CN-120831417-B - Wind power tower cylinder depression detection method based on phased array technology

CN120831417BCN 120831417 BCN120831417 BCN 120831417BCN-120831417-B

Abstract

The invention relates to a wind power tower barrel depression detection method based on a phased array technology, which realizes indirect quantification of depressions through detecting raised areas, prepares a calibration test block containing stepped protrusions and paint layer thickness gradients, establishes a mapping relation between geometric parameters and ultrasonic response, establishes a mathematical model of paint layer thickness (g) and gain compensation value (i), fits a linear equation of raised inclination tangent value (tan theta) and gain value (h), positions the horizontal size and length of defects through amplitude disappearing boundaries, and inverts depression depth through three-dimensional quantification calculation, thereby obtaining the size and position of the defects, having high detection precision and error control within 1 percent, simultaneously realizing scaffold-free operation, reducing equipment downtime and scaffold lease cost, greatly reducing single detection cost, being convenient to use and good in effect, and being innovation on the wind power tower barrel depression detection method.

Inventors

WANG HAO
Fan Zhangshuai
FENG KAIHANG
MA ZHIHANG
Shan Mengjuan
QIAO LIANG
JU GUANGYU
ZHU GUOBIN
Pan Yinkui
LIU WENSHENG
JIANG YE
JIA SHAOWEI
DENG HUI

Assignees

中国大唐集团科学技术研究总院有限公司
中国大唐集团科学技术研究总院有限公司中南电力试验研究院

Dates

Publication Date: 20260512
Application Date: 20250717

Claims (1)

1. The wind power tower cylinder depression detection method based on the phased array technology is characterized by comprising the following steps of: step one, manufacturing a reference block Reference block a: manufacturing a reference block A containing bulges, manufacturing at least 10 reference blocks A, wherein the center of each reference block A is provided with bulges, the direction along the length direction of the reference block A is defined as Y direction, the direction along the width direction of the reference block is X direction, the direction vertically upwards is Z direction, the angle theta is defined as the inclination angle of the bulges of the tower barrel, and the difference between the 10 reference blocks A is that the inclination angles theta of the bulges are different; reference block B: manufacturing a plurality of comparison test blocks B, wherein the comparison test blocks B are of cuboid structures, paint layers with different thicknesses are respectively coated on the surfaces of the comparison test blocks B, and the paint layers of the test blocks are g1, g2, g3, g4 and g5., and at least comprise 5 different paint layer thicknesses; Step two, selecting a probe The probe is a phased array probe, 10L 64-0.5X10 linear array probe is adopted, wherein 10 is the central frequency of the probe, L represents the linear array probe, 64 represents the number of array elements of the probe, 0.5 in 0.5X10 represents the central distance of the array elements to be 0.5mm, the gap between adjacent array elements to be 0.1mm, and 10 represents the length of the array elements to be 10mm; The N63-90S surface wave wedge block is adopted in a matched way, a displacement sensor is arranged in the probe, and the moving distance of the probe is recorded; Step three, calibration test 3.1 Paint layer calibration test Calculating the compensation of the surface wave gain values of different paint layer thicknesses, selecting a reference test block B, transmitting surface waves on the reference test block B, and adjusting the bottom wave amplitude to 80% to obtain the compensation gain of different paint layer thicknesses; Drawing a corresponding relation diagram of the paint layer thickness g and the compensation gain i through Origin software aiming at compensation gains corresponding to different paint layer thicknesses, and fitting a formula conforming to the relation of g and i through a formula fitting method in Origin, wherein the formula Pearson (correlation coefficient) is required to be more than 0.97, and the R-Square (fitting degree) is more than 0.97, namely a paint layer compensation gain equation; 3.2 Inclination angle calibration test The probe is placed at the left upper corner edge of the reference test block A, a surface wave is launched, the left upper corner of the reference test block A is defined as an origin of coordinates, namely a (0, 0) point, a scanning path is that the probe firstly starts to scan the reference test block A positively along a Y axis from the (0, 0) point until the edge of a convex area of the test block A, then the probe carries out negative scanning along the Y axis from the edge of the convex area of the reference test block A until the left edge of the reference test block A with 40-50% of the last scanning path overlapping with the previous scanning path in the Y axis direction, and the probe repeatedly circulates in the way until reaching the lower measuring edge of the reference test block A, the scanning speed is not more than 150mm/s, when the probe scans the surface convex area, reflected waves exist at the convex position, the reflected wave intensity is related to the angle theta of the convex, the reflected wave amplitude is adjusted to 80%, and the minimum gain values of different convex angles and the wave amplitude corresponding to 80% are obtained; Drawing a corresponding relation diagram of a tangent value tan (theta) of the convex inclination angle theta and a gain value h corresponding to the amplitude 80% through Origin software, fitting a formula conforming to the relation of tan (theta) and h, and requiring the formula Pearson to be more than 0.97 and R-Square to be more than 0.97, namely a gain equation of the gain value h corresponding to the tangent value tan (theta) of the convex inclination angle theta and the amplitude 80%; Step four, on-site detection Defining the horizontal direction along the tower barrel as the X direction, the height direction along the tower barrel as the Y direction, the protruding direction of the tower barrel as the Z direction, wherein the tower barrel is composed of different barrel sections, the different barrel sections are welded and connected by welding seams, the scanning mode firstly scans the bottom of the tower barrel to the welding seam H1, then scans the welding seam H1-H2 and the welding seam H2-H3., and the scanning is completed until the welding seam Hn is the top of the tower barrel; When a concave area without a bulge is scanned, the surface wave has no defect of reflected bottom wave, if the surface bulge is found, reflected wave is generated at the starting point of the bulge, the amplitude at the moment is fixed to be 80%, after the minimum gain value is found, the gain value at the moment is fixed to be hxdB, and the position of the probe at the moment is recorded and recorded as the (1, 1) position; 4.1 Defect X-direction dimension measurement Moving along X negative direction from the position of the coordinate (1, 1), the wave amplitude is gradually reduced, when no reflection surface wave exists, the recording probe moves along X positive direction, the wave amplitude is gradually reduced, when no reflection surface wave exists, the recording probe moves along X negative direction, the distance Xb, xa+Xb is the size of the defect X direction; 4.2 Defect Y-direction dimension measurement Recording the horizontal movement along the positive X direction from the position of the recorded coordinates (1, 1) until the amplitude disappears, returning to the position (1, 1), horizontally moving along the negative X direction until the amplitude disappears, and recording the minimum abscissa of the reflected wave in the process, namely the minimum forward propagation distance value of the surface wave, which is recorded as Y1 min ; The probe is placed in the protruding area along the other side of the tower barrel in the height direction, the wave amplitude of the defect is fixed to be 80%, the gain value is fixed at the moment after the position with the minimum gain value is found, the position of the probe is recorded, the position is recorded as the (2, 2) position, the probe is horizontally moved from the recorded (2, 2) position along the X positive direction until the wave amplitude disappears, the probe is returned to the (2, 2) position and horizontally moved along the X negative direction until the wave amplitude disappears, and the minimum abscissa of the reflected wave in the process, namely the minimum forward propagation distance value of the surface wave, is recorded as Y2 min ; Measuring the Y-direction distance between the two probes along the height of the tower, and marking as Y3; The Y-direction dimension calculating method is that Y=Y3-Y1 minn -Y2 min ; 4.3 Defect Z-direction dimension measurement Measuring the thickness of the paint layer of the tower drum, determining a paint layer compensation gain value, measuring the thickness g of the paint layer, carrying out the paint layer compensation gain equation obtained in the step 3.1 to obtain a paint layer compensation gain value i under the thickness g, Adding paint layer compensation idB, wherein the total gain value is h=hx+i; Bringing the total gain value h into a gain equation of the gain value h corresponding to the tangent value tan (theta) of the convex inclination angle theta and the amplitude of 80% in the step 3.2 to obtain tan (theta); tan(θ)=Z/(Y/2) obtaining the defect height, namely Z value; and obtaining the position and the size of the tower bulge defect.

Description

Wind power tower cylinder depression detection method based on phased array technology Technical Field The invention relates to the technical field of nondestructive testing, in particular to a wind power tower cylinder depression detection method based on a phased array technology. Background In the context of the acceleration of global energy structures to renewable energy, wind power generation is one of the main forces, the capacity of a single machine is continuously increased, and the weight of core components (such as cabins, hubs and blades) of the unit and the height of a tower are also increased obviously. The tower drum is used as a key bearing structure for supporting the whole wind turbine, and the structural integrity and the safety of the tower drum are directly related to the operation safety and the economic benefit of a wind farm. With the complexity of the service environment and the increase of the service life of the tower, the phenomenon of local sinking of the wall of the tower is sometimes generated in industry, and the damage is an important hidden danger threatening the safety of the tower structure. However, there is currently a general lack of effective means for efficient, accurate quantitative detection of tower dent damage within the industry. The existing mainstream method relies on manual measurement by using a simple ruler-gauge tool, and has the remarkable limitations that firstly, a large-area scaffold is required to be erected before measurement, a large amount of labor, material resources and time cost are consumed, safety risks exist in high-altitude operation, secondly, the manual ruler-gauge method is poor in positioning accuracy and low in repeatability and is difficult to acquire accurate and reliable quantitative data for the measurement of the boundary range definition and the pit depth value of pit damage, and particularly, when auxiliary ladders, cables, platforms or other facilities are blocked on the surface of a tower, the feasibility of the method is severely limited, and even effective measurement cannot be performed at all. Therefore, in the face of increasingly large and high-rise modern wind turbine generator tower drums, development of an efficient and safe detection technology and method which can overcome the blockage of field facilities and accurately position the concave boundary and the quantized concave depth without setting up a scaffold is an urgent need and a necessary trend for guaranteeing safe operation of wind power plants, improving operation and maintenance efficiency and promoting technical progress of industries. Disclosure of Invention Aiming at the situation, in order to overcome the defects of the prior art, the invention aims to provide a wind power tower cylinder depression detection method based on a phased array technology, which can effectively solve the problem of wind power tower cylinder depression detection. The technical scheme of the invention is as follows: A wind power tower cylinder depression detection method based on a phased array technology comprises the following steps: step one, manufacturing a reference block Reference block a: Manufacturing a reference block A containing bulges, manufacturing at least 10 reference blocks A, wherein the center of each reference block 1 is provided with bulges, the direction along the length direction of the reference block is defined as Y direction, the direction along the width direction of the reference block is X direction, the direction vertically upwards is Z direction, the angle theta is defined as the inclination angle of the bulges of the tower barrel, and the difference between the 10 reference blocks 1 is that the inclination angles theta of the bulges are different; reference block B: Manufacturing a plurality of comparison test blocks B, wherein the comparison test blocks B are of cuboid structures, paint layers with different thicknesses are respectively coated on the surfaces of the comparison test blocks B, and the paint layers of the test blocks are g1, g2, g3, g4 and g5., and at least comprise 3 different paint layer thicknesses; Step two, selecting a probe The probe is a phased array probe, 10L 64-0.5X10 linear array probe is adopted, wherein 10 is the central frequency of the probe, L represents the linear array probe, 64 represents the number of array elements of the probe, 0.5 in 0.5X10 represents the central distance of the array elements to be 0.5mm, the gap between adjacent array elements to be 0.1mm, and 10 represents the length of the array elements to be 10mm; The N63-90S surface wave wedge block is adopted in a matched way, a displacement sensor is arranged in the probe, and the moving distance of the probe is recorded; Step three, calibration test 3.1 Paint layer calibration test Calculating the compensation of the surface wave gain values of different paint layer thicknesses, selecting a reference test block B, transmitting surface waves on the test