed between the probe and the detection end, and the first elastic element is configured to maintain a 90° angle between the detection end and the probe when no external force is applied; The driving member is connected to the detection end, and the driving member is configured to overcome the elastic force of the first elastic member and drive the detection end to rotate relative to the probe rod, so as to reduce the included angle between the detection end and the probe rod.

6. The method according to claim 5, characterized in that, The driving component is a pull rope.

7. The method according to claim 6, characterized in that, The angle adjustment mechanism also includes a second elastic element and a push button; The second elastic element is disposed at the first end of the probe and connected to the driving element. The second elastic element has a free state and a compressed state. In the free state, the second elastic element pulls the driving element to drive the detection end to rotate relative to the probe to reduce the angle between the detection end and the probe. In the compressed state, the second elastic element releases the driving element to maintain a 90° angle between the detection end and the probe. The push button is located at the first end of the probe rod, and the push button is configured to move relative to the probe rod to change the state of the second elastic element.

8. The method according to claim 1, characterized in that, The detection probe also includes a spring-loaded mechanism, which is disposed at the second end of the probe rod. The spring-loaded mechanism includes a guide tube, a connecting end, and an elastic support member. The catheter is disposed at the second end of the probe, and the axis of the catheter coincides with the axis of the probe; The connecting end is movably disposed on the conduit, the detection end is disposed on the connecting end, and the connecting end is capable of moving along the axial direction of the conduit when the eddy current sensor squeezes the rotor interpole connecting line; The elastic support is sleeved on the conduit and located between the probe and the connecting end. The elastic support can stretch / contract when the connecting end moves, so that the eddy current sensor fits against the part to be measured under the elastic force of the elastic support.

9. The method according to claim 1, characterized in that, The detection probe also includes a vision sensor, which is disposed at the second end. The vision sensor is used to acquire image information of the rotor inter-pole connection line, and the image information is used to verify defects in the rotor inter-pole connection line.

10. The method according to claim 9, characterized in that, The detection probe also includes a steering mechanism, which is disposed at the second end of the probe rod and includes a base plate and a rotating part. The substrate is disposed on the probe; The rotating part is rotatably disposed on the substrate, and the vision sensor is disposed on the rotating part. The rotating part can rotate relative to the substrate to adjust the shooting angle of the vision sensor.

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