Multi-channel vibration and displacement synchronous monitoring system for offshore wind power transmission unit
By adopting a multi-channel synchronous monitoring system in the offshore wind power transmission system, the problems of signal synchronization and anti-interference were solved by using a unified clock source and signal conditioning module. This enabled high-precision monitoring of vibration and displacement, improved fault diagnosis capabilities, and enhanced the operational reliability and economic benefits of the wind turbine.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- GUANGDONG WIND POWER CO LTD
- Filing Date
- 2025-09-25
- Publication Date
- 2026-07-14
AI Technical Summary
Existing monitoring devices cannot achieve synchronous monitoring of vibration and displacement of offshore wind power transmission systems. They face challenges in clock synchronization and sampling synchronization, contradictions in signal conditioning, range and anti-interference matching, and conflicts in data bandwidth, real-time performance and reliability. Furthermore, their anti-interference capabilities are insufficient, resulting in inaccurate monitoring data and low processing efficiency.
A multi-channel vibration and displacement synchronous monitoring system is adopted, including a central control module, a sensor module, a signal conditioning module, a data acquisition module, a data storage module, and a data analysis and processing module. The system uses a multi-channel data acquisition card with a unified clock source to achieve synchronous signal acquisition, improves signal stability through amplification and filtering circuits, and combines big data and artificial intelligence for fault diagnosis.
It has achieved high-precision synchronous monitoring of vibration and displacement signals, improved the accuracy and reliability of monitoring data, increased the efficiency and accuracy of fault diagnosis, reduced equipment failure rate, and enhanced the operational reliability and economic benefits of offshore wind turbines.
Smart Images
Figure CN224496640U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the technical field of monitoring equipment for offshore wind turbines, and in particular to a multi-channel vibration and displacement synchronous monitoring system for offshore wind turbine transmission units. Background Technology
[0002] Offshore wind turbines operate in harsh environments, constantly exposed to sea winds, waves, and complex weather conditions. As a core component of the wind turbine, the stability of its transmission system is crucial. Components such as the main shaft and gearbox in the transmission system are prone to abnormal vibrations and displacement deviations during operation. If these problems are not detected and addressed promptly, they can lead to component damage or even cause the entire wind turbine to fail, resulting in significant economic losses and energy supply disruptions.
[0003] Currently, the monitoring methods for transmission systems still have the following shortcomings:
[0004] 1. Most existing monitoring devices can only monitor vibration or displacement separately. Due to the following problems, it is impossible to achieve synchronous monitoring of vibration and displacement, making it difficult to comprehensively and accurately reflect the operating status of the transmission system: (1) Clock synchronization and sampling synchronization problem: vibration (high frequency) and displacement (low frequency) signals require different sampling rates. Moreover, because sensors often use independent acquisition equipment and long-distance wiring, there is clock drift and trigger delay, making it difficult to achieve accurate synchronization. (2) Matching contradiction between signal conditioning, range and anti-interference: the amplitude, frequency band and output type of vibration and displacement signals are very different. If the acquisition card and conditioning circuit are shared, they will restrict each other in terms of range, gain and anti-interference, resulting in signal distortion. (3) Triangular conflict between data bandwidth, real-time performance and reliability: high sampling rate multi-channel synchronous monitoring will generate massive amounts of data. Due to the limited transmission bandwidth at sea and the edge computing capabilities in the harsh environment of the cabin, synchronous monitoring is often forced to be abandoned in order to ensure real-time performance and reliability.
[0005] 2. In complex marine environments, existing monitoring devices have weak anti-interference capabilities, and signal transmission is easily affected by electromagnetic interference, wave impact, and other factors, resulting in inaccurate and unstable monitoring data. In addition, the efficiency of multi-channel data acquisition and processing is low, which cannot meet the needs of real-time monitoring and rapid response. Utility Model Content
[0006] In order to overcome the shortcomings of the existing technology, the purpose of this utility model is to provide a multi-channel vibration and displacement synchronous monitoring system for offshore wind turbine generator sets.
[0007] The objective of this utility model is achieved through the following technical solution: a multi-channel vibration and displacement synchronous monitoring system for offshore wind turbine generator sets, comprising a central control module and sensor modules, signal conditioning modules, data acquisition modules, data storage modules, and data analysis and processing modules electrically connected to the central control module, wherein:
[0008] The sensor module includes a vibration sensor mounted on the main shaft bearing housing and the gearbox housing, and a displacement sensor mounted on the main shaft extension end and the gearbox output shaft, which is used to collect the vibration signal and displacement signal of the offshore wind turbine drive unit to the same propagation path;
[0009] The signal conditioning module includes an amplification circuit for amplifying the sensor signal and a filtering circuit for filtering out noise.
[0010] The data acquisition module uses a multi-channel data acquisition card to simultaneously acquire signals from multiple vibration sensors and displacement sensors;
[0011] The data storage module is used to store the collected data locally.
[0012] The data analysis and processing module is used to analyze and process the data exported from the data storage module, and to determine whether there is a fault in the offshore wind turbine drive unit through the fault diagnosis system.
[0013] Furthermore, the vibration sensor is a piezoelectric vibration sensor, and multiple vibration sensors are respectively arranged in the horizontal, vertical, and axial directions of the gearbox housing.
[0014] Furthermore, the synchronous monitoring system is installed during the wind turbine shutdown and maintenance period. The displacement sensor is a laser or eddy current displacement sensor, and the measurement optical path of the displacement sensor is made perpendicular to the axis of the measured component by means of a laser calibration device.
[0015] Furthermore, both the vibration sensor and the displacement sensor are mounted on the measuring part using rigid mounting clamps and fixing bolts, ensuring that each sensor is in close contact with the measuring surface.
[0016] Furthermore, the signal conditioning module's amplification circuit is composed of a low-noise, high-gain operational amplifier, and the filtering circuit is a bandpass filter circuit used to filter out high-frequency noise and low-frequency interference.
[0017] Furthermore, the multi-channel data acquisition card has multiple analog input channels, and the time synchronization deviation between each channel does not exceed 20μs.
[0018] Furthermore, the data storage module supports data export via a wired method, including a network cable or a USB interface.
[0019] Furthermore, the data analysis and processing module uses the Fourier transform algorithm to convert the time-domain vibration and displacement signals into frequency-domain signals for frequency component analysis, thereby determining the fault type and location.
[0020] Furthermore, the fault diagnosis system, based on big data and artificial intelligence technologies, compares and analyzes the monitoring data with pre-stored normal operation data and fault sample data to determine the fault type and issue corresponding early warning signals.
[0021] Furthermore, the synchronous monitoring system also includes a waterproof, dustproof, and electromagnetic interference-resistant control cabinet, in which the signal conditioning module, data acquisition module, and data storage module are all installed.
[0022] Compared with the prior art, the beneficial effects of this utility model are as follows:
[0023] In this embodiment, vibration sensors and displacement sensors are installed at appropriate locations on the main shaft and gearbox of the wind turbine drive unit, respectively, so that the signals collected by the two types of sensors can converge to the same propagation path. By using a multi-channel data acquisition card with a unified clock source for data acquisition, true synchronous signal acquisition is achieved, effectively overcoming the problems of clock drift and trigger delay. This solves the technical difficulties of "clock synchronization and sampling synchronization" in traditional monitoring devices. This solution can comprehensively and accurately reflect the operating status of the offshore wind turbine drive system, providing richer and more accurate data support for fault diagnosis, thereby achieving high-precision synchronous monitoring of vibration and displacement.
[0024] Furthermore, the signal conditioning module amplifies and filters the signal, improving the stability and reliability of signal transmission and ensuring the accuracy of monitoring data in complex marine environments. The data analysis and processing module's precise analysis and judgment capabilities significantly improve data processing efficiency, enabling effective monitoring and rapid fault diagnosis. This helps to promptly identify and address potential problems in the transmission system, reducing equipment failure rates and thus enhancing the operational reliability and economic benefits of offshore wind turbines. Attached Figure Description
[0025] Figure 1 This is a block diagram illustrating the module control principle in a preferred embodiment of the present invention.
[0026] Figure 2 This is a schematic diagram showing the vibration sensor and displacement sensor installed on the main shaft and gearbox respectively in a preferred embodiment of the present invention.
[0027] Figure 3 This is a schematic diagram of the vibration sensor mounted on the gearbox in a preferred embodiment of the present invention;
[0028] Figure 4 This is a schematic diagram of the displacement sensor installed on the spindle extension end in a preferred embodiment of the present invention;
[0029] Figure 5 This is a schematic diagram of the amplification circuit of the signal conditioning module in a preferred embodiment of the present invention;
[0030] Figure 6 This is a schematic diagram of the filtering circuit of the signal conditioning module in a preferred embodiment of the present invention.
[0031] In the picture:
[0032] 11. Sensor module; 110. Vibration sensor; 111. Displacement sensor;
[0033] 12. Signal conditioning module; 120. Data storage module; 121. Data acquisition module;
[0034] 13. Data Analysis and Processing Module;
[0035] 14. Central control module. Detailed Implementation
[0036] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.
[0037] like Figure 1-6 As shown, the multi-channel vibration and displacement synchronous monitoring system for offshore wind turbines of this application mainly includes a central control module 14, a sensor module 11, a signal conditioning module 12, a data acquisition module 121, a data storage module 120, and a data analysis and processing module 13. The modules are electrically connected and exchange data via cables, connectors, and communication protocols. The entire system is installed in a dedicated control cabinet inside the offshore wind turbine nacelle and is waterproof, dustproof, and resistant to electromagnetic interference.
[0038] More specifically, the synchronous monitoring system is centered on the Central Control Module 14, which is used to send commands to control and coordinate the work of various functional modules to achieve global control.
[0039] like Figure 2 As shown, the offshore wind turbine transmission unit of this application has a general structure including a motor, a main shaft bearing housing, and a gearbox housing. The sensor module 11 includes a vibration sensor 110 mounted on the main shaft bearing housing and the gearbox housing, and a displacement sensor 111 mounted on the main shaft extension end and the gearbox output shaft, for converging the vibration signal and displacement signal of the transmission system to the same propagation path.
[0040] Signal conditioning module 12 receives sensor signals and performs preprocessing, such as... Figure 5-6 As shown, the signal conditioning module 12 provided in this embodiment includes an amplification circuit and a filtering circuit. The amplification circuit uses a low-noise, high-gain operational amplifier, and the filtering circuit is a bandpass filter used to filter out high-frequency noise and low-frequency interference. By amplifying weak signals with high gain and retaining the effective frequency band through bandpass filtering, noise coupling is avoided, thereby further resolving the "matching contradiction between signal conditioning, range, and anti-interference" in traditional monitoring devices and improving signal quality.
[0041] The data acquisition module 121 employs a multi-channel data acquisition card to synchronously acquire signals from multiple vibration sensors 110 and displacement sensors 111. Each channel of this multi-channel data acquisition card uses a unified clock source, with time synchronization deviation controlled within 20μs. Through hardware synchronization and the use of a unified precision clock allocation technology for vibration and displacement signals, time alignment of multi-channel data is ensured, resolving clock drift and transmission delay issues, thereby achieving true data acquisition synchronization.
[0042] The data storage module 120 performs local storage and also supports wired data export via Ethernet cable or USB interface, avoiding the instability and increased cost issues associated with wireless transmission (such as 4G / 5G / satellite communication / microwave transmission) in the marine environment. Wired data transmission offers high reliability (e.g., maintenance personnel can directly copy data using handheld devices via Ethernet cable or USB interface after boarding the wind turbine), is unaffected by electromagnetic interference and signal obstruction, ensuring the integrity and reliability of data export, and is particularly suitable for harsh communication environments at sea.
[0043] The data analysis and processing module 13 is responsible for subsequent fault diagnosis. After importing the data from the data storage module 120 to the analysis device, it uses the Fourier transform algorithm to convert the time-domain vibration and displacement signals into frequency-domain signals and performs spectrum analysis. Frequency-domain analysis can identify characteristic frequency components, thereby determining the fault type and location.
[0044] In addition, a fault diagnosis system has been established. This system, based on big data and artificial intelligence technologies, uses machine learning models to identify abnormal patterns, enabling intelligent early warning and fault classification. It compares and analyzes imported monitoring data with pre-stored normal operation data and fault sample data. When abnormalities are detected in the monitoring data, the fault diagnosis system can quickly and accurately determine the fault type and issue an early warning signal, providing timely maintenance guidance to operations and maintenance personnel.
[0045] This enables intelligent fault diagnosis, improves the accuracy and efficiency of fault diagnosis, supports rapid response, and enhances the system's early warning capabilities and reliability.
[0046] Therefore, vibration sensors 110 and displacement sensors 111 are installed at appropriate positions on the main shaft and gearbox of the wind turbine drive unit, respectively, so that the signals collected by the two types of sensors can converge to the same propagation path. By using a multi-channel data acquisition card with a unified clock source for data acquisition, true signal synchronous acquisition is achieved, effectively overcoming the problems of clock drift and trigger delay, and solving the technical difficulties of "clock synchronization and sampling synchronization" in traditional monitoring devices. This solution can comprehensively and accurately reflect the operating status of the offshore wind turbine drive system, providing richer and more accurate data support for fault diagnosis, thereby achieving high-precision synchronous monitoring of vibration and displacement.
[0047] In addition, the signal conditioning module 12 amplifies and filters the signal, improving the stability and reliability of signal transmission and ensuring the accuracy of monitoring data in complex marine environments. The data analysis and processing module 13 has precise analysis and judgment capabilities, which greatly improves the efficiency of data processing, enabling effective monitoring and rapid fault diagnosis. This helps to promptly identify and address potential problems in the transmission system, reduce equipment failure rates, and thus improve the operational reliability and economic benefits of offshore wind turbines.
[0048] like Figure 2-3 As shown, regarding the selection and arrangement of the vibration sensor 110, the vibration sensor 110 in this embodiment adopts a piezoelectric accelerometer, which is arranged in the horizontal, vertical and axial directions at the end of the gearbox housing to comprehensively capture vibration signals and associate "structural response (vibration)" with "relative displacement (displacement / eccentricity / oscillation)" on the same propagation path, thereby facilitating the location of the fault source through time domain / frequency domain correlation (for example, the local impact caused by the crack in the outer ring of the bearing will show coherent events in both vibration and displacement).
[0049] Therefore, by arranging the sensors in three directions, multi-dimensional vibration information of the gearbox can be captured. Piezoelectric sensors are suitable for high-frequency vibration measurement and have high sensitivity, thereby improving the comprehensiveness and accuracy of vibration signals and helping to more accurately locate the fault source of the transmission system.
[0050] like Figure 4 As shown, regarding the selection and installation of the displacement sensor 111, a laser or eddy current displacement sensor 111 is selected. In this embodiment, during the wind turbine shutdown and maintenance, the displacement sensor 111 is installed on the main shaft extension end and the gearbox output shaft. During installation, a laser calibration device is used to ensure that the measurement optical path of the displacement sensor 111 is perpendicular to the axis of the transmission system. Therefore, by using the displacement sensor 111 for non-contact measurement to avoid mechanical wear, and laser calibration to ensure measurement accuracy, it is particularly suitable for harsh marine environments, thereby improving the accuracy and reliability of displacement measurement and resolving the contradiction between range and anti-interference in signal conditioning of traditional monitoring devices.
[0051] Furthermore, during sensor installation, both vibration sensor 110 and displacement sensor 111 are mounted on the measurement site using rigid mounting clamps (such as sensor brackets) and fixing bolts, maintaining good rigidity to ensure no significant resonance occurs within the measurement frequency range. This prevents sensor readings from being contaminated by bracket modes and avoids interference from sensor vibrations. This ensures close contact between each sensor and the measurement surface, improving the signal-to-noise ratio, enhancing signal stability, and reducing data distortion caused by loose installation.
[0052] In this embodiment, all electronic functional modules are installed in a waterproof, dustproof, and electromagnetic interference-resistant control cabinet. The cabinet features heat dissipation design and salt spray protection. The control cabinet's sealed structure and shielding materials protect the internal equipment, adapting to the high-temperature, high-humidity, and high-salt environment at sea. This further improves the system's stability and lifespan in harsh environments.
[0053] The overall working process of the synchronous monitoring system in this embodiment is as follows:
[0054] 1. During the installation phase, when the wind turbine is shut down for maintenance, vibration sensors 110 are installed in the horizontal, vertical, and axial directions at the end of the gearbox housing; displacement sensors 111 are installed on the main shaft extension end and the gearbox output shaft, and laser calibration is used to ensure that the optical path of the displacement sensor 111 is vertical to ensure measurement accuracy; in addition, it is ensured that each sensor is in close contact with the surface of the component, and special mounting clamps and fixing bolts are used to ensure that the sensors will not loosen or shift during operation.
[0055] 2. Data acquisition: After the unit starts running, the sensors collect the vibration and displacement signals of the transmission system in real time, which are then amplified and filtered by the signal conditioning module 12.
[0056] 3. Synchronous acquisition: The multi-channel data acquisition card synchronously acquires signals from each channel using a unified clock, with a time deviation of less than 20μs.
[0057] 4. Local storage: Collected data is stored in local storage and can be exported via wired connection later.
[0058] 5. Data analysis: After the data is exported, it is analyzed using Fourier transform and artificial intelligence algorithms to quickly identify fault characteristics.
[0059] 6. Fault early warning: When the synchronous monitoring system detects an anomaly, it issues an early warning to guide maintenance personnel to carry out repairs.
[0060] Therefore, through the overall operation of this synchronous monitoring system, with its multi-channel synchronous acquisition, high-precision signal conditioning, intelligent data analysis and anti-interference design, the problems of synchronization, anti-interference and data processing efficiency in the monitoring of offshore wind turbine transmission systems have been comprehensively solved, demonstrating significant technological advancement and practical value.
[0061] The above embodiments are merely preferred embodiments of this utility model and should not be construed as limiting the scope of protection of this utility model. Any non-substantial changes and substitutions made by those skilled in the art based on this utility model shall fall within the scope of protection claimed by this utility model.
Claims
1. A multi-channel vibration and displacement synchronous monitoring system for offshore wind turbine drive units, characterized in that, It includes a central control module and sensor modules, signal conditioning modules, data acquisition modules, data storage modules, and data analysis and processing modules electrically connected to the central control module, wherein: The sensor module includes a vibration sensor mounted on the main shaft bearing housing and the gearbox housing, and a displacement sensor mounted on the main shaft extension end and the gearbox output shaft, which is used to collect the vibration signal and displacement signal of the offshore wind turbine drive unit to the same propagation path; The signal conditioning module includes an amplification circuit for amplifying the sensor signal and a filtering circuit for filtering out noise. The data acquisition module uses a multi-channel data acquisition card to simultaneously acquire signals from multiple vibration sensors and displacement sensors; The data storage module is used to store the collected data locally. The data analysis and processing module is used to analyze and process the data exported from the data storage module, and to determine whether there is a fault in the offshore wind turbine drive unit through the fault diagnosis system.
2. The multi-channel vibration and displacement synchronous monitoring system for offshore wind turbines as described in claim 1, characterized in that, The vibration sensor is a piezoelectric vibration sensor, and multiple vibration sensors are arranged in the horizontal, vertical and axial directions of the gearbox housing.
3. The multi-channel vibration and displacement synchronous monitoring system for offshore wind turbines as described in claim 1, characterized in that, The synchronous monitoring system is installed during the wind turbine shutdown and maintenance period. The displacement sensor is a laser or eddy current displacement sensor, and the measurement optical path of the displacement sensor is made perpendicular to the axis of the measured component by means of laser calibration equipment.
4. The multi-channel vibration and displacement synchronous monitoring system for offshore wind turbines as described in claim 1, characterized in that, Both the vibration sensor and the displacement sensor are mounted on the measurement location using rigid mounting clamps and fixing bolts, ensuring that each sensor is in close contact with the measurement surface.
5. The multi-channel vibration and displacement synchronous monitoring system for offshore wind turbines as described in claim 1, characterized in that, The signal conditioning module's amplifier circuit consists of a low-noise, high-gain operational amplifier, and the filter circuit is a bandpass filter circuit used to filter out high-frequency noise and low-frequency interference.
6. The multi-channel vibration and displacement synchronous monitoring system for offshore wind turbines as described in any one of claims 1-5, characterized in that, The multi-channel data acquisition card has multiple analog input channels, and the time synchronization deviation between each channel does not exceed 20μs.
7. The multi-channel vibration and displacement synchronous monitoring system for offshore wind turbines as described in any one of claims 1-5, characterized in that, The data storage module supports data export via wired means, including network cable or USB interface.
8. The multi-channel vibration and displacement synchronous monitoring system for offshore wind turbines as described in any one of claims 1-5, characterized in that, The data analysis and processing module uses the Fourier transform algorithm to convert time-domain vibration and displacement signals into frequency-domain signals for frequency component analysis, thereby determining the fault type and location.
9. The multi-channel vibration and displacement synchronous monitoring system for offshore wind turbines as described in any one of claims 1-5, characterized in that, The fault diagnosis system is based on big data and artificial intelligence technologies. It compares and analyzes the monitoring data with pre-stored normal operation data and fault sample data to determine the fault type and issue corresponding early warning signals.
10. The multi-channel vibration and displacement synchronous monitoring system for offshore wind turbines as described in any one of claims 1-5, characterized in that, The synchronous monitoring system also includes a waterproof, dustproof, and electromagnetic interference resistant control cabinet, in which the signal conditioning module, data acquisition module, and data storage module are all installed.