A vertical gap laser measuring device for guide vanes of a hydraulic turbine

Abstract

The utility model discloses a kind of for water turbine guide vane's facade gap laser measuring device, including measuring host computer, positioning adsorption module, data acquisition processing module and display control terminal, measuring host computer includes waterproof dustproof shell and built-in high-precision laser displacement sensor array, its measurement range covers the facade gap width of water turbine guide vane.Positioning adsorption module is located at the back of host computer, and strong magnetic adsorption base is formed using Nd-Fe-B permanent magnet, and host computer can be firmly adsorbed on the surface of guide vane.Data acquisition processing module is integrated in the inside of host computer, including microcontroller, signal conditioning circuit and wireless communication module, responsible for controlling the data acquisition, signal processing and data transmission of sensor array.The device can greatly reduce maintenance time and power station downtime cost, significantly improve measurement accuracy, avoid error caused by insufficient experience of operator or local omission, while reducing the residence time of personnel in narrow volute, ensure safety.

Description

Technical Field

[0001] This utility model relates to the field of laser measurement device technology, specifically a laser measurement device for the vertical gap of a water turbine guide vane. Background Technology

[0002] With the development of hydropower technology, the efficiency and safety performance of turbine guide vanes have become important factors affecting the operation of hydropower stations. In particular, proper clearance control is crucial for ensuring the efficient operation of the turbine, especially in the management of guide vane clearance.

[0003] However, the commonly used feeler gauge measurement method has obvious limitations and shortcomings in practical applications. First, the feeler gauge measurement method is inefficient, requiring the measurement of multiple points on multiple guide vanes one by one, which is time-consuming and labor-intensive. This undoubtedly prolongs maintenance time and increases the downtime and maintenance costs of power plants. Second, the accuracy of feeler gauge measurement results is difficult to guarantee, relying on the operator's experience and feel, and it is easy to miss local deviations, affecting the overall measurement accuracy.

[0004] Finally, due to the special measurement environment, such as the narrow space and slippery environment inside the volute, operators need to perform measurement work for a long time, which increases the work risk and poses a certain threat to the safety of the staff. Utility Model Content

[0005] In view of the shortcomings of the prior art, the purpose of this utility model is to provide a laser measuring device for the vertical gap of turbine guide vanes, so as to solve the problems mentioned in the background art.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: This invention provides a laser measurement device for the vertical clearance of turbine guide vanes, comprising a measurement host, a positioning and adsorption module, a data acquisition and processing module, and a display and control terminal. The measurement host includes a waterproof and dustproof housing and a built-in high-precision laser displacement sensor array. The measurement range of the laser displacement sensor array is configured to cover the vertical clearance width of the turbine guide vanes. The positioning and adsorption module is located on the back of the measurement host and includes a strong magnetic adsorption base composed of neodymium iron boron permanent magnets. The strong magnetic adsorption base is used to adsorb and fix the measurement host to the surface of the guide vanes. The data acquisition and processing module is integrated inside the measurement host and includes a microcontroller, a signal conditioning circuit, and a wireless communication module. The data acquisition and processing module is used to control the data acquisition, signal processing, and data transmission of the laser displacement sensor array. The display and control terminal communicates with the data acquisition and processing module wirelessly and is used to receive measurement data, display clearance information, and control the measurement process.

[0007] In one or more embodiments of this utility model, the housing is provided with a laser sensor array window, status indicator lights, and interfaces.

[0008] In one or more embodiments of this utility model, the outer shell is made of an alloy shell or an engineering plastic shell.

[0009] In one or more embodiments of this utility model, the high-precision laser displacement sensor array comprises at least two linearly arranged laser probes, configured to collect multiple data points on a line segment of the guide vane facade gap at one time.

[0010] In one or more embodiments of this utility model, the positioning adsorption module further includes a universal fine-tuning structure, which is used to adjust the angle and position of the measuring host after adsorption.

[0011] In one or more embodiments of this utility model, the microcontroller of the data acquisition and processing module is configured to control the scanning sampling of the laser displacement sensor array and to filter and average the acquired displacement voltage signal.

[0012] In one or more embodiments of this utility model, the wireless communication module is a Wi-Fi or Bluetooth module, which enables wireless data transmission between the measurement host and the display and control terminal.

[0013] In one or more embodiments of this utility model, the display and control terminal is configured to display the gap curve in real time, calculate the maximum value, minimum value and average value, and determine whether the gap is within the qualified range.

[0014] The beneficial effects of this utility model are as follows: it can significantly reduce maintenance time, thereby reducing the downtime and maintenance costs of power plants; the accuracy of feeler gauge measurement results can be greatly improved, without relying on the operator's experience and feel, avoiding the omission of local deviation points, and improving the accuracy of measurement results; at the same time, it can reduce the long time that operators stay in the narrow space inside the volute, which is conducive to protecting the safety of operators. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the structure of a laser measuring device for vertical gap of water turbine guide vanes in one embodiment of the present invention; Figure 2 This is a three-dimensional structural schematic diagram of a laser measurement device for vertical gap of water turbine guide vanes in one embodiment of the present invention; Figure 3 This is a structural block diagram of a laser measurement device for vertical gap of water turbine guide vanes in one embodiment of the present invention; Figure 4 This is a schematic diagram of the display and control terminal software interface of a laser measurement device for vertical gap of water turbine guide vanes in one embodiment of the present invention; Figure 5 This is a block diagram of the electrical system of a laser measuring device for vertical gap of a water turbine guide vane according to one embodiment of the present invention; Figure 6 This is a schematic diagram illustrating the working principle of a laser measuring device for vertical gap of water turbine guide vanes in one embodiment of the present invention. Figure 7 This is a flowchart illustrating the operation of a laser measurement device for vertical gaps of water turbine guide vanes in one embodiment of the present invention.

[0017] Explanation of reference numerals in the attached figures: 1. Measurement host; 2. Housing; 3. Laser sensor array window; 4. Status indicator light; 5. Interface; 6. Positioning adsorption module; 7. Permanent magnet; 8. Universal fine-tuning structure. Detailed Implementation

[0018] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0019] Example 1: like Figures 1-3 As shown, an embodiment of this utility model discloses a laser measuring device for the vertical clearance of turbine guide vanes, comprising a measuring host 1, and a housing 2. The housing 2 is dustproof and waterproof, and is made of high-strength aluminum alloy to ensure a robust structure and light weight, facilitating carrying and operation inside the volute. Alternatively, the housing 2 can also be made of engineering plastics.

[0020] like Figures 1-3As shown, a laser sensor array window 3 is located on the lower front of the housing 2. This window is covered with a protective material that is both light-transmitting and wear-resistant. The specific material of the laser sensor array window 3 can be tempered glass, used to protect the internal sensor. A status indicator light 4 is located on one side of the laser sensor array window 3 to display the device's power, connection, and operating status. For example, it is solid blue in standby mode, flashing green during measurement, and solid red in case of fault. An interface 5 is located on the side of the housing 2. This interface 5 can function as a combined power and communication interface. It can be Type-C or an aviation plug, used for device charging or wired data export.

[0021] The outer casing 2 of the measuring host 1 features a sealed design with an IP65 protection rating. This means it can completely prevent dust intrusion and withstand low-pressure water spray from all directions, effectively addressing common on-site environments characterized by humidity, splashes, and dust. Furthermore, to address the potential interference from the strong magnetic field generated by the neodymium iron boron permanent magnet 7 in the positioning adsorption module 6 to the internal precision circuitry, specialized magnetic shielding measures have been implemented in the layout of the data acquisition and processing module. Specifically, shielding covers made of high-permeability materials are placed around key electronic components, and the power supply and signal lines are properly grounded and filtered. These designs effectively suppress mutual interference between external magnetic fields and internal circuitry, ensuring the accuracy of laser sensor signal acquisition and the reliability of system operation from a hardware perspective.

[0022] like Figures 1-3 As shown, the back of the measuring host 1 is fixedly connected to the positioning and adsorption module 6 via a connecting structure. The core of the positioning and adsorption module 6 is a strong magnetic adsorption base, which contains multiple high-performance neodymium iron boron permanent magnets 7 arranged in an array. This design allows the measuring host 1 to generate a strong magnetic attraction force, thus firmly adsorbing onto the surface of the movable guide vane made of steel, without manual support. On one side of the strong magnetic adsorption base, there is a universal fine-tuning structure 8. This universal fine-tuning structure 8 can be a spherical hinge or two sets of mutually perpendicular sliding table structures, allowing the operator to make minor adjustments to the up / down, left / right, and pitch angles of the measuring host 1 after it is adsorbed and fixed, ensuring that the laser beam emitted from the laser sensor array window 3 accurately and vertically strikes the fixed guide vane surface to be measured, thereby guaranteeing the accuracy of the measurement data.

[0023] like Figure 5As shown, the measurement host 1 integrates a data acquisition and processing module. This module includes a laser sensor array, a signal conditioning circuit, a microcontroller (MCU), and a wireless communication module. The laser sensor array consists of multiple high-precision laser displacement probes arranged linearly, and its measurement range covers the common widths of the gaps between the guide vanes of a water turbine. The MCU controls the laser sensor array to emit lasers sequentially or synchronously and receives the light signals reflected back from the fixed guide vane surface. After amplification, filtering, and analog-to-digital conversion by the signal conditioning circuit, the signal is processed by the MCU into actual displacement data. The processed data is then sent to the display and control terminal via the wireless communication module.

[0024] See Figure 4 The control terminal is an industrial-grade tablet PC running customized measurement software. The software interface is divided into three main areas: a waveform display area, a data information area, and a control function area. The waveform display area plots the continuous gap curve of the measured cross-section in real time, overlaying preset upper and lower acceptable limits, and highlighting areas exceeding the acceptable range in red. The data information area displays the specific values ​​of each measurement point in a list format and automatically calculates the maximum, minimum, and average gap values ​​for that cross-section. The control function area provides buttons for "Start / Stop Measurement," "Parameter Setting," and "Report Generation." Operators can use the software to set sensor parameters, acceptable thresholds, and control the measurement process. After measurement, the software can generate a standardized inspection report containing waveforms, data lists, and conclusions with a single click.

[0025] like Figures 6-7 As shown, the workflow of a laser measurement device for the vertical clearance of turbine guide vanes in this embodiment is as follows: After the unit is shut down, the operator enters the volute and first cleans the measurement area on the vertical surfaces of the movable and fixed guide vanes. Then, the measurement host 1 is attached to a predetermined height position on the movable guide vane using the positioning adsorption module 6, and the host's attitude is finely adjusted using the universal micro-adjustment structure 8. Clicking "Start Measurement" on the display and control terminal software activates the MCU, which drives the laser sensor array to acquire dozens of clearance data points along a single line of the cross-section. The data is processed and wirelessly transmitted to the terminal, where the software displays the results in real time. The operator moves the measurement host 1 along the guide vane height direction to repeat the measurement at multiple cross-sections to comprehensively understand the vertical clearance situation, and finally generates a comprehensive report.

[0026] Furthermore, such as Figure 7 As shown, the specific steps include: (a) Preparation: The unit is shut down for maintenance, and the interior of the volute is entered. Oil and scale are cleaned from the vertical surface area of ​​the guide vanes to be tested.

[0027] (ii) Installation device: The measuring host 1 is firmly attached to the specific height position of the movable guide vane via the positioning adsorption module 6 on its back. The angle of the host is finely adjusted by the universal fine-tuning structure 8.

[0028] (III) Start Measurement: The operator starts the measurement software on the display and control terminal. The software connects to the measurement host 1 via Bluetooth. After setting the measurement parameters in the software, click "Start Measurement".

[0029] (iv) Data acquisition: The MCU drives the laser displacement sensor array to emit laser and receive reflected signals, acquiring dozens of gap data points on a line of the current section at one time.

[0030] Data processing and transmission: After initial processing by the MCU, the data is sent to the display and control terminal via the wireless module.

[0031] (v) Results display: The terminal software draws a continuous curve of the gap in real time, and automatically marks the maximum and minimum values, and compares them with the preset acceptable range. Points exceeding the acceptable range are marked in red.

[0032] (vi) Moving and repeating: After completing the measurement of a position, remove the measuring host 1, select multiple sections along the guide vane height direction and repeat steps 2-6 to obtain the full gap distribution of the facade.

[0033] Report generation: After all measurements are completed, the software generates a standardized test report containing all measurement point data, graphs, and conclusions with a single click.

[0034] In this embodiment, by employing a laser sensor array and non-contact measurement, the core pain points of the traditional feeler gauge method—low efficiency, poor accuracy, and insufficient safety—are fundamentally solved. The device achieves quick and stable installation via a strong magnetic adsorption base, freeing the operator's hands and ensuring the stability and safety of the measurement process. Its array scanning can acquire a continuous gap data line at once, replacing tedious single-point measurements and improving efficiency by orders of magnitude. Simultaneously, the measurement data, after being processed by a microcontroller, is presented in real-time on the display terminal as visualized waveforms and digital results, and reports are automatically generated, realizing the digitalization and intelligentization of the inspection process and providing a revolutionary means for the precision maintenance of turbine guide vanes.

[0035] The above technical solution achieves significant and concrete technical benefits compared to traditional feeler gauge measurement methods. Firstly, it significantly improves measurement efficiency: based on non-contact scanning using a laser sensor array, dozens of data points can be acquired on a continuous line segment of the guide vane facade in a single measurement, drastically reducing the comprehensive inspection time for a single guide vane facade from 20-30 minutes using traditional methods to less than 3 minutes, an efficiency improvement of over 6 times. Secondly, measurement accuracy is fundamentally guaranteed: utilizing a high-precision laser displacement sensor combined with digital filtering processing by a microcontroller, the absolute accuracy of gap measurement is stably improved from ±0.05mm (dependent on feeler gauge method) to within ±0.01mm, completely eliminating errors caused by subjective human judgment and feeler gauge insertion force. Thirdly, operational safety is significantly enhanced: the strong magnetic adsorption base firmly fixes the measuring unit, eliminating the need for manual support. Operators can monitor the measurement from a safe area at least 5 meters away via a display and control terminal, greatly reducing the risks of prolonged operation in slippery, confined spaces within the volute. Finally, the testing process was digitized and made intelligent: measurement data was wirelessly transmitted to the display and control terminal, the software automatically processed the data, plotted curves, determined the pass / fail status, and generated a standardized test report with one click, reducing the time for subsequent data processing and report writing from an average of 1 hour to almost zero, and eliminating errors and omissions that may occur with manual recording, providing a precise and efficient digital means for the condition-based maintenance of water turbines.

[0036] Example 2: Based on Embodiment 1, this embodiment further optimizes the versatility and automation of the device, making it applicable to a wider range of unit models and more efficient measurement scenarios.

[0037] In this embodiment, the structure of the positioning adsorption module 6 has been optimized. The strong magnetic adsorption base is designed to be detachable or adjustable by sliding. For example, the position of the permanent magnet 7 on the back of the housing 2 can be adjusted back and forth according to the curvature of the guide vane of different models through a slide rail mechanism, thereby ensuring that the magnetic adsorption surface is completely attached to the surface of the guide vane, enhancing the adsorption stability and expanding the applicability of the device.

[0038] Furthermore, the number of probes in the laser sensor array can be increased according to the commonly used guide vane height, for example, using more probes to form a measurement area covering a larger vertical range. Alternatively, a stepper motor can be integrated inside the measurement host 1 to drive the laser sensor array to scan within a smaller angular range, rather than performing non-linear array measurements, thereby acquiring gap distribution data in a two-dimensional plane with less hardware cost, realizing "quasi-area array" measurement, and providing richer three-dimensional gap information.

[0039] In terms of data processing, the display and control terminal software in this embodiment is further enhanced. The software can pre-store a standard database of guide vane clearances for various turbine models. At the start of the measurement, the operator simply selects the current turbine model from the list, and the software automatically loads the corresponding acceptable threshold and measurement parameters. Simultaneously, the software possesses intelligent positioning capabilities, automatically determining the relative position of the current measurement section on the guide vane height based on the data characteristics of multiple measurements, and prompting the operator for the next suggested measurement point, thus avoiding missed measurements and improving the standardization and completeness of the measurement.

[0040] The wireless communication module preferably adopts the industrial Wi-Fi protocol, which offers a longer transmission distance and stronger anti-interference capabilities compared to Bluetooth, allowing operators to perform monitoring operations in safer and more open areas. The power management unit supports fast charging technology and low-power modes, ensuring that the device can meet the needs of long-term, high-volume maintenance tasks.

[0041] This embodiment, building upon Embodiment 1, further enhances the device's versatility, measurement dimensions, and intelligence. By designing an adjustable positioning adsorption module and an expandable sensor system, the device can better adapt to different turbine models and acquire richer gap information from "line" to "surface," achieving a more comprehensive condition assessment. Its built-in standard database, intelligent positioning prompts, and more powerful wireless communication capabilities significantly reduce reliance on operator experience, making the measurement process more standardized and automated, and expanding remote operation capabilities. This provides stronger technical support for lean maintenance and predictive health management of turbines.

[0042] Obviously, the above-described embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model. Thus, if these modifications and variations of this utility model fall within the scope of the claims of this utility model and their equivalents, then this utility model also intends to include these modifications and variations.

Claims

1. A laser measuring device for the vertical gap of a water turbine guide vane, characterized in that, Measurement host (1), positioning adsorption module (6), data acquisition and processing module and display and control terminal; The measuring host (1) includes a waterproof and dustproof housing (2) and a built-in high-precision laser displacement sensor array. The measuring range of the laser displacement sensor array is configured to cover the vertical gap width of the turbine guide vanes. The positioning adsorption module (6) is located on the back of the measuring host (1). The positioning adsorption module (6) includes a strong magnetic adsorption base made of neodymium iron boron permanent magnet (7). The strong magnetic adsorption base is used to adsorb and fix the measuring host (1) to the surface of the guide vane. The data acquisition and processing module is integrated inside the measurement host (1). The data acquisition and processing module includes a microcontroller, a signal conditioning circuit and a wireless communication module. The data acquisition and processing module is used to control the data acquisition, signal processing and data transmission of the laser displacement sensor array. The display and control terminal communicates with the data acquisition and processing module via a wireless connection. The display and control terminal is used to receive measurement data, display gap information, and control the measurement process.

2. The laser measurement device for vertical gap of turbine guide vanes as described in claim 1, characterized in that, The outer casing (2) is provided with a laser sensor array window (3), a status indicator (4) and an interface (5).

3. The laser measurement device for vertical gap of turbine guide vanes as described in claim 2, characterized in that, The outer shell (2) is made of alloy or engineering plastic.

4. The laser measurement device for vertical gap of turbine guide vanes as described in claim 1, characterized in that, The high-precision laser displacement sensor array comprises at least two linearly arranged laser probes, configured to collect multiple data points on a line segment of the guide vane facade gap at one time.

5. The laser measurement device for vertical gap of turbine guide vanes as described in claim 1, characterized in that, The positioning adsorption module (6) also includes a universal fine-tuning structure (8), which is used to adjust the angle and position of the measuring host (1) after adsorption.

6. The laser measurement device for vertical gap of turbine guide vanes as described in claim 1, characterized in that, The microcontroller of the data acquisition and processing module is configured to control the scanning and sampling of the laser displacement sensor array, and to filter and average the acquired displacement voltage signal.

7. The laser measurement device for vertical gap of turbine guide vanes as described in claim 1, characterized in that, The wireless communication module is a Wi-Fi or Bluetooth module, which enables wireless data transmission between the measurement host (1) and the display and control terminal.

8. A laser measuring device for vertical clearance of turbine guide vanes as described in claim 1 or 7, characterized in that, The display and control terminal is configured to display the gap curve in real time, calculate the maximum, minimum and average values, and determine whether the gap is within the acceptable range.

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