Hydraulic Turbine Wicket Gate Force Calibration
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Solution Overview
Problem
The existing hydraulic turbine gating systems experience premature wear and maintenance issues due to excessive forces applied during startup and shutdown, leading to water leaks and operational inefficiencies, as the forces required for watertight closure are not accurately calibrated, causing abnormal friction and wear.
Innovation Solution
A method that involves calculating the theoretical force needed for watertight closure using static mechanics, measuring the applied force with strain gauges, adjusting the cylinder rod travel to match the theoretical force, and repeating the process until the measured force is accurate, ensuring optimal preload without excess strain, and incorporating strain gauges on tie rods for fusible components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cylinder applies excess force to ensure watertight closure of the gating system, then the water-tightness is improved, but the wear of wicket gates, crank pins and tie rods increases prematurely
Solution Approach 1:
The invention changes the parameter of cylinder force from excessive to optimized by introducing a calibration method that determines the exact force needed for watertight closure. Strain gauges measure the actual force applied, and the cylinder travel is adjusted to achieve the theoretical force calculated from static mechanics, eliminating both insufficient and excessive forcing.
Solution Approach 2:
The invention implements feedback by using strain gauges to measure the actual force applied by the cylinder and comparing it with the theoretical force calculated from static mechanics. This feedback loop allows for precise adjustment of the cylinder rod travel to achieve the optimal force level that ensures watertight closure without causing premature wear.
2Reliability
If the cylinder rod travel is increased to ensure closure, then the water-tightness is improved, but the friction and wear in the kinematic chain increase
Solution Approach 1:
The invention optimizes the cylinder rod travel parameter by calibrating it to the exact value needed to achieve watertight closure. The method involves calculating the theoretical force from static mechanics, measuring the actual force with strain gauges, and adjusting the rod travel until the measured force matches the theoretical force, thereby eliminating excessive travel that causes friction and wear.
Solution Approach 2:
The invention applies the principle of avoiding excessive action by determining the precise, minimal cylinder travel required to achieve watertight closure. Instead of applying excessive force or travel to ensure closure, the calibration method identifies and applies only the necessary amount, thereby reducing friction and wear while maintaining reliability.
3Duration of action of stationary object
If the gating system is adjusted to reduce wear, then the maintenance frequency is reduced, but the water-tightness may be compromised
Solution Approach 1:
The invention simultaneously optimizes both service life and water-tightness by changing the force parameter from excessive to precise. The calibration method using strain gauges and static mechanics calculations determines the exact force level that achieves watertight closure without causing premature wear, thereby improving both durability and reliability concurrently.
Solution Approach 2:
The invention uses feedback through strain gauge measurements to ensure that the force applied is exactly what is needed for watertight closure. This feedback mechanism allows for precise adjustment of the cylinder rod travel to achieve the theoretical force, ensuring both optimal service life and reliable water-tightness without compromise.
4Reliability
If the cylinder applies sufficient force for rapid closure during emergency stop, then the hydraulic safety is improved, but the wear of the kinematic chain increases
Solution Approach 1:
The invention optimizes the force parameter to achieve the minimum necessary level for both normal operation and emergency stop functions. By calibrating the cylinder rod travel based on theoretical calculations from static mechanics and verifying with strain gauges, the system applies sufficient force for rapid emergency closure while avoiding excessive force that would cause premature wear.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method optimizes the adjustment of the gating system, reducing wear, maintenance frequency, water losses, and operational losses, ensuring continuous hydraulic safety and productivity by accurately calibrating the closure forces and reducing leakage.
Implementation Method 1
measurement, via said strain gauge, of the force applied to said cylinder
Data Source
AI summary
The present invention relates to a method for optimizing the adjustment of the gating of a hydraulic turbine (1), the turbine (1) is provided with a set of wicket gates (2), wicket gates (2) are moving with a single, conjoined movement between a closing position in which they press against one another and an opening position in which they are apart from one another, by a control ring (4) that is kinematically connected to each one of these wicket gates (2), this control ring (4) being moved in rotation by at least one actuator (3), this actuator (3) including a device (31) for adjusting the travel of its rod (30), the method includes at least the following steps, the turbine (1) is previously stopped and dry and the rod (30) of the actuator (3) is provided with at least one strain gauge: 1) calculating the theoretical force to be applied to the actuator (3) in order to obtain watertight closure of the wicket gates (2); 2) measuring, via the strain gauge, the force applied to the actuator (3), the latter being inoperative; 3) after bringing the actuator (3) online, moving its rod (30) until the wicket gates (2) adopt the closing position and measuring the corresponding force, referred to as the “measured force”; 4) comparing the measured force with the theoretical force calculated in step 1.