Large fan hoisting deformation detection device

Abstract

This utility model discloses a deformation detection device for large wind turbine hoisting, belonging to the field of wind power equipment installation technology. It includes: multiple sensor units for detachable installation on the surface of the wind turbine component to be hoisted, with each sensor unit consisting of a housing and a strain gauge, a triaxial accelerometer, and a wireless data transmission module housed within the housing; a central processing and control hub for receiving and processing deformation data from the multiple sensor units, and communicating with the wireless data transmission module; and a monitoring and alarm terminal for displaying deformation data in real time and issuing alarm signals when a risk is detected, electrically connected to the central processing and control hub. This device, by arranging multiple sensor units on the wind turbine component, achieves full-process, real-time, and quantitative monitoring of structural deformation and vibration status of key parts during hoisting, solving the technical problem that traditional methods cannot dynamically grasp the actual stress condition of the component.

Description

Technical Field

[0001] This utility model belongs to the field of wind power equipment installation technology, and in particular relates to a structural safety monitoring device for the hoisting process of large wind turbine components, specifically a large wind turbine hoisting deformation detection device. Background Technology

[0002] With the continued growth in global demand for renewable energy, wind power, as a clean and sustainable energy source, is playing an increasingly important role in the global energy structure. To improve power generation efficiency, wind power equipment is rapidly developing towards larger capacity and higher power output, which directly leads to a significant increase in the height of the wind turbine tower, the length of the blades, and the overall weight of the nacelle. For example, large wind turbines with a single unit capacity of 5.0MW and a tower height exceeding 115 meters have been widely used in onshore wind power projects.

[0003] The massive size of wind turbine components has brought unprecedented technical challenges and safety risks to hoisting operations. Hoisting is a crucial step in wind farm construction, involving complex mechanical problems and variable environmental factors. Especially in mountainous wind farms with rugged terrain and complex geological conditions, such as projects in northeastern Chongqing, construction teams not only face narrow and winding transport roads but also the unpredictable and unpredictable weather conditions in mountainous areas, such as sudden strong winds and gusts. These factors significantly increase the difficulty and uncertainty of hoisting operations, posing a serious threat to equipment stability and structural safety.

[0004] Currently, the safety of large wind turbine hoisting operations mainly relies on preliminary theoretical calculations and scheme design. Before construction, technicians use numerical simulation methods such as finite element analysis (FEA) to simulate the hoisting process, predict potential mechanical problems, and optimize hoisting parameters. However, this method is essentially a static, proactive risk assessment. In actual hoisting, site conditions change rapidly. Sudden changes in wind load, minor swaying of hoisting slings, or deviations in equipment operation can all cause the actual stress state of wind turbine components to deviate from the theoretical model. Existing technologies generally lack effective methods for real-time, quantitative monitoring of component structural deformation, stress concentration, and dynamic vibration during hoisting. Safety monitoring still largely depends on the visual observation and subjective experience of on-site engineers and crane operators, which proves inadequate when dealing with the risks of hoisting giant components.

[0005] Therefore, the industry urgently needs a technological means to bridge this gap, namely a detection device that can provide real-time feedback on the structural status throughout the entire hoisting operation, so as to realize the transformation of the safety management model from passive defense to proactive early warning. Utility Model Content

[0006] In view of this, the purpose of this utility model is to provide a large wind turbine hoisting deformation detection device that is simple in structure, convenient to use, and accurate in measurement, so as to solve the problem that the existing technology lacks a means to monitor the structural deformation of large wind turbine components in real time and accurately, which leads to huge safety hazards in hoisting operations.

[0007] To achieve the above objectives, this utility model provides the following technical solution:

[0008] This utility model provides a large-scale wind turbine hoisting deformation detection device, comprising: multiple sensor units for detachable installation on the surface of the wind turbine component to be hoisted, each sensor unit consisting of a housing and a strain gauge, a triaxial accelerometer, and a wireless data transmission module housed within the housing. The housing protects the internal components and facilitates installation, enabling a single sensor unit to simultaneously monitor static / quasi-static deformation caused by bending and torsion as measured by the strain gauge, and dynamic response caused by wind-induced vibration or hoisting sway as measured by the triaxial accelerometer, thereby providing a comprehensive assessment of the component's structural health status; the wireless data transmission module transmits important information in real time; a central processing and control hub receives and processes deformation data from multiple sensor units, performs risk assessment based on preset safety thresholds, and communicates with the wireless data transmission module to aggregate real-time monitoring data; and a monitoring and alarm terminal displays deformation data in real time and issues alarm signals when a risk is detected, electrically connected to the central processing and control hub to ensure real-time data updates and responses. By adopting the above solution and using this large-scale wind turbine hoisting deformation detection device, comprehensive and real-time monitoring of the wind turbine component structure can be achieved during the hoisting process, significantly improving operational safety. Integrating static, quasi-static, and dynamic monitoring functions allows the construction team to accurately assess the health status of components, make rapid and scientific decisions, effectively reduce safety hazards, and ensure the smooth progress of hoisting operations.

[0009] Optionally, a single sensor unit also includes a three-axis gyroscope housed within the housing. The integration of the three-axis gyroscope enables the sensor unit to possess more comprehensive dynamic monitoring capabilities. Thus, a single sensor unit integrating a three-axis gyroscope significantly enhances the ability of the large wind turbine hoisting deformation detection device to monitor dynamic responses. Through comprehensive monitoring of strain, acceleration, and attitude changes, and by combining this information with efficient data analysis from the central processing and control center, real-time monitoring and risk warnings of the hoisting operation process can be achieved, thereby ensuring the safety and smooth progress of the hoisting work.

[0010] Optionally, each sensor unit also includes an anemometer mounted on the housing, enabling the wind turbine hoisting deformation detection device to monitor wind speed in real time. Thus, by integrating the anemometer, the individual sensor unit significantly optimizes its ability to monitor environmental factors during wind turbine hoisting. This device can not only accurately track the structural state of wind turbine components but also monitor external environmental conditions in real time, comprehensively improving the safety and efficiency of hoisting operations. Effective coordination with the central processing and control center will ensure that the construction team can make scientific and timely safety decisions under complex operating conditions.

[0011] Optionally, each sensor unit also includes a power module housed within the housing and electrically connected to the strain gauge, triaxial accelerometer, wireless data transmission module, gyroscope, and anemometer, respectively. This power module provides stable power to various sensors, meeting their power requirements during operation. This is crucial for ensuring sensor accuracy and response speed.

[0012] Optionally, each sensor unit also includes a magnetic mounting base or adjusting straps mounted on the housing for installation. This adaptability to various surface materials, such as steel towers and composite blades, facilitates quick, convenient, and non-destructive installation and removal.

[0013] Optionally, the housing of a single sensor unit can be waterproof. Considering the harsh construction environment of wind farms, which is often accompanied by wind and rain, the robust waterproof housing ensures reliable operation of the equipment under complex weather conditions.

[0014] The large-scale wind turbine hoisting deformation detection device of this utility model has the following beneficial effects:

[0015] 1) This utility model, by arranging multiple sensor units on the wind turbine components, achieves full-process, real-time, and quantitative monitoring of structural deformation and vibration status of key parts during hoisting, solving the technical problem that traditional methods cannot dynamically grasp the actual stress situation of components. Simultaneously, operators can, for the first time, intuitively see the changes in internal stress of components during hoisting, providing corresponding data support for safety decisions.

[0016] 2) This utility model combines the results of prior finite element analysis with real-time on-site data to construct a scientific safety threshold system, which can perform intelligent risk warning and promptly alarm when the deformation or vibration amplitude approaches the danger value, providing decision-making basis for on-site personnel to take preventive measures (such as suspending hoisting, adjusting posture, etc.), and greatly improving the active safety of hoisting operations.

[0017] 3. The sensor unit of this utility model adopts wireless communication and portable installation, which is convenient and quick to deploy and does not affect the normal hoisting process; and the real-time data display and alarm functions reduce the over-reliance on personnel experience, making safety monitoring more standardized and reliable, which helps to optimize the hoisting process, improve work efficiency, and accumulate valuable data for post-event analysis and continuous improvement of hoisting plans.

[0018] In summary, this utility model's large wind turbine hoisting deformation detection device not only significantly enhances the real-time performance and accuracy of safety monitoring, but also greatly improves the work efficiency and responsiveness of the construction team, providing technical assurance and support for the safe hoisting of large wind turbines.

[0019] Other advantages, objectives, and features of this invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination and study, or may be learned from practice of this invention. The objectives and other advantages of this invention can be realized and obtained through the following description. Attached Figure Description

[0020] To make the objectives, technical solutions, and advantages of this utility model clearer, the preferred embodiments of this utility model will be described in detail below with reference to the accompanying drawings, wherein:

[0021] Figure 1 A schematic diagram illustrating the application scenario of the large wind turbine hoisting deformation detection device of this utility model;

[0022] Figure 2 This is a system architecture block diagram of the large-scale wind turbine hoisting deformation detection device of this utility model;

[0023] Figure 3 This is a schematic diagram of the structure of a sensor unit in the large wind turbine hoisting deformation detection device of this utility model;

[0024] Reference numerals: 1-Wind turbine blade; 2-Lifting device; 3-Sensor unit; 4-Central processing and control hub; 5-Monitoring and alarm terminal; 30-Housing; 31-Strain gauge; 32-Triaxial accelerometer; 33-Wireless data transmission module; 34-Triaxial gyroscope; 35-Anemometer; 36-Power supply module; 37-Magnetic base. Detailed Implementation

[0025] The present invention will be further described below with reference to specific embodiments. The accompanying drawings are for illustrative purposes only, representing schematic diagrams rather than actual physical objects, and should not be construed as limiting the scope of this patent. To better illustrate the embodiments of the present invention, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0026] like Figure 1-3 As shown in the figure, the large wind turbine hoisting deformation detection device mentioned in this embodiment, in a typical application scenario, such as when hoisting a large wind turbine blade 1, detachably installs multiple sensor units 3 along the length of the wind turbine blade 1 at key locations determined in advance through mechanical analysis, such as the blade root, the maximum chord length in the middle of the blade, and the blade tip—areas prone to large deformation or stress concentration. These sensor units 3 transmit the collected deformation data in real time to the central processing and control center 4 located in a safe area on the ground via the built-in wireless data transmission module 33. The central processing and control center 4 synchronously processes, analyzes, and judges the received multi-channel data, and transmits the results to the monitoring and alarm terminal 5 held by the on-site engineer or safety officer for visualization.

[0027] Specifically, the structure of sensor unit 3 is described in detail. This single sensor unit 3 is a highly integrated self-powered module. It mainly consists of a waterproof housing 30 and multiple core sensing element assemblies housed within the housing 30. The core sensing elements include strain gauges 31 for measuring minute tensile or compressive deformations on the surface of components, and triaxial accelerometers 32 for measuring acceleration changes in three orthogonal directions. The strain data fed back from the strain gauges 31 can directly reflect the bending and torsional stress state of the component to be hoisted, such as the wind turbine blade 1, while the acceleration data fed back from the triaxial accelerometers 32 can accurately capture the vibration frequency and amplitude caused by wind loads or swaying of the hoisting system. At the same time, the measured deformation data is initially processed by the microcontroller built into the housing 30 and then transmitted through the wireless data transmission module 33. To meet the communication needs of large construction sites, the wireless data transmission module 33 adopts communication protocols such as LoRa, which have long-distance and low-power characteristics. The entire unit is powered by an internal rechargeable power module 36, whose battery life is sufficient to cover the entire hoisting operation cycle. All components are encapsulated within a robust, industrial-grade waterproof housing 30, which features magnetic mounting bases 37 on its bottom and / or sides for strong magnetic adsorption, facilitating quick and secure attachment to steel structures such as towers. Alternatively, adjustable straps can be provided on the housing 30 in different examples to secure the individual sensor unit 3.

[0028] In another embodiment, the single sensor unit 3 also includes a three-axis gyroscope 34 disposed within the housing 30. The angle change data fed back by the three-axis gyroscope 34 can monitor the attitude changes of the hoisted wind turbine components in the air, such as tilting or twisting. Specifically: tilt monitoring – the three-axis gyroscope can capture any tilt changes that may occur in the wind turbine components during hoisting. This information is crucial for determining whether the components are in a stable hoisting state; any tilt exceeding a set threshold may indicate potential risks. Twist monitoring – in addition to tilt, the gyroscope can also monitor twisting changes that may occur in the wind turbine components in the air. Real-time monitoring of the twisting state helps the construction team identify possible relative movements between components during assembly, allowing for timely corrective measures. Attitude change feedback – the angle change data provided by the three-axis gyroscope can be used to analyze complex motion patterns (such as rotation and tilt) during hoisting, providing a basis for more accurate dynamic assessment. This feedback helps ensure that the wind turbine components maintain the correct attitude before landing, thereby reducing safety hazards caused by improper installation.

[0029] In another embodiment, the individual sensor unit 3 also includes an anemometer 35 mounted on the housing 30. This offers the following advantages: real-time wind speed monitoring, as the anemometer 35 continuously monitors the wind speed in the environment where the hoisted wind turbine component is located, capturing data on instantaneous wind speed changes. This is crucial for analyzing the impact of external wind on the hoisting process. Environmental adaptability assessment, through real-time wind speed data, the central processing and control center 4 can react quickly to environmental changes that may be encountered during hoisting. For example, if the wind speed exceeds a preset safety threshold, the system can immediately issue an alarm, prompting personnel to suspend hoisting operations to avoid the risk of equipment instability due to excessive wind. Data analysis assistance, as the environmental data provided by the anemometer is combined with the monitoring data from the strain gauges, triaxial accelerometers, and triaxial gyroscopes in the sensor unit, it provides the central processing and control center 4 with more comprehensive information. This enables the system to perform more accurate risk assessments and data analysis, improving overall monitoring capabilities. Improving safety and decision-making basis: Real-time wind speed monitoring not only helps improve the safety of hoisting operations, but also provides the construction team with important decision-making basis, helping them to adjust hoisting strategies and countermeasures in a timely manner, thereby ensuring the smooth completion of hoisting tasks.

[0030] The central processing and control hub 4 is the core of the entire device's data processing and decision-making, typically a ruggedized industrial computer equipped with dedicated software. Its workflow is as follows: Data reception: The central processing and control hub 4 synchronously receives data streams from all deployed sensor units 3 via its wireless communication interface. Data processing: Based on signal processing, the raw strain readings are converted into specific stress values ​​for engineering applications, and Fourier transform and other analyses are performed on the acceleration signals to identify the main vibration frequencies and amplitudes. Risk assessment: The real-time processed data is continuously compared with a multi-level safety threshold system. This threshold system (e.g., Level 1 yellow warning and Level 2 red alarm) is set before hoisting based on the finite element analysis (FEA) results of the component. By inputting parameters such as the maximum allowable stress, strain, and vibration amplitude of key parts obtained from previous numerical simulations, a scientific and hierarchical alarm threshold system is constructed. This allows the device to directly correlate theoretical safety boundaries with real-time field data, achieving model-based intelligent risk assessment, rather than simple fixed-value alarms. Output and Recording: The central processing and control hub 4 then sends the processed data, system status, and any alarm commands to the monitoring and alarm terminal 5, and simultaneously records and archives all raw data and analysis results for subsequent analysis.

[0031] The monitoring and alarm terminal 5, serving as the human-machine interface, is typically a portable, ruggedized tablet or a handheld device with a display screen. Its graphical user interface displays information intuitively: for example, it shows the real-time placement of each sensor unit 3 on a 3D model of a hoisted component. Deformation and vibration data at each measuring point are dynamically updated using numerical values ​​and color coding (e.g., green for safety, yellow for caution, and red for danger), providing on-site management personnel with a clear overview of the entire component's structural status. Once the data from any measuring point exceeds a preset alarm threshold, the monitoring and alarm terminal 5 immediately triggers a strong visual (e.g., full-screen red flashing) and audible (e.g., high-decibel alarm) alarm, ensuring that danger signals are communicated to crane operators and ground control personnel immediately for prompt execution of emergency plans.

[0032] The specific implementation steps of this large-scale wind turbine hoisting deformation detection device are as follows: First, pre-hoisting preparation: Based on the structural drawings and hoisting plan of specific wind turbine components (such as blades, towers, or nacelles), finite element analysis is performed to identify weak points and key monitoring points in the structure, and the safety thresholds for each monitoring point are calculated accordingly. Next, real-time monitoring: As the hoisting operation begins, the system automatically enters real-time monitoring mode, continuously collecting, processing, displaying, and recording data. Then, device installation and system debugging: Before the official start of the hoisting operation, one or more sensor units 3 are installed on the key monitoring points identified in the previous step; and the magnetic mounting base 37 of the sensor unit 3 is used to firmly attach it to the metal surface of the wind turbine component. Subsequently, the power modules 36 of all sensor units 3 are turned on, and the central processing and control center 4 is activated in a safe area on the ground. System communication tests were conducted to confirm that the central processing and control hub 4 could stably receive the wireless signals transmitted from each sensor unit 3. Initial readings of each sensor were checked for normality, and battery power was verified to ensure the entire monitoring system was in standby mode. Next, an alarm response was initiated. If an alarm occurred, on-site personnel must immediately follow the predetermined emergency response procedures, typically including immediately stopping the hoisting operation and slowly lowering the component for unloading. Finally, post-hoisting analysis was performed. After the hoisting task was completed, the recorded data for the entire process was exported from the central processing and control hub 4. This primary data can be used to compare and verify with previous FEA simulation results, thereby optimizing future simulation models and hoisting construction plans, and providing corresponding data support for the formation of a project technical summary.

[0033] The technical aspect of this utility model is:

[0034] 1) Multi-sensor integration and real-time wireless transmission. Multiple sensors, such as strain gauges, triaxial accelerometers, triaxial gyroscopes, and anemometers, are integrated into a detachable sensor unit, and real-time data transmission is achieved through a wireless data transmission module (such as LoRa). This solves the problem of not being able to obtain structural response data in real time and in multiple dimensions in traditional hoisting monitoring.

[0035] 2) Synergistic monitoring of dynamic and static deformation. Simultaneously monitor static / quasi-static deformation (strain gauges) and dynamic response (accelerometers, gyroscopes) to achieve a comprehensive assessment of the structural health status during wind turbine installation.

[0036] 3) Easy installation and environmental adaptability. Magnetic base / straps enable quick and non-destructive installation, while the waterproof casing adapts to harsh construction environments, enhancing on-site applicability and reliability.

[0037] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solution of this utility model without departing from the spirit and scope of this technical solution, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. A large wind turbine hoisting deformation detection device, characterized in that, include: Multiple sensor units (3) are detachably mounted on the surface of the wind turbine component to be hoisted, and each sensor unit (3) consists of a housing (30) and a strain gauge (31), a triaxial accelerometer (32) and a wireless data transmission module (33) disposed in the housing (30); The central processing and control hub (4) is used to receive and process deformation data from multiple sensor units (3) and is communicatively connected to the wireless data transmission module (33); The monitoring and alarm terminal (5) is used to display deformation data in real time and can issue an alarm signal when a risk is detected. It is electrically connected to the central processing and control hub (4).

2. The large wind turbine hoisting deformation detection device according to claim 1, characterized in that, Each of the sensor units (3) also includes a three-axis gyroscope (34) disposed within the housing (30).

3. The large wind turbine hoisting deformation detection device according to claim 2, characterized in that, Each of the sensor units (3) also includes an anemometer (35) mounted on the housing (30).

4. The large wind turbine hoisting deformation detection device according to claim 3, characterized in that, Each sensor unit (3) further includes a power module (36) disposed in the housing (30) and electrically connected to the strain gauge (31), triaxial accelerometer (32), wireless data transmission module (33), gyroscope (34) and anemometer (35), respectively.

5. The large wind turbine hoisting deformation detection device according to any one of claims 1-4, characterized in that, Each sensor unit (3) also includes a magnetic mount (37) or an adjustment strap disposed on the housing (30) for mounting.

6. The large wind turbine hoisting deformation detection device according to claim 5, characterized in that, The housing (30) of a single sensor unit (3) is made of a waterproof shell.

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