CN-116696684-B - Fan blade state monitoring system and method for production and transportation processes

CN116696684BCN 116696684 BCN116696684 BCN 116696684BCN-116696684-B

Abstract

The invention provides a fan blade state monitoring system and method used in the production and transportation process, which belong to the field of online monitoring of fan blades of wind turbines, wherein the system comprises a multidimensional sensing data acquisition terminal and a blade state early warning terminal; the multi-dimensional sensing data acquisition terminal comprises a vibration acceleration acquisition module, a multi-node strain monitoring module, a first control module and a first wireless transmission module, wherein the multi-node strain monitoring module comprises a plurality of strain monitoring nodes distributed at the easily lost part of the blade, each strain monitoring node comprises two groups of strain monitoring components which are arranged in a mutually perpendicular mode, each group of strain monitoring components comprises a monitoring strain sensor and a compensation strain sensor, the monitoring strain sensor is arranged on the blade, and the compensation strain sensor is arranged on a compensation plate which is made of the same material as the blade. The monitoring system provided by the invention can compensate the strain signal, effectively inhibit the influence of factors such as environmental temperature and the like on strain monitoring, and effectively improve the blade state estimation precision.

Inventors

ZHANG CHUANG
WANG XIAODAN
YANG HAO
JIANG DEXU
NING HUISEN
HE ZHANQI
JU NA
FU XIUJUAN

Assignees

国能联合动力技术(保定)有限公司

Dates

Publication Date: 20260508
Application Date: 20230517

Claims (8)

1. The fan blade state monitoring system used in the production and transportation process is characterized by comprising a multidimensional sensing data acquisition terminal and a blade state early warning terminal; the multi-dimensional sensing data acquisition terminal comprises a vibration acceleration acquisition module, a multi-node strain monitoring module, a first control module and a first wireless transmission module, wherein, The vibration acceleration acquisition module comprises a plurality of triaxial vibration acceleration sensors arranged on the SS surface of the blade and is used for acquiring vibration acceleration signals of different positions of the blade; The multi-node strain monitoring module is used for collecting strain signals of the blade under consideration of environmental factors and comprises a plurality of strain monitoring nodes distributed at the position where the blade is easy to lose, each strain monitoring node comprises two groups of strain monitoring components which are mutually perpendicular to each other so as to monitor the stress states of the blade in the length direction and the width direction, each group of strain monitoring components comprises a monitoring strain sensor and a compensation strain sensor, the monitoring strain sensor is arranged on the blade and used for measuring the strain generated by the blade in the production process and/or the transportation process, and the compensation strain sensor is arranged on a compensation plate made of the same material as the blade and used for compensating strain errors caused by environmental temperature; The first control module is used for controlling the first wireless transmission module to transmit multidimensional sensing data to the blade state early warning terminal, wherein the multidimensional sensing data comprises a strain signal and a vibration acceleration signal; The blade state early warning terminal is used for analyzing and processing the multidimensional sensing data to obtain a blade state characteristic value, and comprises a digital signal processing unit, a positioning module, a second wireless transmission module and a second control module; The digital signal processing unit comprises a preprocessing module, a time domain conversion module and a blade state determining module, wherein the preprocessing module is used for carrying out supplementing processing and full-phase processing on multidimensional sensing data to obtain normalized full-phase strain signals and vibration acceleration signals, the time domain conversion module is used for carrying out fast Fourier transformation on the normalized full-phase strain signals and vibration acceleration signals to obtain a plurality of strain signal frequency domain characteristics and acceleration signal frequency domain characteristics, the blade state determining module is used for inputting the effective frequency domain characteristics of the strain signals and the vibration acceleration signals to a joint Kalman filter to obtain a blade state characteristic value, the blade state determining module comprises an optimal estimation submodule and an optimal state joint estimation submodule, the joint Kalman filter comprises two sub Kalman filters and a main Kalman filter, the optimal estimation submodule is used for inputting the effective frequency domain characteristics of the strain signals and the vibration acceleration signals to the respective sub Kalman filters to carry out time and state updating so as to obtain optimal estimation characteristics of strain and optimal estimation characteristics of vibration acceleration, and the optimal state joint estimation submodule is used for inputting the optimal estimation characteristics of strain and the optimal estimation characteristics and the vibration acceleration to the optimal state to the main Kalman filter to obtain a fusion state value; The positioning module is used for acquiring the position information of the blade; The second control module is used for controlling the communication between the second wireless transmission module and the first wireless transmission module.
2. The system of claim 1, wherein the monitoring strain sensor is a monitoring strain gauge, the compensating strain sensor is a compensating strain gauge, and the monitoring strain gauge, the compensating strain gauge and the two resistors are respectively located on four legs of the wheatstone bridge to form a strain monitoring circuit.
3. The fan blade state monitoring system for use in a production and transportation process according to claim 1, wherein the blade state early warning terminal further comprises an early warning unit, and the early warning unit is configured to compare the blade state characteristic value with a blade early warning threshold value, and generate early warning information when the blade state characteristic value is greater than or equal to the blade early warning threshold value.
4. The fan blade state monitoring system for use in a production and transportation process according to claim 3, wherein the blade state early warning terminal further comprises a display module and a voice broadcasting module, the display module is used for displaying blade state information and/or early warning information, the voice broadcasting module is used for broadcasting blade state information and/or early warning information, and the blade state information comprises blade state characteristic values and position information.
5. The fan blade state monitoring system for use in a production and transportation process according to claim 1, further comprising a cloud server and a client, wherein the cloud server is connected with a blade state early warning terminal and is used for remotely storing blade state characteristic values and position information; The client is connected with the cloud server and used for acquiring and displaying the blade state characteristic value and the position information.
6. A method for monitoring the status of a fan blade during production and transportation, characterized in that the monitoring method is realized by the fan blade status monitoring system for production and transportation according to any one of claims 1 to 5, comprising: collecting multidimensional sensing data, wherein the multidimensional sensing data comprises vibration acceleration signals of different positions of the blade and strain signals of vulnerable parts of the blade under consideration of environmental factors, and the calculation formula of the strain signals is as follows: Wherein Δu O is the output voltage of the strain monitoring component, U ref is the reference voltage, R S1 is the resistance value of the monitoring strain sensor, and R S2 is the resistance value of the compensating strain sensor; The resistance change of R S1 ; The resistance change of R S2 ; preprocessing multidimensional sensing data to obtain normalized full-phase strain signals and vibration acceleration signals, wherein the preprocessing comprises supplementing processing and full-phase processing; Performing fast Fourier transform on the normalized full-phase strain signal and vibration acceleration signal to obtain a plurality of strain signal frequency domain features and acceleration signal frequency domain features; And inputting the effective frequency domain characteristics of the strain signal and the vibration acceleration signal into a joint Kalman filter to obtain a blade state characteristic value.
7. The method for monitoring the state of a fan blade during production and transportation according to claim 6, wherein the inputting the effective frequency domain characteristics of the strain signal and the vibration acceleration signal into the joint kalman filter to obtain the characteristic value of the state of the fan blade comprises: Inputting the effective frequency domain characteristics of the strain signal and the vibration acceleration signal into respective sub-Kalman filters, and updating time and state to obtain the optimal estimated characteristics of the strain and the optimal estimated characteristics of the vibration acceleration; and inputting the optimal estimation characteristics of the strain and the optimal estimation characteristics of the vibration acceleration into a main Kalman filter, and carrying out time updating and optimal fusion to obtain a blade state characteristic value.
8. The method for monitoring the status of a fan blade during production and transportation of claim 6, further comprising: comparing the blade state characteristic value with a blade early warning threshold value; if the blade state characteristic value is smaller than the blade early warning threshold value, the blade state is continuously monitored, and if the blade state characteristic value is larger than or equal to the blade early warning threshold value, early warning information is generated.

Description

Fan blade state monitoring system and method for production and transportation processes Technical Field The invention relates to the technical field of on-line monitoring of fan blades of wind turbines, in particular to a fan blade state monitoring system and a fan blade state monitoring method in a production and transportation process. Background With the rapid development of new energy technologies, wind power generation represented by wind power generation sets occupies an important position. The fan blade is a component for absorbing wind energy of the wind turbine, and the running condition of the fan blade directly influences the power generation efficiency of the wind turbine and the service lives of other components. As the fan runs, defects such as cracks, bulges, breakage, pits, etc., on the blade surface begin to appear, and in severe cases fracture occurs, all of which are directly or indirectly related to the blade condition during production and transportation. The blade is subjected to external force in the stages of mold closing, overturning, hoisting, transferring, polishing and the like in the production process and in the transportation process, so that the damage which is not easy to detect easily occurs, and the damage is an important cause for further generating defects of the blade. The wind power generation unit is mostly located in the seas, mountains and deserts far away from urban areas under the limitation of wind resource environments, so that the maintenance cost of the operation of the fan is high, and therefore the fan blade state is monitored and early-warned in the production and transportation processes, the damage which is not easy to detect is found in advance, further defects are avoided, and the wind power generation unit has important significance in reducing the operation and maintenance cost of the fan and prolonging the service life of the fan. The existing blade state monitoring technology mainly monitors the blade state in the running process of the fan, the monitored variables are many and complex, the influence of environmental factors is not considered in the measurement of the strain signals, and the stress sensor or the strain sheet is extremely easy to be influenced by the environmental temperature, so that the measured strain signals have larger errors. In addition, the existing monitoring method mainly reflects the state of the blade through time domain features, but the time domain features have limited indicating capability and cannot comprehensively reflect the state of the blade. Therefore, the application provides a fan blade state monitoring and early warning system for use in the production and transportation process, damage is found in advance, and the possibility of further generating defects is reduced. Disclosure of Invention Aiming at the technical problem that the blade state monitoring technology in the prior art does not consider the influence of environmental factors on a strain signal, the invention provides a fan blade state monitoring and early warning system used in the production and transportation process, and the system can monitor the real strain state and vibration state of the blade, so that the blade state estimation precision can be effectively improved. The fan blade state monitoring and early warning system comprises a multi-dimensional sensing data acquisition terminal and a blade state early warning terminal, wherein the multi-dimensional sensing data acquisition terminal comprises a vibration acceleration acquisition module, a multi-node strain monitoring module, a first control module and a first wireless transmission module, the vibration acceleration acquisition module comprises a plurality of triaxial vibration acceleration sensors arranged on an SS surface of the blade and used for acquiring vibration acceleration signals of different positions of the blade, the multi-node strain monitoring module is used for acquiring strain signals of the blade under consideration of environmental factors and comprises a plurality of strain monitoring nodes distributed at positions where the blade is easy to lose, each strain monitoring node comprises two groups of strain monitoring assemblies which are arranged perpendicularly to each other and used for monitoring stress states of the blade in the length direction and the width direction, each group of strain monitoring assemblies comprises a monitoring strain sensor and a compensation strain sensor, the monitoring strain sensors are arranged on the blade and used for measuring strains generated in the blade during the production process and/or the transportation process, the compensation strain sensors are arranged on a compensation plate which is made of the same material as the blade and used for acquiring the strain signals of the blade under consideration of environmental factors, the multi-dimensional sensing data acquisition module is used for acquiring the multi-dimension