CN-121717276-B - Intelligent collaborative replacement system and method for large parts of offshore wind turbine

CN121717276BCN 121717276 BCN121717276 BCN 121717276BCN-121717276-B

Abstract

The invention relates to the technical field of offshore wind power operation and maintenance, and discloses an intelligent collaborative replacement system and method for large parts of an offshore wind turbine. The system comprises a bottom-mounted operation platform, a hoisting control device, a multi-mode anti-collision and gesture stabilizing device and a modularized tool set. The hoisting control device plans and instructs the main crane and the auxiliary crane to act cooperatively through the cooperative controller. The multi-mode anti-collision and gesture stabilizing device fuses real-time data to generate a track correction instruction for restraining swing and preventing collision through a gesture sensing unit, a data processing center and an executing mechanism, and the executing mechanism is an active cable rope array. The modularized tool set comprises a profiling adjustable image leg tool, a multi-point self-adaptive balance hanging beam and a buffering protector component. The replacement method comprises the steps of intelligent platform residence, intelligent collaborative disassembly and reinstallation of the impeller assembly, intelligent replacement operation of the host machine and the like, so that the accurate control of the replacement operation of the large part in the wind disturbance environment is realized, and the operation safety and reliability are improved.

Inventors

DU SIYU
LU CHAOWEI
Xu Shuohui
XING ZHOU
CHEN JIAJI

Assignees

中交路桥华东工程有限公司
中交路桥建设有限公司

Dates

Publication Date: 20260505
Application Date: 20260212

Claims (7)

1. An intelligent collaborative replacement system for large parts of an offshore wind turbine, comprising: the bottom-sitting type operation platform is used for sitting at the bottom of the sea area of the target machine position to provide a stable operation foundation; The hoisting control device is integrated on the bottom-sitting type operation platform and comprises a main crane, an auxiliary crane, a hoisting process controller and a cooperative controller in communication connection with the main crane and the auxiliary crane, wherein the cooperative controller is used for planning and instructing the cooperative action of the main crane and the auxiliary crane in time and space; The multi-mode anti-collision and gesture stabilizing device comprises a gesture sensing unit, a data processing center and a group of executing mechanisms, wherein the gesture sensing unit is arranged on a hoisted part, the data processing center is positioned on a platform ship, and the executing mechanisms are driven by the data processing center; The modularized tooling set at least comprises a profiling adjustable image leg tooling for supporting an impeller by a deck, a multipoint self-adaptive balance hanging beam for hoisting a host machine and a buffer protector component for protecting a contact surface, wherein the profiling adjustable image leg tooling is integrated with a pressure and inclination sensor for monitoring the parking state of the impeller and feeds back monitoring data to the data processing center; The system comprises a data processing center, a hoisting space, a data processing center, a model-based predictive control algorithm, a data processing center, a main crane and an auxiliary crane, wherein the data processing center is used for constructing a nonlinear constraint force field which can be dynamically adjusted and acts on a hoisted part in the hoisting space by dynamically adjusting the winding and unwinding speed and the output tension of each servo winch according to a space track correction instruction, the model-based predictive control algorithm is used for constructing a dynamic model, an environmental wind disturbance model and a safe space boundary model of the hoisted part in the model-based predictive control algorithm, and a servo winch control sequence which can minimize the swinging energy of the part and keep away from a collision boundary in a future period is solved through real-time rolling optimization; The multi-point self-adaptive balance hanging beam in the modularized tool set is characterized in that a lower distribution beam is connected with a host hanging point through a force sensor and a quick connector, and force sensor data is fed back to the data processing center in real time and used for evaluating and dynamically adjusting actual load distribution of each hanging point on line in the moment and the process of lifting the host, so that the posture of the host is ensured to be stable.
2. A method for replacing a large part of an offshore wind turbine based on the system of claim 1, wherein the method is performed by the hoisting control device in linkage with the multi-mode anti-collision and posture stabilization device, and comprises the following steps: step S10, evaluating intelligent residence and operation window of platform Planning accurate sitting position and posture of the sitting operation platform and an anchoring scheme based on geological sweep data and real-time weather marine forecast; Step S20, intelligent collaborative disassembly of impeller assembly Under the whole-course closed-loop control of the multi-mode anti-collision and attitude stabilizing device, the cooperative operation of main crane bearing-auxiliary crane tail-cable wind array damping is executed, the bolt disassembly, the space separation and the controllable aerial turning of the impeller and the main machine are completed, the impeller is positioned on the profiling adjustable image leg tool, and the falling position is confirmed to be stable through the pressure and inclination angle sensor; Step S30, intelligent replacement operation of host machine The method comprises the steps of programmed dismantling and fixing of the old host cables, load balancing hoisting based on the multi-point self-adaptive balance hoisting beam and digital screw-down management of bolts in the replacement process of the new host and the old host; Step S40, intelligent cooperative refitting of impeller assembly And (3) reversely executing the cooperative logic of the step (S20), and completing the lifting, turning over, vertical and butt joint of the impeller and the host under the control of the multi-mode anti-collision and posture stabilizing device.
3. The method of claim 2, wherein the control process of the controllable aerial turning in the steps S20 and S40 is that the data processing center calculates the lifting speed of the main crane, the motion track of the auxiliary crane and the tension matching sequence of each servo winch of the active cable rope array according to the target turning angle and the current component gesture, and the cooperative controller controls the main crane and the auxiliary crane to act according to the sequences in turning, and simultaneously the servo winch array applies the calculated dynamic constraint force to enable the impeller assembly to turn quasi-statically around the axis near the center of mass at a uniform speed so as to reduce dynamic load.
4. The method according to claim 2, wherein the digital tightening management of bolts in step S30 includes assigning an electronic identifier to each bolt, using a hydraulic tool in wireless communication with the data processing center during tightening, and the data processing center sending a target torque or a stretching amount command to the hydraulic tool according to pre-stored tightening parameters and sequences, and recording and checking actual tightening data, operation time and operator information of each bolt to form a traceable electronic assembly record.
5. The method of claim 2, wherein the multi-level wind speed-process association model includes a dynamic rule set of time decay factors, the dynamic rule set sets a starting wind speed threshold for each process, predicts a subsequent available operation time according to a wind speed change trend, provides a safe break point and a state save for a process interrupted by a wind speed overrun, and the cooperative controller dynamically adjusts the operation plan according to an output of the model.
6. The method of claim 2, wherein after the impeller is disassembled in step S20 and before the impeller is reinstalled in step S40, the method further comprises a step of pre-checking health of the part based on data, wherein micro-vibration signals of the impeller in a free damping state are collected by using a sensor on the profiling adjustable image leg tool, and are subjected to spectrum analysis by the data processing center and are compared with a standard health spectrum library for preliminary screening of potential looseness or damage of the blade bolts.
7. The method according to claim 2, wherein before hoisting the host machine in step S30, the method further comprises a virtual test hoisting step of performing dynamic simulation of the whole hoisting process in the data processing center based on a three-dimensional model of the host machine, actual hoist configuration and current environmental wind field data, predicting maximum swing amplitude, key part stress and minimum clearance with the tower, and optimizing control parameters of an actual hoisting path and the multi-mode anti-collision and attitude stabilization device based on simulation results.

Description

Intelligent collaborative replacement system and method for large parts of offshore wind turbine Technical Field The invention relates to the technical field of offshore wind power operation and maintenance, in particular to an intelligent collaborative operation system and method for replacing large parts of an offshore wind turbine, which are particularly suitable for safely and efficiently completing the replacement construction of the large parts of a fan under open sea, deep water and complex sea conditions. Background Offshore wind power is an important component of clean energy, and has rapidly developed worldwide in recent years, and the installed capacity is continuously increasing. With the early operation of the offshore wind farm gradually entering the middle and later stages of operation, the problems of unit component aging, technology lag, reduced matching degree with wind resources and the like are increasingly remarkable, so that the power generation efficiency is reduced, and the operation and maintenance cost is increased. Therefore, large-part replacement and technical upgrading of the old wind turbine generator system become key means for improving economy, safety and power generation efficiency of the wind farm. Currently, the replacement of large components (e.g., impellers, main engines) of offshore wind turbines typically relies on large offshore engineering vessels, such as jack-up or submersible platform vessels. The operation faces many challenges including complex and changeable sea condition, short construction window period, obvious influence of wind, wave and current in the hoisting process, easy initiation of component swing and collision risk, large weight and large size of impellers and a host, high difficulty in hoisting gesture control and accurate butt joint, outstanding safety risk of high-altitude and offshore cross operation, poor synergy and low efficiency due to dependence on manual experience and decentralized control, and lack of whole process data tracing and intelligent decision support. In the prior art, the hoisting operation is mainly dependent on simple matching of a main crane and an auxiliary crane and artificial cable rope adjustment, and a systematic cooperative control and real-time posture correction mechanism is lacked. Especially in key processes such as impeller turning over, host machine butt joint, dynamic load control, anti-collision and accurate positioning still take manual operation as the main process, and the problems of response lag, insufficient precision, large potential safety hazard and the like exist. In addition, the links of bolt tightening, part health detection and the like do not realize digital management and preventive maintenance, and the modern construction requirements of offshore wind power on high efficiency, safety and traceability are difficult to meet. Therefore, development of a large-component replacement system and a construction method for an offshore wind turbine, which integrate intelligent sensing, cooperative control and multi-mode stability, are needed to improve the operation safety, precision and efficiency, and meet the high-standard construction requirements in a complex marine environment. Disclosure of Invention The invention aims to provide a high-efficiency, safe and intelligent system and method for replacing large parts of an offshore wind turbine, which are used for solving the problems of low operation efficiency, high risk, large restriction by environmental factors and the like of the large parts of the offshore wind turbine in the prior art. In order to achieve the above purpose, the present invention provides the following technical solutions: The invention provides an intelligent collaborative replacement system for large parts of an offshore wind turbine, which comprises a bottom-mounted operation platform, a hoisting control device, a multi-mode anti-collision and gesture stabilizing device and a modularized tool set. The multi-mode anti-collision and attitude stabilization device comprises an attitude sensing unit arranged on a hoisted part, a data processing center arranged on the platform and a group of actuating mechanisms driven by the data processing center and used for restraining part swing and preventing collision, wherein the modularized tool group at least comprises a profiling adjustable image leg tool used for supporting an impeller by a deck, a multi-point self-adaptive balance hanging beam used for hoisting by a host machine and a buffer protector component used for protecting a contact surface, and the profiling adjustable image leg tool is integrated with a pressure and inclination sensor used for monitoring the parking state of the impeller and feeds back monitoring data to the data processing center. Besides the technical characteristics, the invention also optimizes and improves the following aspects: as a preferable technical scheme of the invention, the actuating mechani