Measurement method of bolt axial stress based on ultrasonic guided waves

doi:10.3785/j.issn.1006-754X.2024.03.188

Chinese Journal of Engineering Design

2024, Vol. 31

Issue (3): 280-291 DOI: 10.3785/j.issn.1006-754X.2024.03.188

Theory and Method of Mechanical Design

Measurement method of bolt axial stress based on ultrasonic guided waves

Yu YANG¹(

),Changqun YANG²,Bo ZHAO^3,⁴(

)

^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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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

Received: 14 July 2023 Published: 27 June 2024

CLC:

TH 73

Corresponding Authors: Bo ZHAO E-mail: 271674266@qq.com;hitzhaobo@hit.edu.cn

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Cite this article:

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

URL:

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

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。

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

Fig.1 Simplified bolt model

Table 1 Material performance parameters of alloy steel

Fig.2 Ultrasonic guided wave stress measurement simulation model for bolt

Fig.3 Ultrasonic guided wave echo waveform

Fig.4 Simulation results of ultrasonic guided wave echo under different axial stress

Fig.5 Noise reduction process of ultrasonic guided wave echo signal

Fig.6 Comparison of ultrasonic guided wave echo signals before and after noise reduction processing

Fig.7 Comparison of time-frequency analysis result of ultrasonic guided wave echo signals before and after noise reduction processing

Fig.8 Spectrum diagram of wavelet filter

Fig.9 Ultrasonic guided wave echo simulation signal

Fig.10 Modal decomposition results of ultrasonic guided wave echo simulation signal based on EWT

Fig.11 Spectrum diagram of modal component of ultrasonic guided wave echo simulation signal based on EWT

Fig.12 Modal decomposition results of ultrasonic guided wave echo simulation signal based on EMD

Fig.13 Spectrum diagram of modal component of ultrasonic guided wave echo simulation signal based on EMD

Fig.14 Physical drawing of some bolts

Fig.15 Ultrasonic guided wave echo experimental signal (M36×385 bolt)

Fig.16 Modal decomposition results of ultrasonic guided wave echo experimental signal based on EWT (M36×385 bolt)

Fig.17 Spectrum diagram of modal component of ultrasonic guided wave echo experimental signal based on EWT (M36×385 bolt)

Table 2 Calibration experiment results for M36×385 bolt

Fig.18 Fitting curve between axial stress of M36×385 bolt and acoustic time difference of ultrasonic guided wave echo signal

Table 3 Measurement results of axial stress of M36×385 bolt

Fig.19 Relative measurement error of axial stress of 18 types of bolts


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