A data acquisition system for monitoring the vibration of rotating components of a wind turbine generator.

Abstract

This utility model discloses a data acquisition system for monitoring the vibration of rotating components of a wind turbine generator set. The system includes a piezoelectric sensor, a constant current source, a power supply module, a signal conditioning link, a signal judgment link, an analog-to-digital converter (ADC), and a signal processing module. The constant current source is connected to the piezoelectric sensor. The output signal of the piezoelectric sensor is input to the signal conditioning link and the signal judgment link. The output signal of the signal judgment link is input to the signal processing module. The output signal of the signal conditioning link is input to the ADC. The output terminal of the ADC is connected to the signal processing module. The input terminal of the signal processing module is connected to an external pulse input. This utility model enables the monitoring of the status of the core rotating components of the wind turbine generator set in the high electromagnetic interference environment of offshore wind power, improving the operational reliability of the wind turbine generator set.

Description

Technical Field

[0001] This utility model relates to the field of vibration monitoring and acquisition technology, and in particular to an acquisition system for monitoring the vibration of rotating components of a wind turbine generator. Background Technology

[0002] In recent years, wind power has become one of the most popular new energy power generation technologies and has developed rapidly worldwide. In order to improve the power generation efficiency of individual wind turbine units, the development of wind turbine units has shown a trend towards larger sizes in recent years.

[0003] Offshore wind power has become a key development area due to its abundant wind resources and lack of reliance on land-based resources. However, offshore wind turbines operate under harsh environments, facing challenges such as salt spray, humidity, corrosion, typhoons, and waves. Rotating components like the generator, gearbox, and bearings, as core parts of the generator set, endure complex and varying loads over long periods, posing a significant risk of failure. Major mechanical failures, such as broken gearbox teeth, can lead to turbine downtime and power loss, and these major mechanical failures often originate from minor malfunctions.

[0004] Traditional wind turbine monitoring systems mainly rely on operating parameters collected by the main controller, such as speed, power, temperature, and gearbox oil pressure. These parameters can directly or indirectly reflect some faults in the wind turbine, but they cannot sensitively reflect some early faults in rotating components. Often, the fault is only reflected when it has developed to a certain extent, but by then, it has already caused considerable losses.

[0005] Vibration signal analysis is currently recognized in the industry as one of the most effective and direct technical means for monitoring the condition and diagnosing faults of rotating components. By installing accelerometers, such as those with integrated piezoelectric sensors, at key locations on rotating components, vibration signals from equipment operation can be collected in real time. Analyzing these vibration signals can sensitively identify early faults in rotating components, such as wear, cracks, broken teeth, and loosening.

[0006] Current monitoring methods still face the following challenges: 1. Sensor validity cannot be self-checked: Existing data acquisition devices lack a step to determine whether the piezoelectric sensor itself is faulty, disconnected, or has output drift before startup. This results in data acquisition continuing for a long time even when the sensor is malfunctioning, generating a large amount of invalid data and consuming transmission bandwidth and storage resources.

[0007] 2. Data acquisition timing is out of sync with rotation frequency: Existing systems mostly use timed or continuous acquisition modes, which fail to synchronize with the actual rotation cycle of rotating components such as wind turbines and gearboxes. As a result, they are very likely to miss early fault characteristics in the low-frequency band and bring redundant data.

[0008] 3. Power supply and signal crosstalk: Sensor excitation, analog conditioning, digital processing and network communication share a single power plane. In the strong electromagnetic environment at sea, digital noise can easily crosstalk into the front-end analog link, reducing the signal-to-noise ratio. Utility Model Content

[0009] To address the aforementioned issues, this invention provides a data acquisition system for monitoring the vibration of rotating components in wind turbine generator sets. This system enables the monitoring of the status of the core rotating components of the generator set, thereby improving the operational reliability of the wind turbine generator set and reducing maintenance costs and the risk of major malfunctions.

[0010] This utility model provides a data acquisition system for monitoring the vibration of rotating components of a wind turbine generator set. The specific technical solution is as follows: The system includes a piezoelectric sensor, a constant current source, a power supply module, a signal conditioning link, a signal judgment link, an analog-to-digital converter, and a signal processing module; The constant current source is connected to the piezoelectric sensor. The output signal of the piezoelectric sensor is input to the signal conditioning link and the signal judgment link. The output signal of the signal judgment link is input to the signal processing module. The output signal of the signal conditioning link is input to the analog-to-digital converter. The output terminal of the analog-to-digital converter is connected to the signal processing module. The input terminal of the signal processing module is connected to an external pulse input.

[0011] The piezoelectric sensor is used to convert mechanical vibrations into a low-impedance voltage signal containing both DC and AC components. The constant current source is used to provide a constant excitation current to the integrated piezoelectric sensor; The analog-to-digital converter is used to acquire the vibration signal.

[0012] Furthermore, the signal conditioning link includes a high-pass filter, an amplification / buffer circuit, and a low-pass filter connected in sequence. The input terminal of the high-pass filter is connected to the output terminal of the piezoelectric sensor, and the output terminal of the low-pass filter is connected to the analog-to-digital converter.

[0013] The signal conditioning link is used to filter out the DC component and high-frequency interference of the voltage signal and amplify the AC component to form a vibration signal.

[0014] Furthermore, the signal judgment link includes an attenuation circuit and a buffer circuit. The attenuation circuit is connected to the buffer circuit. The input terminal of the attenuation circuit is connected to the output terminal of the piezoelectric sensor, and the output terminal of the buffer circuit is connected to the signal processing module.

[0015] The signal judgment link is used to proportionally reduce the voltage signal to form a sensor status judgment signal.

[0016] Furthermore, the signal processing module includes a microcontroller unit and a processor. The microcontroller unit is provided with a port for receiving external pulse input, and the microcontroller unit is data connected to the memory.

[0017] Furthermore, the signal processing module also includes an Ethernet interface, which is connected to the microcontroller unit.

[0018] The vibration data stored in the memory is uploaded to the target device via an Ethernet interface.

[0019] This utility model also provides a method for collecting data for vibration monitoring of rotating components of a wind turbine generator set. Based on the aforementioned data collection system, the method includes: S1: The system is powered on and initialized. The microcontroller unit enters a waiting state, waiting to receive a valid pulse signal from an external pulse input. S2: After receiving a valid pulse signal, the microcontroller samplees the piezoelectric sensor status judgment signal and determines whether the output of the piezoelectric sensor is within the preset normal range. S3: If the output of the piezoelectric sensor is within the normal range, drive the analog-to-digital converter to continuously acquire the vibration signal output from the signal conditioning link for a set time. The collected vibration data is written into the memory in real time; If the output of the piezoelectric sensor is not within the normal range, a sensor abnormality warning will be issued, and the current data acquisition process will be skipped.

[0020] Furthermore, step S3 also includes: The microcontroller performs amplitude over-limit analysis on the vibration data. When the amplitude exceeds a preset threshold, the corresponding over-limit marker is written into the memory along with the vibration data.

[0021] Furthermore, if the piezoelectric sensor is determined to be abnormal multiple times in a row, the microcontroller enters a low-power maintenance mode.

[0022] Furthermore, when the pulse signal received from the external pulse input is invalid, the microcontroller uploads the data in its memory to the target device via the Ethernet interface.

[0023] The beneficial effects of this utility model are as follows: 1. The system of this utility model realizes a closed-loop process of pulse triggering-sensor self-testing-local storage-data upload through each module. Before data acquisition, it removes data from failed sensors and accurately collects data by opening a window according to the rotation frequency, thereby realizing effective monitoring of the status of the core rotating components of the unit and improving the operational reliability of wind turbines in the offshore environment.

[0024] 2. In the system of this utility model, the power supply module includes a first power supply, a second power supply and a third power supply. The three power supplies are isolated from each other and independently supply power to the constant current source, analog link and digital link, respectively, so as to meet the requirements of reliable data acquisition in the high electromagnetic interference environment at sea.

[0025] 3. The system of this utility model uses attenuation-buffer-ADC to form an independent judgment channel, which can achieve rapid power-on self-test without increasing the power consumption of the main ADC, avoiding the invalid operation of the sensor disconnection only after several hours of data acquisition in the prior art. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the system architecture of this utility model.

[0027] Figure 2 This is a schematic diagram of the method flow of this utility model. Detailed Implementation

[0028] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present utility model, and not all of them. The components of the embodiments of the present utility model described and shown in the accompanying drawings can be arranged and designed in various different configurations. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the scope of protection of the present utility model.

[0029] In the description of the embodiments of this utility model, it should be noted that the indicated orientation or positional relationship is based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use, or the orientation or positional relationship commonly understood by those skilled in the art, or the orientation or positional relationship commonly used when the utility model product is in use. These are only for the convenience of describing the utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the utility model. Furthermore, the terms "first" and "second" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0030] In the description of the embodiments of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0031] Example 1 Embodiment 1 of this utility model discloses a data acquisition system for monitoring the vibration of rotating components of a wind turbine generator set, such as... Figure 1 As shown, the system includes a piezoelectric sensor, a constant current source, a power supply module, a signal conditioning link, a signal judgment link, an analog-to-digital converter, and a signal processing module. The constant current source is connected to the piezoelectric sensor. The output signal of the piezoelectric sensor is input to the signal conditioning link and the signal judgment link. The output signal of the signal judgment link is input to the signal processing module. The output signal of the signal conditioning link is input to the analog-to-digital converter. The output terminal of the analog-to-digital converter is connected to the signal processing module. The input terminal of the signal processing module is connected to an external pulse input.

[0032] The power module includes a first power supply, a second power supply, and a third power supply, which are grounded and isolated from each other to reduce the interference of digital noise on the analog signal link. The first power supply is used to power the constant current source, the second power supply is used to power the high-pass filter, the amplification / buffer circuit, and the low-pass filter, and the third power supply is used to power the attenuation circuit, the buffer circuit, the analog-to-digital converter, the microcontroller unit, the Ethernet interface, and the memory. The piezoelectric sensor is used to convert mechanical vibrations into a low-impedance voltage signal containing both DC and AC components. The constant current source is used to provide a constant excitation current to the integrated piezoelectric sensor; The analog-to-digital converter is used to acquire the vibration signal.

[0033] In a preferred embodiment, the signal conditioning link includes a high-pass filter, an amplification / buffer circuit, and a low-pass filter connected in sequence. The input terminal of the high-pass filter is connected to the output terminal of the piezoelectric sensor, and the output terminal of the low-pass filter is connected to the analog-to-digital converter. The signal conditioning link is used to filter out the DC component and high-frequency interference of the voltage signal and amplify the AC component to form a vibration signal. The mixed voltage signal output by the integrated piezoelectric sensor is filtered out by a high-pass filter, leaving only the AC component, which is the vibration voltage signal. Since the AC component representing vibration often has a small amplitude and contains high-frequency interference, the amplification / buffer circuit and the low-pass filter will increase the amplitude of the AC component and filter out its high-frequency interference components. Specifically, the amplification / buffer circuit amplifies the AC vibration signal output by the high-pass filter and matches it with a high input impedance to reduce distortion in subsequent signal transmission; the low-pass filter filters out the high-frequency interference components in the AC signal after it has been processed by the amplification / buffer circuit.

[0034] In a preferred embodiment, the signal judgment link includes an attenuation circuit and a buffer circuit. The attenuation circuit is connected to the buffer circuit. The input terminal of the attenuation circuit is connected to the output terminal of the piezoelectric sensor, and the output terminal of the buffer circuit is connected to the signal processing module. The signal judgment link is used to proportionally reduce the voltage signal to form a sensor status judgment signal. Specifically, the attenuation circuit proportionally reduces the mixed voltage signal output by the integrated piezoelectric sensor; the buffer circuit matches the output of the attenuation circuit with a high input impedance and reduces subsequent distortion of the voltage signal.

[0035] In a preferred embodiment, the signal processing module includes a microcontroller unit and a processor. The microcontroller unit is provided with a port for receiving external pulse input, and the microcontroller unit is data-connected to the memory. The microcontroller unit uses a controller unit with a built-in small analog-to-digital converter, and the microcontroller unit is configured to start the acquisition process only when it receives a valid pulse signal from an external pulse input. The external pulse input pulse signal originates from the speed synchronization pulse or key phase pulse output by the main control system of the wind turbine generator set, so as to synchronize the vibration signal acquisition with the rotation frequency of the rotating parts. Specifically, the sensor status judgment signal is first sampled, and after determining that the output of the integrated piezoelectric sensor is within a preset normal range, the analog-to-digital converter is started to collect vibration signals and the collected vibration data is written to the local memory.

[0036] Furthermore, the signal processing module also includes an Ethernet interface, which is connected to the microcontroller unit and uploads the vibration data stored in the memory to the host computer via the Ethernet interface.

[0037] Example 2 Embodiment 2 of this utility model discloses a data acquisition method for vibration monitoring of rotating components of a wind turbine generator set, based on the data acquisition system described in Embodiment 1 above, such as... Figure 2 As shown, the specific steps of the method are as follows: S1: The system is powered on and initialized. The microcontroller unit enters a waiting state, waiting to receive a valid pulse signal from an external pulse input. In this embodiment, when the microcontroller receives an invalid pulse signal from an external pulse input, it uploads the data in its memory to a designated location via an Ethernet interface.

[0038] S2: After receiving a valid pulse signal, the microcontroller samplees the piezoelectric sensor status judgment signal and determines whether the output of the piezoelectric sensor is within the preset normal range. In this embodiment, if the piezoelectric sensor is judged to be abnormal multiple times in a row, that is, the output of the piezoelectric sensor is not within the preset normal range, the microcontroller shuts down other power modules except for itself and the Ethernet interface, enters a low-power maintenance mode, and sends a maintenance request to the host computer.

[0039] S3: If the output of the piezoelectric sensor is within the normal range, drive the analog-to-digital converter to continuously acquire the vibration signal output from the signal conditioning link for a set time. The AC component is acquired after passing through a high-pass filter, an amplification / buffer circuit, and a low-pass filter. Acquisition typically lasts for hundreds of seconds for subsequent vibration analysis. During acquisition, the analog-to-digital converter sends the data to the microcontroller unit every time it successfully acquires data. The collected vibration data is written to the memory in real time. Specifically, the microcontroller unit performs amplitude over-limit analysis on the vibration data. When the amplitude exceeds a preset threshold, the corresponding over-limit marker is written to the memory along with the vibration data. If the output of the piezoelectric sensor is not within the normal range, a sensor abnormality warning will be sent to the host computer, and the current data acquisition process will be skipped.

[0040] The above description is merely an embodiment of this utility model and does not limit the patent scope of this utility model. Any equivalent structural or procedural transformations made based on the content of this utility model specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this utility model.

Claims

1. A data acquisition system for monitoring the vibration of rotating components of a wind turbine generator set, characterized in that, It includes piezoelectric sensors, constant current sources, power modules, signal conditioning links, signal judgment links, analog-to-digital converters, and signal processing modules; The constant current source is connected to the piezoelectric sensor. The output signal of the piezoelectric sensor is input to the signal conditioning link and the signal judgment link. The output signal of the signal judgment link is input to the signal processing module. The output signal of the signal conditioning link is input to the analog-to-digital converter. The output terminal of the analog-to-digital converter is connected to the signal processing module. The input terminal of the signal processing module is connected to an external pulse input.

2. The data acquisition system for monitoring the vibration of rotating components of a wind turbine generator as described in claim 1, characterized in that, The signal conditioning link includes a high-pass filter, an amplification / buffer circuit, and a low-pass filter connected in sequence. The input terminal of the high-pass filter is connected to the output terminal of the piezoelectric sensor, and the output terminal of the low-pass filter is connected to the analog-to-digital converter.

3. The data acquisition system for monitoring the vibration of rotating components of a wind turbine generator as described in claim 2, characterized in that, The signal judgment link includes an attenuation circuit and a buffer circuit. The attenuation circuit is connected to the buffer circuit. The input terminal of the attenuation circuit is connected to the output terminal of the piezoelectric sensor, and the output terminal of the buffer circuit is connected to the signal processing module.

4. The data acquisition system for monitoring the vibration of rotating components of a wind turbine generator as described in claim 1, characterized in that, The signal processing module includes a microcontroller unit and a processor. The microcontroller unit is provided with a port for receiving external pulse input and is connected to a memory for data processing.

5. The data acquisition system for monitoring the vibration of rotating components of a wind turbine generator set according to claim 4, characterized in that, The signal processing module also includes an Ethernet interface, which is connected to the microcontroller unit.

6. The data acquisition system for monitoring the vibration of rotating components of a wind turbine generator set according to claim 3, characterized in that, The power module includes a first power supply, a second power supply, and a third power supply, which are grounded and isolated from each other. The first power supply is connected to the constant current source. The second power supply is connected to the high-pass filter, the amplification / buffer circuit, and the low-pass filter. The third power supply is connected to the attenuation circuit, the buffer circuit, the analog-to-digital converter, the microcontroller unit, the Ethernet interface, and the memory.

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