Videometric research on deformation measurement of large-scale wind turbine blades

Utilization of wind energy is a promising way to generate power,and wind turbine blades play a key role in collecting the wind energy effectively.This paper attempts to measure the deformation parameter of wind turbine blades in mechanics experiments using a videometric method. In view that the blades experience small buckling deformation and large integral deformation simultaneously, we proposed a parallel network measurement(PNM) method including the key techniques such as camera network construction,camera calibration,distortion correction,the semi-automatic high-precision extraction of targets,coordinate systems unification,and bundle adjustment,etc. The relatively convenient construction method of the measuring system can provide an abundant measuring content,a wide measuring range and post processing.The experimental results show that the accuracy of the integral deformation measurement is higher than 0.5 mm and that of the buckling deformation measurement higher than 0.1mm.

Measurement Uncertainty of Blade Surface by Coordinates Measuring Machines in Rotation and Parallel Sampling Modes

This paper aims to investigate the measurement uncertainty of blade surface by coordinates measuring machines (CMMs) in different sampling modes.Two different sampling methods for the blade surface, which are the parallel mode and the rotation mode, are studied to examine their measurement uncertainty.The fundamental principles and operational processes of the two modes are presented and discussed.The measurements were performed on a twisted-face blade, and data processing was also conducted to fit the cross-section profile both of the base surface and back surface separately.Then the measurement uncertainties of two sampling methods were evaluated on different parts of the blade surface in terms of the surface profile’s curvature and twist rate.It is found that the measurement of blade surface by CMMs shows much uncertainty for both of the sampling modes because of the complexity of the blade surface.The back surface’s measurement uncertainty is larger than that of the base surface.The measurement uncertainty of cross-section profiles on the top blade surface is larger than that of the bottom blade surface.In addition, the difference between the measurement uncertainties of two sampling methods is small, especially for the base blade surface.The research means that both sampling methods can be a practical application choice for the measurement of blade surface by CMMs.

Study of the helicopter blade running elevation measurement system

Helicopter blade running elevation measurement is an important measure target in helicopter blade dynamic balance experimentation. The elevation influences the helicopter's security and other performance capabilities. In testing, however, it has been difficult to measure the elevation when the rotor reaches high speeds. To get a simple, fast and highly accurate measurement system, photo electricity technology was applied to measuring the blade running elevation. Discussed is the measurement principle of blade running elevation, the design of the measurement system and analysis of the measurement precision.

A real-time measuring technology for studying distortion of hydraulic turbine blade castings during heat treatment process

During heat treatment process, the distortion behavior inevitably appears in hydraulic turbine blade castings. In this research, a technology was developed for real-time measurement of the distortion in hydraulic turbine blade castings at the still air cooling and forced air cooling stages during heat treatment process. The method was used to measure the distortion behavior at the cooling stages in both normalizing and tempering processes. At the normalization, the distortion at the blade corner near outlet side undergoes four stages with alternating bending along positive and negative directions. At the tempering stage, the distortion could be divided into two steps. The temperature difference between the two surfaces of blade casting was employed to analyze the distortion mechanism. The measured results could be applied to guide the production, and the machining allowance could be reduced by controlling the distortion behavior.

Technique for Measuring the Sharpness of Staple Fiber Cutter Blades

Quantitative measurement of the cutter blade sharpness is yet a difficult problem, since so far there has been no appropriate testing method. In this paper, a technique is introduced for measuring the cutter blade sharpness at different testing conditions. The sharpness of cutter blades are measured by detecting the force to cut off the fiber with a material strength testing machine, and the results indicated that the technique could be used to measure the cutter blade sharpness satisfactorily. The fiber tension and downward speed of cutter blades are recommended to be 4.9 cN and 50 mm/min respectively for cutting 0.22 mm PET fiber.

压力敏感涂料测量技术在掠型叶栅表面测压中的应用

为了获得某掠型叶片吸力面压力分布,对一稠度为1.53,掠角为10.7°的掠叶栅进行了光路布局以及压力敏感涂料(PSP)压力测量,利用图像处理和三维重构算法得到了可读性高、便于数据提取的三维叶片吸力面压力分布,并和测压孔测量结果进行了对比。结果表明:利用自主发展的光路布局方法,有效解决了叶片表面光照辐照度不均匀、拍摄视角受限的问题;得到了高信噪比的原始压敏图像以及宽范围多工况的掠叶栅吸力面全域压力分布。与测压孔测量相比,PSP测量误差在5%以内,并且PSP测量结果还捕捉到了峰值等熵马赫数位置沿弦向的迁移以及叶片尾缘的气流分离现象。对不同攻角和来流马赫数下的掠型叶片吸力面压力分布进行分析:掠型叶片在零攻角和正攻角下存在明显的径向压力梯度,促使后掠型叶片气流向前掠迁移,增加了前掠下流低能流体的能量,使得前掠更有利于延迟角区分离,后掠则更容易发生角区分离;掠型叶片在低来流马赫数下展向压力对称性良好,掠设计的影响不显著,高来流马赫数则放大了前后掠对角区分离控制效果的不同。相比传统测压孔有限的压力分辨率,PSP测量可为掠型叶片设计和流动机理分析提供丰富可靠的压力实验数据。

矿用通风机叶片线激光测量数据优化方法研究

测量模型的提取是矿用通风机叶片几何变形检测的关键,为了提高叶片测量模型的精度,提出一种基于最小二乘准则的线激光测量数据优化方法。首先,利用卡尔曼滤波算法实时处理线激光传感器原始测量数据,提高坐标测量精度,为后续模型构建提供精准数据;然后,采用三次多项式法、三次B样条法、高阶贝塞尔法分别拟合求解三个测量模型,并基于最小二乘准则评价各模型的显著性水平,从而优选出适合通风机叶片几何特征的测量模型;最后,进行了实验研究。结果表明,采用三次B样条函数构建叶片测量模型可以获得最佳的拟合效果,其显著性评价因子最小(小于0.05),本方法通过数据优化有效提高了叶片测量模型的精度,为后续通风机叶片几何评价提供一种有效的技术解决方案。

基于LM方法的麻花钻刃带宽度测量研究

提出一种基于二值化的麻花钻刃带宽度检测方法。首先对目标边缘进行锐化,然后用巴特沃斯高通滤波提取边缘信息;其次通过改进的大津二值化算法对疑似边缘点进行阈值分割,获取边缘点坐标;再次使用列文伯格-马夸尔特(LM)方法对边缘附近的点进行拟合,得到刃带宽度曲线并求其拐点,求取麻花钻刃带宽度的数据。最后进行对比实验,用LM方法对未处理的M35直径2.5 cm的刃带图像进行处理得到刃带宽度1.467 mm,测量误差0.467 mm。改进后的测量结果为0.853 mm,测量误差为0.147 mm。

基于声表面波传感器的转子叶片应变无线测量研究

声表面波传感器可以实现无线无源工作,该特性使其在高速旋转部件测试中有重要的应用前景。利用硅酸镓镧压电晶体设计并制备了谐振型SAW传感器,研究了其应变敏感特性,并成功应用于转子叶片应变的无线测试试验。结果表明,所制备的SAW传感器的谐振频率为217.794 MHz,品质因子达到5807,应变灵敏度为-317 Hz/με。在3000~15000 r/min转速下,无线测试了转子叶片应变,测试结果与电阻应变计测量结果及有限元仿真计算结果基本一致。研究结果可以为SAW传感器在高速旋转设备的无线测试工程应用提供参考。

基于叶尖定时数据奇异值分解的振动事件识别

叶尖定时数据自动化测量及处理是旋转机械在线监测和智能运维的必要环节,快速、准确判断叶片振动类型,实现振动事件识别是数据自动化测量及处理的关键。提出了一种基于加窗叶尖定时数据奇异值分解的振动事件识别方法,仅需单只传感器准确识别叶片同步、异步振动事件。基于不同叶片叶尖定时数据时延特性,加窗构造了“类重构吸引子矩阵”,根据矩阵奇异值特征实现振动事件识别。开展了方法仿真及实验验证,仿真与实验结果一致性良好,压气机试验件测试数据表明,叶片发生振动事件时第1奇异值增大为7倍以上,其中发生异步振动事件时第2奇异值增大为14倍以上,提出方法能够准确识别叶片同步、异步振动事件。

基于超声导波的螺栓轴向应力测量方法

风电叶片是风力发电机的核心部件,叶片螺栓不仅是承受复杂应力的零件,也是承受最高负载的零件。为避免螺栓断裂造成危险隐患和经济损失,设计了一种基于超声导波的在役螺栓轴向应力测量系统,可实现对多种型号螺栓轴向应力的精确测量。首先,通过数值计算得到超声导波群速度频散曲线,基于胡克定律和声弹性效应建立了螺栓轴向应力与超声导波声时的线性数学模型,并在COMSOL软件中通过仿真验证了单纵波换能器实现超声导波应力测量的有效性。然后,针对超声导波回波信号模态混叠以及实际测量中噪声对超声导波声时测量结果的干扰,利用基于回波补偿的降噪算法实现了对实际测量信号的降噪处理,并采用经验小波变换算法对超声导波回波信号进行了模态分解,利用互相关法得到超声导波模态的精确声时。最后,通过实验测试完成了18种型号的螺栓在30%~90%屈服强度内的轴向应力的精确测量,相对测量误差小于2%。研究结果有助于改进螺栓装配工艺以及规范工人操作流程。

基于光纤复合测量技术的涡轮叶片气膜孔检测

为了解决航空发动机涡轮叶片气膜孔几何特征参数有效检测手段缺乏、测量结果一致性差的问题,设计并搭建了基于光纤复合测量技术的涡轮叶片气膜孔检测系统,提出了利用该系统对涡轮叶片气膜孔进行测量的方法,通过试验进行了方法验证。搭建的系统为多传感器测量系统,具备叶片接触与非接触测量、空间姿态定位及3D投影能力,实现了涡轮叶片全范围气模孔的测量。在试验中,选取高压涡轮叶片作为被测物体,应用该测量系统对叶片上的气膜孔进行了测量,计算得到了气膜孔直径、轴线角度及位置度的准确信息。结果表明:通过测量不确定度的分析评定可知,该系统对气膜孔直径、位置度的测量不确定度均小于0.01 mm,完全满足设计公差对测量仪器的精度要求,可以用于涡轮叶片气膜孔工程化测量。

复合材料桨叶静力矩测量影响因素研究

为了解决复合材料桨叶的静力矩测量结果差异较大、难以完成准确合格性判定等问题,采用基于天平基本理论的控制变量法对多组桨叶的静力矩展开研究。通过分析造成实验数据差异的原因,结合测量设备本身的精度,发现了对测量影响较大的关键因素,并进行了定量分析计算。通过对比实验,证明了对大轴线力矩测量影响最大的是定位面与测量刀口之间的距离以及其平面加工精度;对小轴线力矩测量影响最大的是对桨叶特定截面的角度测量精度。本研究为后续螺旋桨设计、生产、维修提供了工艺优化的理论和数据基础,对后期新型桨叶的研发具有重要意义。

压力敏感涂料技术在涡轮叶片和平面叶栅中的应用进展

由于传统压力测量技术难以实现涡轮叶片表面压力分布的连续监测,因此,开发新型测量技术变得尤为迫切。压力敏感涂料作为一种非接触式的光学表面压力测量技术,其以低成本、高空间分辨率、全域测量能力以及对气动流场影响小的显著优点,已经成为压力测量领域的一个研究热点。本文从实验装置设计、测量结果分析等多个维度,详细介绍了压力敏感涂料技术在涡轮叶片和平面叶栅压力测量中的应用现状,深入讨论了实验设备参数选择、测量布局优化等关键问题。同时,结合国内外的研究与应用案例,探讨了压力敏感涂料技术在叶片表面压力测量领域所遇到的挑战和发展前景。

基于叶尖定时技术的非接触式叶片叶尖扭转角测试及应用

为了验证风扇转子叶片反扭设计的准确性及获取不同气动状态、不同转速条件下叶片扭转变形情况,建立叶片扭转应用理论模型,开发了基于叶尖定时技术的非接触式叶片叶尖扭转角测试技术,在发动机风扇转子叶片上开展了旋转状态下的叶片叶尖扭转角测试和仿真计算。结果表明:叶片叶尖扭转角变形理论计算值为1.5°,实测值为1.4°;采用统计分析方法计算稳态转速风扇转子叶片所有叶片叶尖扭转角最大标准偏差为0.1°,是因加工误差、装配误差、气流扰动和振动因素导致的;单个叶片叶尖扭转角最大标准偏差为0.01°,是因气流扰动和振动因素影响所导致的。该项测试技术成功地验证了叶型反扭设计,稳态转速风扇转子单个叶片叶尖扭转角小于所有叶片叶尖扭转角的离散度。

涡轮叶片辐射测温中反射辐射误差校正方法综述(特邀)

涡轮叶片表面温度的精确测量是保障航空发动机安全稳定运行的关键,能够防止叶片过热和损坏,延长整个发动机的工作寿命,保证飞机的安全飞行。非接触式辐射测温法测温范围广,精度高,且不会破坏待测对象的原温度场分布,在涡轮叶片温度测量中具有重要应用价值。然而,在涡轮叶片运行的高温环境下使用辐射测温法会受到多方面因素的干扰产生误差,其中反射辐射造成的误差占比最大,因此校正该类误差对进一步提升涡轮叶片测温精度至关重要。总结了基于建立反射辐射模型的校正方法、基于发射率的反射辐射误差校正算法以及基于双光谱区域温度测量(DSAP)的误差校正法等校正反射辐射误差的方法,并在此基础上对反射辐射校正方法的未来发展进行了展望。

矩阵模式下高速检测汽轮机叶片

针对汽轮机叶片的结构特点,设计了一种快速、精确的装夹装置,并采用矩阵测量方案,在三坐标测量机检测汽轮机叶片复杂曲面时不仅保证了检测的稳定和精度,也实现了高速、高效检测。

Alternative flexible correction forming of a blade: multipoint correction with surface measurement and deformation simulation

Distortion during the forging or machining processes of a blade causes problems in subsequent manufacturing. This paper proposes an alternative multipoint correction method integrated with blade measurement, determination of correcting parameters, and adjustment of the correcting die. An iterative algorithm for determining the correcting parameters is proposed. Measuring equipment combining a laser displacement sensor with multipoint flexible support is manufactured to measure the blade shape. Multipoint correcting equipment with an adaptive lower die and rapid adjustment is manufactured, and software is developed for data analysis and equipment control. The correction experiment for a rough-machined steam-turbine blade indicates that the correcting parameters can be determined after one modification based on numerical simulation, and that a rough blade that meets the allowance for finish machining can be obtained using the determined correction parameters.

Experimental Investigation of Unsteady Pressure on an Axial Compressor Rotor Blade Surface

The inherent unsteady pressure fluctuations on the rotating blade suction surface of an axial compressor were experimentally measured by directly mounting five high response miniature pressure transducers into the rotor blade along a streamline at 50% span respectively. The results show that the unsteady pressure fluctuations of rotor blade surface could be measured successfully by this means. The relations about the period, altitude of unsteady pressure with rotating speed, the discipline of pressure fluctuation along the streamwise direction were obtained.

风电机组叶片结冰的光纤感知及厚度分布估计

分析光纤感知叶片结冰厚度的检测原理并设计四通道双窗口专用结冰探测器,采用模拟计算并分析不同攻角和水滴粒径下叶片水滴收集率分布,借助风电机组所在空气流场构建风电机组机舱顶部结冰探测器与叶片间运行环境结冰信息的内在关联,进而实现叶片表面结冰厚度检测及分布估计并在风场风电机组进行结冰实测验证,结果表明叶片表面结冰状态呈现前缘结冰最厚且沿叶尖方向逐渐增加的分布特征,探测器检测值与实测值偏差在8%内,可满足风电机组叶片防除冰的工程应用需求。