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工程设计学报  2024, Vol. 31 Issue (3): 280-291    DOI: 10.3785/j.issn.1006-754X.2024.03.188
机械设计理论与方法     
基于超声导波的螺栓轴向应力测量方法
杨宇1(),杨昌群2,赵勃3,4()
1.广东宇成达通信科技有限公司,广东 深圳 518000
2.国家石油天然气管网集团有限公司华南分公司,广东 广州 510000
3.哈尔滨工业大学 超精密光电仪器工程研究所,黑龙江 哈尔滨 150080
4.哈尔滨工业大学 超精密仪器技术及智能化工业和信息化部重点实验室,黑龙江 哈尔滨 150080
Measurement method of bolt axial stress based on ultrasonic guided waves
Yu YANG1(),Changqun YANG2,Bo ZHAO3,4()
1.Guangdong Yuchengda Communication Technology Co. , Ltd. , Shenzhen 518000, China
2.South China Company, China Oil & Gas Pipeline Network Corporation Co. , Ltd. , Guangzhou 510000, China
3.Research Institute of Ultra-precision Optoelectronic Instrument Engineering, Harbin Institute of Technology, Harbin 150080, China
4.Key Lab of Ultra-precision Intelligent Instrumentation of the Ministry of Industry and Information Technology, Harbin Institute of Technology, Harbin 150080, China
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摘要:

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。

关键词: 叶片螺栓轴向应力测量超声导波频散曲线经验小波变换    
Abstract:

Wind turbine blade is the core component of wind turbines. The blade bolt is not only the part that bears complex stress, but also the part that bears the highest load. In order to avoid potential hazard and economic loss caused by bolt breakage, an axial stress measurement system for in-service bolts based on ultrasonic guided waves is designed, which can achieve accurate measurement of axial stress for various types of bolts. Firstly, the group velocity dispersion curve of ultrasonic guided wave was obtained through numerical calculation, and a linear mathematical model of bolt axial stress and ultrasonic guided wave acoustic time was established based on the Hooke's law and acoustic elasticity effect. The effectiveness of ultrasonic guided wave stress measurement by single longitudinal wave transducer was verified by simulation in COMSOL software. Then, in view of the modal aliasing of ultrasonic guided wave echo signals and the interference of noise on the measured results of ultrasonic guided wave acoustic time in actual measurement, the denoising algorithm based on echo compensation was used to denoise the actual measurement signal. The empirical wavelet transform algorithm was used to decompose the modal of ultrasonic guided wave echo signal, and the cross-correlation method was used to obtain the accurate acoustic time of ultrasonic guided wave modal. Finally, the precise measurement of axial stress for 18 types of bolts within the 30%-90% yield strength was completed through experimental tests, and the relative measurement error was less than 2%. The research results are helpful to improve the bolt assembly process and standardize the worker's operation process.

Key words: blade bolt    axial stress measurement    ultrasonic guided wave    dispersion curve    empirical wavelet transform
收稿日期: 2023-07-14 出版日期: 2024-06-27
CLC:  TH 73  
基金资助: 国家重点研发计划资助项目(2022YFB3403904)
通讯作者: 赵勃     E-mail: 271674266@qq.com;hitzhaobo@hit.edu.cn
作者简介: 杨 宇(1991—),男,河南南阳人,工程师,学士,从事电子信息研究,E-mail: 271674266@qq.com
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引用本文:

杨宇,杨昌群,赵勃. 基于超声导波的螺栓轴向应力测量方法[J]. 工程设计学报, 2024, 31(3): 280-291.

Yu YANG,Changqun YANG,Bo ZHAO. Measurement method of bolt axial stress based on ultrasonic guided waves[J]. Chinese Journal of Engineering Design, 2024, 31(3): 280-291.

链接本文:

https://www.zjujournals.com/gcsjxb/CN/10.3785/j.issn.1006-754X.2024.03.188        https://www.zjujournals.com/gcsjxb/CN/Y2024/V31/I3/280

图1  螺栓简化模型
参数数值
弹性模量/GPa210
泊松比0.31
密度/(kg/m3)7 850
表1  合金钢材料性能参数
图2  螺栓的超声导波应力测量仿真模型
图3  超声导波回波波形
图4  不同轴向应力下的超声导波回波仿真结果
图5  超声导波回波信号的降噪处理流程
图6  降噪处理前后超声导波回波信号对比
图7  降噪处理前后超声导波回波信号的时频分析结果对比
图8  小波滤波器的频谱图
图9  超声导波回波仿真信号
图10  基于EWT的超声导波回波仿真信号模态分解结果
图11  基于EWT的超声导波回波仿真信号模态分量的频谱图
图12  基于EMD的超声导波回波仿真信号模态分解结果
图13  基于EMD的超声导波回波仿真信号模态分量的频谱图
图14  部分螺栓的实物图
图15  超声导波回波实验信号(M36×385螺栓)
图16  基于EWT的超声导波回波实验信号的模态分解结果(M36×385螺栓)
图17  基于EWT的超声导波回波实验信号模态分量的频谱图(M36×385螺栓)
拉伸仪力值/kN

横截面积/

mm2

对应轴向应力/MPa

声时差/

ns

081700
100122102
200245205
300367332
350428385
400490445
450551462
500612552
550673581
600734613
650796713
700857762
750918936
800979971
表2  M36×385螺栓的标定实验结果
图18  M36×385螺栓轴向应力与超声导波回波信号声时差的拟合曲线
拉伸仪力值/kN横截面积/mm2轴向应力/MPa相对误差/%
理论值实测值
4008174894890
4505515591.5
4805885900.3
5506736811.2
6237637650.3
表3  M36×385螺栓的轴向应力测量结果
图19  18种型号螺栓轴向应力的相对测量误差
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