A wind turbine gearbox noise sound power measurement system

Abstract

The utility model discloses a kind of wind power gear box noise sound power measurement systems.Wind power gear box noise sound power measurement system includes: acoustical measurement unit, automatic scanning device, data acquisition instrument and control module;Automatic scanning device is fixed in the safety area of wind power gear box test bench position side, acoustical measurement unit is installed in the end of automatic scanning device, acoustical measurement unit is used to gather wind power gear box noise sound pressure and sound intensity signal;Control module is connected between data acquisition instrument and automatic scanning device, control module is used to receive user instruction, and drive control automatic scanning device movement;Data acquisition instrument is connected with acoustical measurement unit, data acquisition instrument is used to carry out real-time processing, record and preliminary analysis to received sound pressure and sound intensity signal, determine sound intensity and sound power, and output wind power gear box noise test report and visualized sound intensity distribution diagram.The utility model can realize full-automatic, high-precision, high-consistency sound power measurement.

Description

Technical Field

[0001] This utility model relates to the field of wind power generation technology, and in particular to a wind turbine gearbox noise power measurement system. Background Technology

[0002] The gearbox is the core transmission component of a wind turbine, and its noise level is a key indicator for measuring its manufacturing quality, assembly precision, and operational status. Currently, when conducting noise tests on gearboxes on test benches, the industry generally follows the ISO 9614-2 standard (Acoustics - Determination of noise power level by sound intensity - Part 2: Scanning measurement method).

[0003] Existing measurement systems have the following significant drawbacks:

[0004] Manual operation leads to poor consistency: The measurement process relies entirely on technicians holding a sound intensity probe and scanning a predetermined measurement surface. The scanning path, probe movement speed, probe orientation, and distance from the sound source are all difficult to keep constant, and significant deviations can be introduced by different personnel, or even by the same person performing different operations.

[0005] Inefficient and labor-intensive: Gearbox testing has a long cycle, requiring measurements at multiple operating points under different loads and speeds. Prolonged, repetitive manual scanning is physically demanding, easily leading to operator fatigue and further affecting measurement accuracy.

[0006] Data reliability is difficult to guarantee: manual scanning cannot accurately reproduce the standard scanning path and speed, which may lead to omissions or repeated measurements of certain areas of the sound source, resulting in uncertainty in the final calculated sound power level and affecting the credibility and comparability of the test results.

[0007] Safety issues: The testing environment is complex, with rotating parts and high noise levels, posing certain safety risks to manual operation.

[0008] Therefore, there is an urgent need in this field for a solution that can automate, accurately, and repeatedly perform noise scanning measurements of wind turbine gearboxes. Utility Model Content

[0009] This invention provides a wind turbine gearbox noise power measurement system that overcomes the above-mentioned defects, so as to achieve fully automatic, high-precision and high-consistency sound power measurement.

[0010] According to one aspect of the present invention, a wind turbine gearbox noise power measurement system is provided, the wind turbine gearbox noise power measurement system comprising: an acoustic measurement unit, an automatic scanning device, a data acquisition instrument, and a control module;

[0011] The automatic scanning device is fixed in a safe area next to the wind turbine gearbox test bench. The acoustic measurement unit is installed at the end of the automatic scanning device. The acoustic measurement unit is used to collect the sound pressure and sound intensity signals of the wind turbine gearbox noise.

[0012] The control module is connected between the data acquisition instrument and the automatic scanning device. The control module is used to receive user commands and drive the automatic scanning device to move.

[0013] The data acquisition instrument is connected to the acoustic measurement unit. The data acquisition instrument is used to process, record and preliminarily analyze the received sound pressure and sound intensity signals in real time, determine the sound intensity and sound power, and output a test report of the wind turbine gearbox noise and a visualized sound intensity distribution map.

[0014] Optionally, the wind turbine gearbox noise power measurement system also includes: a synchronization unit;

[0015] The synchronization unit is connected to the control module, and the synchronization unit is used to ensure that the acoustic data acquisition of the data acquisition instrument is synchronized with the mechanical scanning position information of the automatic scanning device in real time.

[0016] Optionally, the control module includes: a main controller;

[0017] The main controller is used to receive user instructions and control the automatic scanning device to move according to the planned path.

[0018] Optionally, the control module further includes: a motion control card;

[0019] The motion control card is integrated into the main controller, or the motion control card is connected to the main controller;

[0020] The motion control card is used to generate precise control commands to drive the servo motor or stepper motor in the automatic scanning device.

[0021] Optionally, the control module further includes: a display unit;

[0022] The display unit is connected to the main controller and is used to provide operators with a graphical control interface for setting measurement parameters, monitoring the measurement process, and viewing results.

[0023] Optionally, the acoustic measurement unit includes: multiple sound intensity probes;

[0024] The measuring surfaces of the wind turbine gearbox include: top, front, back, left, and right.

[0025] The plurality of sound intensity probes are sequentially arranged on the top, front, back, left and right sides, and are used to collect sound pressure and sound intensity signals of noise on multiple different measurement surfaces.

[0026] Optionally, the automatic scanning device includes an industrial robot.

[0027] Optionally, the scanning path of the automatic scanning device is S-shaped.

[0028] Optionally, the scanning distance of the automatic scanning device is 0.5m from the outer contour of the wind turbine gearbox.

[0029] Optionally, the scanning time of the automatic scanning device is 30 seconds, and the scanning speed of the automatic scanning device is 0.1 m / s to 0.5 m / s.

[0030] The technical solution of this utility model embodiment provides a wind turbine gearbox noise measurement system based on automatic scanning. It acquires sound pressure and intensity signals of wind turbine gearbox noise through an acoustic measurement unit, overcoming the shortcomings of manual operation and poor consistency. The control module receives user commands and drives the automatic scanning device, solving the problems of low efficiency, high labor intensity, and safety concerns during measurement. The data acquisition instrument processes, records, and performs preliminary analysis on the received sound pressure and intensity signals in real time, determines the sound intensity and sound power, and outputs a test report and a visualized sound intensity distribution map of the wind turbine gearbox noise, solving the problem of unreliable data. It can automatically, accurately, and repeatedly complete wind turbine gearbox noise scanning measurements. In summary, this utility model solves the problem that existing measurement systems cannot automatically, accurately, and repeatedly complete wind turbine gearbox noise scanning measurements.

[0031] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of this utility model, nor is it intended to limit the scope of this utility model. Other features of this utility model will become readily apparent from the following description. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments 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.

[0033] Figure 1 This is a schematic diagram of the overall structure of a wind turbine gearbox noise power measurement system according to an embodiment of the present invention;

[0034] Figure 2 This is a flowchart illustrating the operation of a wind turbine gearbox noise power measurement system according to an embodiment of the present invention.

[0035] Figure 3 This is a schematic diagram of a wind turbine gearbox measuring surface provided according to an embodiment of the present utility model;

[0036] Figure 4 This is a schematic diagram of the scanning path of an automatic scanning device according to an embodiment of the present utility model. Detailed Implementation

[0037] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention 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 invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.

[0038] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this utility model are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the utility model described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0039] Figure 1 This is a schematic diagram of the overall structure of a wind turbine gearbox noise power measurement system according to an embodiment of the present invention. (Refer to...) Figure 1 The present invention provides a wind turbine gearbox noise power measurement system, which includes an acoustic measurement unit 10, an automatic scanning device 20, a data acquisition instrument 30, and a control module 40.

[0040] The automatic scanning device 20 is fixed in a safe area next to the wind turbine gearbox test bench. The acoustic measurement unit 10 is installed at the end of the automatic scanning device 20. The acoustic measurement unit 10 is used to collect the sound pressure and sound intensity signals of the wind turbine gearbox noise.

[0041] The control module 40 is connected between the data acquisition unit 30 and the automatic scanning device 20. The control module 40 is used to receive user commands and drive the automatic scanning device 20 to move.

[0042] The data acquisition unit 30 is connected to the acoustic measurement unit 10. The data acquisition unit 30 is used to process, record and preliminarily analyze the received sound pressure and sound intensity signals in real time, determine the sound intensity and sound power, and output a test report on the noise of the wind turbine gearbox and a visualized sound intensity distribution map.

[0043] Specifically, the drive motor 1 is part of the wind turbine gearbox 2 test bench, and the drive motor 1 is used to drive the wind turbine gearbox 2. The drive motor 1, the wind turbine gearbox 2, and the automatic scanning device 20 are all mounted on the same base 3.

[0044] The acoustic measurement unit 10 may include one or more sound intensity probes (or microphone arrays) conforming to ISO 9614-2 standards for acquiring sound pressure and sound intensity signals. Optionally, the automatic scanning device includes an industrial robot. The automatic scanning device 20 is the core of this system, used to fix and drive the acoustic measurement unit 10 to perform precise movements. Its specific implementation can be a six-degree-of-freedom industrial robot with a multi-degree-of-freedom robotic arm, with the acoustic measurement unit 10 mounted on its end flange. Its advantage lies in its extremely flexible movement, adapting to complex measurement envelope surfaces (such as the various sides of a wind turbine gearbox). The data acquisition unit 30 is used to receive the signals acquired by the acoustic measurement unit 10, and to perform real-time processing, recording, and preliminary analysis to calculate indicators such as sound intensity and sound power.

[0045] Figure 2 This is a flowchart illustrating the operation of a wind turbine gearbox noise power measurement system according to an embodiment of this utility model. (Refer to...) Figure 2 The system's workflow includes the following steps:

[0046] System setup and calibration: Fix the automatic scanning device in a safe area next to the wind turbine gearbox test bench, firmly install the acoustic measurement unit at the end of the automatic scanning device, perform spatial calibration of the automatic scanning device, establish the mapping relationship between its coordinate system and the physical position of the wind turbine gearbox, and perform acoustic calibration of the acoustic measurement unit.

[0047] Measurement parameter settings: On the human-machine interface in the control module, based on the ISO 9614-2 standard and the gearbox shape, a virtual measurement surface (usually a cuboid surface enclosing the sides of the gearbox) is set, and a scanning path is planned on the virtual measurement surface. The path is usually a series of parallel straight lines, and the path spacing can be set according to standard requirements. The scanning speed is also set. Test operating condition information (such as load, speed), sampling frequency, etc., are also set.

[0048] Automatic scanning and data acquisition: Start the test. The control module instructs the automatic scanning device to drive the acoustic measurement unit to move at a constant speed along a preset path starting from the initial point. The data acquisition instrument continuously collects acoustic signals, and the synchronization unit ensures that the acoustic data collected at each moment corresponds to a precise three-dimensional spatial coordinate.

[0049] Data processing and calculation: After the scan is completed, the data acquisition instrument will process the synchronously recorded acoustic data and location information, and use the algorithm specified in ISO 9614-2 to integrate the sound intensity on each measurement surface, and finally calculate the total sound power level of the gearbox, the spectrum diagram, and the sound intensity distribution cloud map of each measurement surface.

[0050] Results Output and Report Generation: The system automatically generates a test report containing information such as sound power level, spectrum, and measurement conditions, and can output a visualized sound intensity distribution map.

[0051] The technical solution of this utility model embodiment provides a wind turbine gearbox noise measurement system based on automatic scanning. It acquires sound pressure and intensity signals of wind turbine gearbox noise through an acoustic measurement unit, overcoming the shortcomings of manual operation and poor consistency. The control module receives user commands and drives the automatic scanning device, solving the problems of low efficiency, high labor intensity, and safety concerns during measurement. The data acquisition instrument processes, records, and performs preliminary analysis on the received sound pressure and intensity signals in real time, determines the sound intensity and sound power, and outputs a test report and a visualized sound intensity distribution map of the wind turbine gearbox noise, solving the problem of unreliable data. It can automatically, accurately, and repeatedly complete wind turbine gearbox noise scanning measurements. In summary, this utility model solves the problem that existing measurement systems cannot automatically, accurately, and repeatedly complete wind turbine gearbox noise scanning measurements.

[0052] Optionally, the wind turbine gearbox noise power measurement system also includes: a synchronization unit;

[0053] The synchronization unit is connected to the control module and is used to ensure that the acoustic data acquisition of the data acquisition instrument and the mechanical scanning position information of the automatic scanning device are synchronized in real time.

[0054] Specifically, the synchronization unit ensures real-time synchronization between acoustic data acquisition and mechanical scanning position information. This is typically achieved by the control module sending a synchronization trigger signal or a position encoder signal to the data acquisition unit.

[0055] Continue to refer to Figure 1 Optionally, the control module 40 includes: a main controller 41;

[0056] The main controller 41 is used to receive user instructions and control the automatic scanning device 20 to move according to the planned path.

[0057] Specifically, the control module 40 is the core component of the system. The control module 40 includes a main controller 41, which can be a PLC or an industrial PC. The main controller 41 is used to receive user commands and control the automatic scanning device 20 to move along a preset path.

[0058] Optionally, the control module may also include: a motion control card;

[0059] The motion control card is integrated into the main controller, or the motion control card is connected to the main controller;

[0060] The motion control card is used to generate precise control commands to drive the servo motors or stepper motors in the automatic scanning device.

[0061] Specifically, the motion control card can be integrated into the main controller or connected to the main controller. The motion control card is used to generate precise control commands to drive the servo motor or stepper motor integrated inside the scanning device.

[0062] Continue to refer to Figure 1 Optionally, the control module 40 further includes a display unit 42;

[0063] The display unit 42 is connected to the main controller 41. The display unit 42 is used to provide operators with a graphical control interface for setting measurement parameters, monitoring the measurement process, and viewing results.

[0064] Specifically, the control module 40 also includes a display unit 42, in which a human-machine interface (HMI) provides operators with a graphical control interface for setting measurement parameters, monitoring the measurement process, and viewing results.

[0065] Figure 3 This is a schematic diagram of a wind turbine gearbox measuring surface according to an embodiment of the present invention, with reference to... Figure 3 Optionally, the acoustic measurement unit includes: multiple sound intensity probes;

[0066] The measuring surfaces of a wind turbine gearbox include: top, front, rear, left, and right.

[0067] Multiple sound intensity probes are sequentially positioned on the top, front, back, left, and right sides. These probes are used to collect sound pressure and sound intensity signals of noise on multiple different measurement surfaces.

[0068] Specifically, a multi-measurement surface arrangement can capture the sound field distribution more comprehensively, especially in complex acoustic environments (such as industrial sites) where it can accurately locate noise sources. By enhancing spatial coverage and interference resistance, a multi-measurement surface arrangement improves the comprehensiveness and accuracy of noise measurements.

[0069] Figure 4 This is a schematic diagram of the scanning path of an automatic scanning device according to an embodiment of the present invention, with reference to... Figure 4 Optionally, the scanning path of the automatic scanning device is S-shaped.

[0070] Specifically, the scanning path of the automatic scanning device is from left to right and from top to bottom, covering the length, width and height of the envelope surface. The scanning path of the envelope surface is S-shaped, and the line spacing is less than or equal to 0.2m.

[0071] Optionally, the scanning distance of the automatic scanning device is 0.5m from the outer contour of the wind turbine gearbox.

[0072] Specifically, setting the scanning distance to 0.5m primarily affects the accuracy and coverage of data acquisition. 0.5m serves as a safety boundary, ensuring a safe distance between the automatic scanning device and the wind turbine gearbox to avoid mechanical collisions or electromagnetic interference, making it particularly suitable for dynamic industrial environments.

[0073] Optionally, the scanning time of the automatic scanning device is 30 seconds, and the scanning speed of the automatic scanning device is 0.1 m / s to 0.5 m / s.

[0074] Specifically, the 30-second scan time determines the completeness and efficiency of data acquisition.

[0075] Comprehensive Coverage: At a scanning speed of 0.1-0.5 m / s, continuous scanning of multiple sides or complex curved surfaces of a gearbox can be completed in 30 seconds, avoiding the omission of critical areas. Compared to traditional measurement, the rapid 30-second scanning significantly improves production line cycle time, making it suitable for batch inspection needs. Automated scanning reduces manual intervention, and the overall inspection cost is reduced by more than 60% compared to traditional methods.

[0076] The scanning speed range of 0.1-0.5 m / s directly affects data quality and applicable scenarios: Low speed (0.1 m / s): Suitable for high-precision inspection, increasing point cloud density by reducing movement speed, but may increase the total time. High speed (0.5 m / s): Suitable for rapid initial inspection or large-sized parts, sacrificing some detail for efficiency.

[0077] The specific embodiments described above do not constitute a limitation on the scope of protection of this utility model. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the scope of protection of this utility model.

Claims

1. A wind turbine gearbox noise power measurement system, characterized in that, include: Acoustic measurement unit, automatic scanning device, data acquisition instrument and control module; The automatic scanning device is fixed in a safe area next to the wind turbine gearbox test bench. The acoustic measurement unit is installed at the end of the automatic scanning device. The acoustic measurement unit is used to collect the sound pressure and sound intensity signals of the wind turbine gearbox noise. The control module is connected between the data acquisition instrument and the automatic scanning device. The control module is used to receive user commands and drive the automatic scanning device to move. The data acquisition instrument is connected to the acoustic measurement unit. The data acquisition instrument is used to process, record and preliminarily analyze the received sound pressure and sound intensity signals in real time, determine the sound intensity and sound power, and output a test report of the wind turbine gearbox noise and a visualized sound intensity distribution map.

2. The system according to claim 1, characterized in that, Also includes: Synchronization unit; The synchronization unit is connected to the control module, and the synchronization unit is used to ensure that the acoustic data acquisition of the data acquisition instrument is synchronized with the mechanical scanning position information of the automatic scanning device in real time.

3. The system according to claim 1, characterized in that, The control module includes: a main controller; The main controller is used to receive user instructions and control the automatic scanning device to move according to the planned path.

4. The system according to claim 3, characterized in that, The control module also includes: a motion control card; The motion control card is integrated into the main controller, or the motion control card is connected to the main controller; The motion control card is used to generate precise control commands to drive the servo motor or stepper motor in the automatic scanning device.

5. The system according to claim 3, characterized in that, The control module further includes: a display unit; The display unit is connected to the main controller and is used to provide operators with a graphical control interface for setting measurement parameters, monitoring the measurement process, and viewing results.

6. The system according to claim 1, characterized in that, The acoustic measurement unit includes: multiple sound intensity probes; The measuring surfaces of the wind turbine gearbox include: top, front, back, left, and right. The plurality of sound intensity probes are sequentially arranged on the top, front, back, left and right sides, and are used to collect sound pressure and sound intensity signals of noise on multiple different measurement surfaces.

7. The system according to claim 1, characterized in that, The automatic scanning device includes an industrial robot.

8. The system according to claim 1, characterized in that, The scanning path of the automatic scanning device is S-shaped.

9. The system according to claim 1, characterized in that, The scanning distance of the automatic scanning device is 0.5m from the outer contour of the wind turbine gearbox.

10. The system according to claim 1, characterized in that, The scanning time of the automatic scanning device is 30 seconds, and the scanning speed of the automatic scanning device is 0.1 m / s-0.5 m / s.

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