A high-strength bolt testing device

Abstract

A high-strength bolt detection device includes a bolt, a nut, a sensor, a signal transmitter, a sealing cover, and a signal receiver. The sensor is fixed to the bottom of the bolt. The signal transmitter is electrically connected to the sensor via a wire. The sealing cover is detachably installed on the outside of the sensor and the signal transmitter. The signal receiver is installed inside a computer host and wirelessly connected to the signal transmitter for receiving and transmitting data. Combined with an application program, it monitors the bolt's working status, the sensor's operation, and the signal transmitter's operating status. The bolt is connected to the nut, fixing the bolt in the target working position. This invention can quickly provide feedback on bolt torque, bolt integrity, and other information. During bolt installation, it can replace a traditional torque wrench, saving construction time. After installation, the working status of each bolt can be monitored in real time, and abnormal signals can be quickly detected to pinpoint the bolt's location.

Description

Technical Field

[0001] This utility model relates to the field of wind turbine generator installation technology, and in particular to a high-strength bolt detection device. Background Technology

[0002] In wind power generation, construction, steel structures, and other fields, high-strength bolts are core components that ensure the structural connection strength and safe operation of equipment. Especially in the installation and operation and maintenance of wind turbine generator sets (hereinafter referred to as "wind turbines"), hundreds to thousands of high-strength bolts need to be deployed in key parts such as the tower, nacelle, and blades of a single wind turbine. These bolts are numerous, widely distributed, and are exposed to complex outdoor environments for extended periods, such as salt spray corrosion, continuous vibration, and extreme wind loads. This places stringent requirements on the installation accuracy, operational reliability, and maintenance efficiency of the bolts.

[0003] However, in traditional construction, it is necessary to rely on manual inspection with a torque wrench to check whether each bolt has reached the designed pre-tightening torque. This method has three major drawbacks: 1. High labor costs: The torque inspection of bolts for a single wind turbine requires 3-5 people to work continuously for 1-2 days. The manpower input for large-scale wind farms increases exponentially; 2. Poor inspection accuracy: Manual operation is susceptible to fatigue and environmental interference, such as strong winds at high altitudes and low temperatures, resulting in a high rate of missed and false inspections, creating a safety hazard of "insufficient pre-tightening force leading to bolt loosening"; 3. Cumbersome process: Repeated stops and starts are required to calibrate the torque, slowing down the overall installation period.

[0004] After a wind turbine is put into operation, bolts are susceptible to failure due to long-term vibration, temperature fluctuations, and load cycles, leading to torque decay, crack initiation, and even breakage. However, current technology lacks real-time sensing capabilities for key bolt conditions such as torque, integrity, and anomalies, making it impossible to provide early warnings of potential faults. This could lead to major safety accidents such as tower loosening and blade detachment, causing equipment damage and loss of power generation revenue. Furthermore, when wind turbines exhibit abnormal vibrations or noises, manual inspection of each bolt is required, a process akin to "finding a needle in a haystack"—a full inspection of a single turbine takes 2-3 days, significantly increasing maintenance costs and extending the fault repair cycle, directly impacting power generation efficiency. Summary of the Invention

[0005] This invention aims to address the shortcomings of existing technologies by providing a high-strength bolt detection device.

[0006] To achieve the above objectives, this utility model adopts the following technical solution:

[0007] A high-strength bolt detection device includes a bolt, a nut, a sensor, a signal transmitter, a sealing cap, and a signal receiver. The sensor is fixed to the bottom of the bolt. Through holes for wires are opened on the bolt shank and nut. The signal transmitter is electrically connected to the sensor via a wire and is fixed in a groove on the top of the bolt nut. The sealing cap is detachably covered on the outside of the signal transmitter. The signal receiver is installed inside a computer host and wirelessly connected to the signal transmitter for receiving and transmitting data. Combined with an application program, it monitors the working status of the bolt, the sensor, and the signal transmitter. The bolt and nut are connected to fix the bolt in the target working position.

[0008] The sensor is one of a torque sensor, a force sensor, or a stress sensor.

[0009] The signal transmitter is a wireless radio frequency transmitter.

[0010] The bolts, sensors, signal transmitters, wires, and sealing caps are integrated into a single unit.

[0011] The sealing cap is made of corrosion-resistant material.

[0012] The beneficial effects of this utility model are: the utility model has a simple and reasonable structure, is easy to operate and transport, and can quickly provide feedback on bolt torque, bolt integrity and other information. When installing bolts, it can replace the traditional torque wrench, saving construction time during the installation process; in the later stage, the working status of each bolt can be monitored in real time, and the bolt position can be quickly identified when abnormal signals are detected, which provides convenience for later maintenance. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of this utility model;

[0014] Figure 2 This is a schematic diagram of the signal structure device of this utility model;

[0015] In the diagram: 1-bolt; 2-nut; 3-sensor; 4-signal transmitter; 5-sealing cap; 6-wire; 7-signal receiver;

[0016] The following will describe in detail the embodiments of this utility model with reference to the accompanying drawings. Detailed Implementation

[0017] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0018] A high-strength bolt detection device includes a bolt 1, a nut 2, a sensor 3, a signal transmitter 4, a sealing cover 5, and a signal receiver 7. The sensor 3 is fixed to the bottom of the bolt 1. Through holes for wires 6 are opened on the shank and nut of the bolt 1. The signal transmitter 4 is electrically connected to the sensor 3 through the wires 6 and is fixed in the groove on the top of the nut of the bolt 1. The sealing cover 5 is detachably covered on the outside of the signal transmitter 4. The signal receiver 7 is installed inside a computer host and is wirelessly connected to the signal transmitter 4 for receiving and transmitting data. Combined with an application program, it can monitor the working status of the bolt, the operating status of the sensor 3 and the signal transmitter 4. The bolt 1 is connected to the nut 2 to fix the bolt 1 in the target working position.

[0019] The sensor 3 is one of a torque sensor, a force sensor, or a stress sensor.

[0020] The signal transmitter 4 is a wireless radio frequency transmitter.

[0021] The bolt 1, sensor 3, signal transmitter 4, wire 6 and sealing cover 5 are an integrated structure.

[0022] The sealing cap 5 is made of corrosion-resistant material.

[0023] When this utility model is in operation, matching industrial-grade components are selected according to the bolt specifications of scenarios such as construction, steel structure, and wind power generation.

[0024] Example 1

[0025] For wind turbine tower assembly, M30×150mm bolts are commonly used as an example to adapt to heavy load scenarios.

[0026] Bolt 1 is a 10.9 grade high-strength bolt of GB / T 1228 standard, with a specification of M30×150mm. Nut 2 is a 10.9 grade high-strength nut of GB / T1229 standard, matching the bolt specification. Sensor 3 is an HBM C16AD1 / 200T pressure / torque integrated sensor with a range of 0-500kN·m and an accuracy of 0.1%FS, simultaneously detecting torque, tensile strength, and integrity. Signal transmitter 4 is a RAKWireless RAK4631 LoRa wireless module with a transmission distance of ≥5km, low power consumption, and suitability for complex outdoor environments. Sealing cover 5 is a custom 316 stainless steel sealing cover with a thickness of 3mm, an IP65 protection rating, and resistance to salt spray and corrosion. Signal receiving device 7 is an Advantech UNO-2484G industrial control computer and customized monitoring software, integrating data analysis, early warning, and positioning functions.

[0027] At the installation locations of the wind turbine tower flange and steel structure node plate, mark the installation hole positions that match the specifications of bolt 1. Insert the component of this utility model into the installation hole and tighten it with nut 2 to fix it, so that bolt 1 and the connected parts such as flange or steel structure node plate are mechanically fastened. After bolt 1 is tightened, sensor 3 is automatically powered on and collects torque value in real time to reflect preload and integrity data, such as strain or cracks. The electrical signal is transmitted to signal transmitter 4 through wire 6. Signal transmitter 4 encodes the data into a wireless signal and continuously sends it to signal receiving device 7. When installing customized monitoring software, the bolt number and physical location are bound in the software to establish a mapping relationship between number, location and data. At the same time, parameters such as data update frequency and early warning threshold are configured. The software interface displays information such as bolt 1 torque value, integrity status and equipment online status in real time. When the software reminds that sensor 3 is offline, data jumps or no data, it can be determined that sensor 3 or transmitter 4 has failed. At this time, the sealing cover 5 can be unscrewed to replace sensor 3 or signal transmitter 4.

[0028] During routine operation and maintenance monitoring, maintenance personnel can view the status of bolts in batches through the software interface: torque value: to determine whether the design preload is met; integrity: to identify bolt cracks / deformation, i.e., sensor strain monitoring and equipment status monitoring: to check whether sensor 3 or signal transmitter 4 is online, and can also quickly locate abnormalities. When the software triggers warnings such as "insufficient torque" or "equipment offline", the system automatically locates the physical location of abnormal bolts. Through number-location mapping, maintenance personnel can accurately go to the site for repair.

[0029] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this 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, and therefore should not be construed as a limitation of this utility model.

[0030] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this utility model, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0031] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0032] The present invention has been described above with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any improvements made using the inventive concept and technical solution of the present invention, or direct application to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A high-strength bolt inspection device characterized by comprising: The device includes a bolt (1), a nut (2), a sensor (3), a signal transmitter (4), a sealing cover (5), and a signal receiver (7). The sensor (3) is fixed to the bottom of the bolt (1). A through hole for the wire (6) is opened on the shank and nut of the bolt (1). The signal transmitter (4) is electrically connected to the sensor (3) through the wire (6) and fixed in the groove at the top of the nut of the bolt (1). The sealing cover (5) is detachably covered on the outside of the signal transmitter (4). The signal receiver (7) is installed inside the computer host and wirelessly connected to the signal transmitter (4) for receiving and transmitting data. It is used in conjunction with the application to monitor the working status of the bolt, the sensor (3), and the signal transmitter (4). The bolt (1) is connected to the nut (2) to fix the bolt (1) in the target working position.

2. The high-strength bolt testing device according to claim 1, wherein The sensor (3) is one of a torque sensor, a force sensor, or a stress sensor.

3. The high-strength bolt testing device of claim 2, wherein The signal transmitter (4) mentioned above is a wireless radio frequency transmitter.

4. The high-strength bolt testing device according to claim 3, wherein The bolt (1), sensor (3), signal transmitter (4), wire (6) and sealing cover (5) are an integrated structure.

5. The high-strength bolt testing device of claim 4, wherein, The sealing cap (5) is made of corrosion-resistant material.

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