A wind power main shaft nondestructive testing device

Abstract

The utility model relates to a kind of wind power main shaft detection devices, belong to wind power generation equipment detection technical field, specifically a kind of wind power main shaft nondestructive testing device, including wind power machine tower pole, drive head part shell, wind power fan blade, power generation driving mechanism, power generation driving mechanism includes generator, driving motor and main shaft pole, detection assembly is equipped on the main shaft pole end face and is distributed in star shape, wind power machine tower pole is equipped with the ultrasonic on-line flaw detection system being wirelessly connected with it;The utility model realizes the on-line real-time nondestructive testing of wind power main shaft by ultrasonic on-line flaw detection system and ultrasonic probe of specific distribution, while limiting protection disc effectively protects detection assembly. Reach the effect of improving detection efficiency and accuracy, guarantee detection assembly stable work, solve the problem that existing wind power main shaft detection is difficult to on-line real-time, detection efficiency is low and probe is easily damaged.

Description

Technical Field

[0001] This utility model relates to the field of wind power equipment testing technology, and in particular to a non-destructive testing device for wind turbine main shafts. Background Technology

[0002] In the field of wind power technology, the wind turbine main shaft, as a key transmission component connecting the gearbox and hub in a wind turbine generator set, plays a crucial role in transmitting power. The main shaft is the primary transmission component connecting the gearbox and hub, bearing the majority of the load from the blades and hub. During long-term operation, due to factors such as extreme loads, the main shaft may develop micro-cracks. The growth and propagation of these cracks can cause internal damage that is not externally noticeable. This insidious damage can even lead to sudden main shaft breakage, resulting in significant property damage.

[0003] Existing non-destructive testing methods for wind turbine main shafts mostly require manual inspection after the turbine is shut down. This is not only cumbersome and inefficient, but also fails to provide real-time monitoring of the main shaft. Manual inspection cannot comprehensively cover all parts of the main shaft, and the accuracy of the results is easily affected by human factors, making it difficult to detect potential micro-cracks and internal damage. This method cannot obtain the main shaft's operating status in a timely manner. If problems occur during operation, measures cannot be taken quickly to address them, posing safety hazards and seriously affecting the stable operation and safety of the wind power generation system. Utility Model Content

[0004] To address the aforementioned technical problems, this invention proposes a non-destructive testing device for wind turbine main shafts. This device utilizes an online ultrasonic flaw detection system and specifically distributed ultrasonic probes to achieve real-time online non-destructive testing of the wind turbine main shafts. Simultaneously, a limiting and protective disc effectively protects the testing components. This improves both testing efficiency and accuracy.

[0005] The technical solution to achieve the purpose of this utility model is: a non-destructive testing device for wind turbine main shafts, including a wind turbine tower, a drive head housing at the bottom front end of the wind turbine tower, and a rotatable wind turbine fan blade driven at the top output end of the drive head housing, characterized in that:

[0006] A power generation drive mechanism is located inside the drive head housing. The power generation drive mechanism includes a generator, a drive motor, and a main shaft. The front side of the main shaft is connected to the wind turbine blades.

[0007] A detection component is provided on the end face of the main shaft, and an ultrasonic online flaw detection system connected to the detection component via wireless signal is provided on the wind turbine tower.

[0008] The detection components are arranged in a star shape on the hub side end face of the main shaft.

[0009] In some embodiments, the detection assembly includes an ultrasonic probe whose detection port is attached to the hub end face of the main shaft. There are twenty-four ultrasonic probes arranged in groups of four, with an included angle of sixty degrees between each group.

[0010] In some embodiments, a limiting protective disc is movably connected to the hub side end face of the main shaft. The limiting protective disc includes a limiting plate that snaps onto the end face of the main shaft. The surface of the limiting plate has a protrusion adapted to the ultrasonic probe, and the outer side of the limiting plate has a groove that fits against the inner wall surface of the hub side end face of the limiting plate.

[0011] In some embodiments, an elastic block is connected between the outer side of each slot and the inner wall of the hub side end face of the limiting disc, and the limiting disc is elastically clamped to the inner wall of the hub side end face of the limiting disc by the compression of the elastic block.

[0012] In some embodiments, the thickness of the limiting disc is the same as the length of each ultrasonic probe.

[0013] In some embodiments, the ultrasonic online flaw detection system includes an ultrasonic probe, a cabin switch, a fiber optic ring network, and a remote service controller. The ultrasonic acquisition unit is mounted inside the hub of the main shaft and rotates synchronously with the hub. The ultrasonic probe is attached to the end face of the main shaft near the hub and is connected to the ultrasonic acquisition unit via a shielded cable. The ultrasonic acquisition unit is wirelessly connected to a bridge located in the cabin via a wireless bridge, transmitting ultrasonic waveform data to the remote service controller via the fiber optic ring network.

[0014] Compared with existing technologies, the significant advantages of this invention are:

[0015] Firstly, this invention features a star-shaped array of detection components on the end face of the main shaft, and an ultrasonic online flaw detection system wirelessly connected to these components is installed on the wind turbine tower. Using 24 ultrasonic probes arranged in a star-shaped pattern, grouped in sets of four with each group at a 60-degree angle, a wide-area, uniform inspection of the main shaft hub end face is performed. The online ultrasonic flaw detection system transmits the detection data to a remote service controller in real time, enabling online, real-time, non-destructive testing of the wind turbine main shaft's operating status. This allows for the timely detection of potential defects, facilitating rapid assessment of the main shaft's condition by staff. Compared to traditional testing methods, this significantly improves testing efficiency and accuracy.

[0016] Secondly, this invention features a limiting protective disc on the hub-side end face of the main shaft. The protrusions on the disc's surface are adapted to accommodate the ultrasonic probe, and the outer groove engages with an elastic block to elastically clamp the disc against the inner wall of the hub-side end face. This structure effectively prevents displacement or damage to the ultrasonic probe during the vibration of the wind turbine main shaft. Furthermore, the thickness of the limiting disc is the same as the length of the ultrasonic probe, providing reasonable protection for the probe and ensuring the stability and service life of the detection components.

[0017] This invention solves the problems of existing non-destructive testing of wind turbine main shafts, such as difficulty in online real-time testing, low testing efficiency, insufficient testing accuracy, and poor testing reliability due to the easy displacement or damage of the testing probe caused by vibration during main shaft operation. Attached Figure Description

[0018] The present invention will be further explained below with reference to the accompanying drawings and embodiments:

[0019] Figure 1 This is a three-dimensional structural schematic diagram of the non-destructive testing device for wind turbine main shaft provided in one embodiment of the present invention;

[0020] Figure 2 This is a schematic diagram of the ultrasonic online flaw detection system provided in one embodiment of the present invention on a wind turbine;

[0021] Figure 3 This is a schematic diagram of the internal connection of the power generation drive mechanism provided in one embodiment of the present invention;

[0022] Figure 4 This is a schematic diagram of the disassembled structure of the detection component on the main shaft in one embodiment of the present invention;

[0023] Figure 5 This is a schematic diagram of the front end of the main shaft provided in one embodiment of the present invention;

[0024] Figure 6 This is a schematic diagram of a half-section structure on the main shaft provided in one embodiment of the present invention.

[0025] Explanation of reference numerals in the attached figures:

[0026] 1. Wind turbine tower; 101. Drive head housing; 2. Wind turbine blade; 3. Fiber optic ring network; 4. Remote service controller; 5. Ultrasonic probe; 501. Nacelle switch; 502. Ultrasonic acquisition instrument; 6. Generator; 7. Drive motor; 8. Main shaft; 9. Limiting plate; 901. Slot; 902. Protrusion; 903. Elastic block. Detailed Implementation

[0027] The present invention will now be described in detail, and the technical solutions in the embodiments of the present invention will be clearly and completely described. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present invention.

[0028] This utility model provides an improved non-destructive testing device for wind turbine main shafts. The technical solution of this utility model is as follows:

[0029] Figure 1 - Figure 6 This is the preferred embodiment of the present invention, which is described below in conjunction with the appendix. Figure 1 - Figure 6 The present invention will be further described below.

[0030] like Figure 1 - Figure 6 As shown, a non-destructive testing device for wind turbine main shafts includes a wind turbine tower 1. A drive head housing 101 is located at the bottom front end of the wind turbine tower 1, and a rotatable wind turbine blade 2 is driven by the top output end of the drive head housing 101. It also includes a power generation drive mechanism, which is located inside the drive head housing 101. The power generation drive mechanism includes a generator 6, a drive motor 7, and a main shaft 8. The front side of the main shaft 8 is connected to the wind turbine blade 2. A detection component is located on the end face of the main shaft 8, and an ultrasonic online flaw detection system connected to the detection component via a wireless signal is installed on the wind turbine tower 1. The detection component is distributed in a star shape on the hub side end face of the main shaft 8.

[0031] like Figure 4 and Figure 5 As shown, in one embodiment, the detection assembly includes 24 ultrasonic probes 5 with their detection ports attached to the hub end face of the main shaft 8. These probes are arranged in groups of four, with each group having a 60-degree angle between them. By using 24 ultrasonic probes 5 arranged in groups of four with a 60-degree angle between each group, a larger and more uniform detection coverage of the hub end face of the main shaft 8 is achieved. This allows for a more comprehensive detection of whether there are any undamaged areas on the hub end face of the main shaft 8, improving the accuracy and comprehensiveness of the detection.

[0032] like Figure 4 - Figure 6 As shown, in one embodiment, a limiting protective disc is movably connected to the hub side end face of the main shaft 8. The limiting protective disc includes a limiting disc 9 that engages with the end face of the main shaft 8. The surface of the limiting disc 9 has a protrusion 902 adapted to the ultrasonic probe 5, and the outer side of the limiting disc 9 has a groove 901 that fits against the inner wall of the hub side end face of the limiting disc 9. By setting the limiting disc 9 and its surface protrusion 902 and outer groove 901, the protrusion 902 can position and protect the ultrasonic probe 5, preventing displacement or damage during testing. The groove 901 facilitates the connection of the limiting disc 9 with other components, achieving effective limiting and protection of the ultrasonic probe 5, as well as a stable connection between the limiting disc 9 and other components.

[0033] like Figure 4 - Figure 6As shown, in one embodiment, an elastic block 903 is connected between the outer side of each slot 901 and the inner wall surface of the hub side end face of the limiting disc 9. The limiting disc 9 is elastically clamped onto the inner wall surface of the hub side end face of the limiting disc 9 by the compression of the elastic block 903. The setting of the elastic block 903 allows the limiting disc 9 to fit more tightly against the inner wall surface of the hub side end face of the limiting disc 9, maintaining a stable installation state even under conditions such as vibration generated during the operation of the wind turbine main shaft, further ensuring the stability of the ultrasonic probe 5 and the reliability of the detection.

[0034] In one embodiment, the thickness of the limiting disk 9 is the same as the length of each ultrasonic probe 5. By setting the thickness of the limiting disk 9 to be the same as the length of the ultrasonic probe 5, the limiting disk 9 can just completely protect the ultrasonic probe 5. It is neither too thick, which would affect the detection effect, nor too thin, which would fail to provide sufficient protection, thus ensuring a reasonable structure and effective protection for the detection component.

[0035] In one embodiment, the ultrasonic online flaw detection system includes an ultrasonic probe 5, a nacelle switch 501, a fiber optic ring network 3, and a remote service controller 4. An ultrasonic acquisition unit 502 is installed inside the hub of the main shaft 8 and rotates synchronously with the hub. The ultrasonic probe 5 is attached to the hub-side end face of the main shaft 8 and connected to the ultrasonic acquisition unit 502 via a shielded cable. The ultrasonic acquisition unit 502 is wirelessly connected to a bridge located in the nacelle via a wireless bridge, transmitting ultrasonic waveform data to the remote service controller 4 through the fiber optic ring network 3. This structural setup of the ultrasonic online flaw detection system enables real-time online detection of the hub-side end face of the main shaft 8 and allows for stable transmission of detection data to the remote service controller 4 via a combination of wireless and wired methods. This facilitates timely access to detection information by personnel, enabling monitoring and analysis of the wind turbine main shaft's operating status and improving the convenience and real-time nature of the detection process.

[0036] The working principle and usage process of this utility model are as follows: When the wind turbine main shaft is working, the wind turbine blades 2 rotate under the drive of the drive head housing 101, driving the main shaft 8 to rotate. At this time, the ultrasonic probe 5 in the detection assembly is attached to the hub side end face of the main shaft 8 for detection. The detected data is transmitted through a shielded wire to the ultrasonic acquisition instrument 502 installed in the hub of the main shaft 8. The ultrasonic acquisition instrument 502 rotates synchronously with the hub and is wirelessly connected to the network bridge located in the nacelle through a wireless bridge. The ultrasonic waveform data is transmitted to the remote service controller 4 through the fiber optic ring network 3. The staff can view the detection data on the remote service controller 4 and analyze whether there is any damage to the main shaft 8. The limiting protective plate is elastically clamped on the inner wall of the hub side end face of the main shaft 8 by the elastic block 903, which protects and limits the ultrasonic probe 5.

[0037] The technical means disclosed in this utility model are not limited to those described above, but also include technical solutions composed of equivalent substitutions of the above technical features. Matters not covered in this utility model are common knowledge to those skilled in the art.

Claims

1. A non-destructive testing device for wind turbine main shaft, comprising a wind turbine tower (1), wherein a drive head housing (101) is provided at the bottom front end of the wind turbine tower (1), and a rotatable wind turbine fan blade (2) is driven at the top output end of the drive head housing (101), characterized in that: The power generation drive mechanism is located inside the drive head housing (101). The power generation drive mechanism includes a generator (6), a drive motor (7), and a main shaft (8). The front side of the main shaft (8) is connected to the wind turbine blade (2). The end face of the main shaft (8) is provided with a detection component, and the wind turbine tower (1) is provided with an ultrasonic online flaw detection system that is connected to the detection component via a wireless signal; The detection components are distributed in a star shape on the hub side end face of the main shaft (8).

2. The non-destructive testing device for wind turbine main shaft according to claim 1, characterized in that: The detection assembly includes an ultrasonic probe (5) whose detection port is attached to the hub end face of the main shaft (8). There are twenty-four ultrasonic probes (5), arranged in groups of four, with an included angle of sixty degrees between each group.

3. The non-destructive testing device for wind turbine main shaft according to claim 1, characterized in that: The hub side end face of the main shaft (8) is movably connected to a limiting protective disc. The limiting protective disc includes a limiting disc (9) that snaps into the end face of the main shaft (8). The surface of the limiting disc (9) is provided with a protrusion (902) that is compatible with the ultrasonic probe (5). A groove (901) is provided on the outer side of the limiting disc (9) that fits against the inner wall of the hub side end face of the limiting disc (9).

4. The non-destructive testing device for wind turbine main shaft according to claim 3, characterized in that: Each of the slots (901) has an elastic block (903) connected between its outer side and the inner wall of the hub side end face of the limiting disc (9). The limiting disc (9) is elastically clamped to the inner wall of the hub side end face of the limiting disc (9) by the compression of the elastic block (903).

5. The non-destructive testing device for wind turbine main shaft according to claim 4, characterized in that: The thickness of the limiting plate (9) is the same as the length of each ultrasonic probe (5).

6. The non-destructive testing device for wind turbine main shaft according to claim 1, characterized in that: The ultrasonic online flaw detection system includes an ultrasonic probe (5), a cabin switch (501), an optical fiber ring network (3), and a remote service controller (4). The ultrasonic acquisition instrument (502) is installed in the hub of the main shaft (8) and rotates synchronously with the hub. The ultrasonic probe (5) is attached to the end face of the main shaft (8) near the hub and is connected to the ultrasonic acquisition instrument (502) through a shielded wire. The ultrasonic acquisition instrument (502) is wirelessly connected to the bridge located in the cabin through a wireless bridge and transmits the ultrasonic waveform data to the remote service controller (4) through the optical fiber ring network (3).

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