Main shaft assembly of a wind turbine

Abstract

A main shaft assembly of a wind turbine is provided, as well as a method for manufacturing the main shaft assembly of the wind turbine. Accordingly, the main shaft assembly includes a structural body / shaft body defining a cavity therein. The shaft body is configured to transmit a load of the wind turbine developed in response to wind. An inner body is located within the cavity. The inner body is non-load bearing with respect to the load. At least one sensor is coupled to the inner body and positioned within the cavity for detecting a deflection of the shaft body in response to the load.

Description

Technical Field

[0001] This disclosure generally relates to wind turbines, and more specifically to wind turbine spindle assemblies with embedded sensors. Background Technology

[0002] Wind power is considered one of the cleanest and most environmentally friendly energy sources available today, and wind turbines are receiving increasing attention in this area. A modern wind turbine typically includes a tower, generator, gearbox, nacelle, and one or more rotor blades. The nacelle contains the rotor assembly, which is connected to the gearbox and generator. The rotor assembly and gearbox are mounted on a base support frame located within the nacelle. One or more rotor blades use known airfoil principles to capture the kinetic energy of the wind. The rotor blades transfer this kinetic energy as rotational energy to rotate the rotor shaft that connects the rotor blades to the gearbox (or, if no gearbox is used, directly to the generator). The generator then converts the mechanical energy into electrical energy, which can be transferred to a converter and / or transformer housed within the tower and subsequently deployed to the public power grid. Modern wind power systems typically take the form of wind farms with multiple such wind turbine generators, capable of operating to supply power to a transmission system that provides power to the electrical grid.

[0003] Loads generated by a wind turbine in response to wind are typically supported by various structural components of the turbine. For example, at least a portion of the load generated by the rotor can be transmitted to the gearbox via the rotor shaft (also known as the main shaft). These loads can cause bending of the shaft. Known control systems utilize bending moment measurements to manage the wind turbine's response to wind.

[0004] Typically, measuring shaft deflection involves mounting sensors to an additional component of a wind turbine and guiding the sensors toward the shaft to be measured. For example, a known approach involves mounting multiple sensors to the main bearing housing to detect the deflection of the main shaft flange relative to the housing. However, since the main bearing typically supports the shaft, loads sufficient to generate bending moments can also cause movement of the main bearing housing. This movement can reduce the fidelity of the deflection measurement. Furthermore, the rotor shaft is typically in motion. Therefore, using known approaches, the sensors are generally pointed toward the moving surface, which can further reduce the accuracy of the system. Additionally, the components supporting the sensors and the components to be measured can be made of different materials and can therefore exhibit different degrees of movement in response to loads. Therefore, it is desirable to utilize a structural assembly that allows for more accurate detection of the main shaft displacement compared to what is currently available using known systems.

[0005] Therefore, the art is constantly seeking new and improved systems and methods to solve the aforementioned problems. In this regard, this disclosure relates to an improved main shaft assembly for wind turbines and a method for manufacturing the same. Summary of the Invention

[0006] Aspects and advantages of the invention will be set forth in part in the description which follows, or may be apparent from the description, or may be learned by practice of the invention.

[0007] In one aspect, this disclosure relates to a shaft assembly for a wind turbine. The shaft assembly may include a shaft body defining a cavity therein and a load path for transmitting loads generated by the wind turbine in response to wind. The shaft assembly may also include an inner body disposed within the cavity and coupled to the shaft body. The inner body may be non-load-bearing. The shaft body and the inner body may be concentric and have a synchronous rotational rate about an axis. Furthermore, the shaft assembly may include at least one sensor coupled to the inner body and positioned within the cavity for detecting deflection of the shaft body in response to a load.

[0008] In one embodiment, attaching the sensors to the internal body defines a physical distance in the radial direction between the sensors and adjacent walls of the cavity.

[0009] In an additional embodiment, the sensors may include a proximity sensor. The proximity sensor may be configured to indicate radial deflection of the shaft body.

[0010] In another embodiment, the sensors may include a sensor array disposed at a first axial location on the axis. The sensor array may be externally connected to an internal body. Each sensor in the sensor array may define a circumferential spacing with at least one adjacent sensor in the sensor array.

[0011] In one embodiment, the sensors may be coupled to the internal body at a first axial location along the axis. The internal body may be coupled to the shaft body at a second axial location within the cavity. The internal body may form a cantilever that extends at least axially between the second axial location and the sensors.

[0012] In an additional embodiment, the shaft body and the inner body may be a single body with no connection between them.

[0013] In another embodiment, the inner body can be attached to the cavity after formation. The shaft body can be a first material. The inner body can be a second material different from the first material.

[0014] In another aspect, this disclosure relates to a component assembly of a wind turbine. The assembly may include a wind turbine component. The wind turbine component may include an outer body defining a cavity therein. The outer body may define a load path for transmitting loads of the wind turbine therethrough. The wind turbine component may also include an inner body disposed within the cavity of the outer body portion. The inner body may be non-load-bearing with respect to the load. Furthermore, the component assembly may include a plurality of sensors coupled to the inner body and positioned within the cavity for detecting deflection of the outer body in response to the load.

[0015] In one embodiment, the outer body and the inner body may be able to rotate during operation of the wind turbine. The outer body and the inner body may be concentric and may have a synchronized rotational rate about an axis.

[0016] In an additional embodiment, attaching the sensors to the internal body can define the physical distance between the sensors and adjacent walls of the cavity.

[0017] In yet another embodiment, the sensors may be a sensor array disposed at a first axial location along the axis of the outer body portion. Each sensor in the sensor array may define an angular spacing with respect to the axis from at least one adjacent sensor in the sensor array.

[0018] In one embodiment, the sensors may be coupled to the inner body at a first axial location along the axis of the outer body, and the inner body may be coupled to the outer body at a second axial location within the cavity. The inner body may form a cantilever that extends at least axially between the sensors at the second axial location.

[0019] In an additional embodiment, the component assembly may further include at least one second sensor, which is coupled to the internal body at a third axial location. The second axial location may be located between the first axial location and the third axial location.

[0020] In another embodiment, the wind turbine components may be rotor blades, high-speed shaft, low-speed shaft, rotatable hub, rotor support spindle, and / or tower of a wind turbine.

[0021] In another aspect, this disclosure relates to a method for manufacturing a shaft assembly for a wind turbine. The method may include forming a shaft body defining a cavity extending in a radial direction. The shaft body may also define a load path for transmitting loads generated by the wind turbine in response to wind. The method may further include arranging an inner body within the cavity in axial and rotational alignment with the axis of the shaft body. The inner body may be non-load-bearing with respect to the load. Furthermore, the method may include coupling multiple sensors to the inner body within the cavity. The multiple sensors may be configured to detect radial deflection of the shaft body in response to a load. The method may also include any of the operations and / or features described herein.

[0022] In one embodiment, the sensors(s) may be coupled to the internal body at a first axial location along the axis. The method may further include coupling the internal body to the shaft body at a second axial location within the cavity to form a cantilever extending at least axially between the second axial location and the sensors(s). The sensors(s) may have a first sensitivity at the axial length of the first cantilever and a second sensitivity corresponding to the axial length of the second cantilever. The second cantilever axial length may be greater than the first cantilever axial length, and the second sensitivity may be greater than the first sensitivity.

[0023] Technical Solution 1. A shaft assembly for a wind turbine, the shaft assembly comprising:

[0024] A shaft body, the shaft body defining a cavity therein and a load path for transmitting loads generated by the wind turbine in response to wind;

[0025] An inner body, disposed within the cavity and connected to the shaft body, the inner body being non-load-bearing with respect to the load, wherein the shaft body and the inner body are concentric and have a synchronous rotational rate about an axis; and

[0026] At least one sensor, coupled to the internal body and positioned within the cavity, is used to detect the deflection of the shaft body in response to the load.

[0027] Technical Solution 2. The shaft assembly according to Technical Solution 1, characterized in that the connection between the at least one sensor and the inner body defines a physical distance in the radial direction between the at least one sensor and the adjacent wall of the cavity.

[0028] Technical Solution 3. The shaft assembly according to Technical Solution 2, characterized in that the at least one sensor includes a proximity sensor configured to indicate radial deflection of the shaft body.

[0029] Technical Solution 4. The shaft assembly according to Technical Solution 1, characterized in that the at least one sensor includes a sensor array disposed at a first axial location on the axis, the sensor array being external to the internal body, and each sensor of the sensor array defining a circumferential spacing with at least one adjacent sensor of the sensor array.

[0030] Technical Solution 5. The shaft assembly according to Technical Solution 1, characterized in that the at least one sensor is connected to the inner body at a first axial location along the axis, and the inner body is connected to the shaft body at a second axial location within the cavity, the inner body forming a cantilever, the cantilever extending at least axially between the second axial location and the at least one sensor.

[0031] Technical Solution 6. The shaft assembly according to Technical Solution 1, characterized in that the shaft body and the inner body are single bodies without any connecting part between them.

[0032] Technical Solution 7. The shaft assembly according to Technical Solution 1, characterized in that the inner body is connected to the cavity after being formed, the shaft body includes a first material, and the inner body includes a second material different from the first material.

[0033] Technical Solution 8. A component assembly for a wind turbine, the assembly comprising:

[0034] Wind turbine components, including:

[0035] An external body defining a cavity therein, the external body defining a load path for transmitting the load of the wind turbine therethrough, and

[0036] An inner body disposed within the cavity of the outer body, the inner body being non-load-bearing with respect to the load; and

[0037] At least one sensor, coupled to the internal body and positioned within the cavity, is used to detect the deflection of the external body in response to the load.

[0038] Technical Solution 9. The component assembly according to Technical Solution 8, characterized in that the outer body and the inner body are rotatable during the operation of the wind turbine, and wherein the outer body and the inner body are concentric and have a synchronous rotational rate about an axis.

[0039] Technical Solution 10. The component assembly according to Technical Solution 8, characterized in that the connection between the at least one sensor and the internal body defines a physical distance between the at least one sensor and an adjacent wall of the cavity.

[0040] Technical Solution 11. The component assembly according to Technical Solution 8, characterized in that the at least one sensor comprises a sensor array disposed at a first axial location along the axis of the outer body, each sensor of the sensor array defining an angular spacing with respect to the axis of at least one adjacent sensor of the sensor array.

[0041] Technical Solution 12. The component assembly according to Technical Solution 8, characterized in that the at least one sensor is connected to the inner body at a first axial location along the axis of the outer body, and the inner body is connected to the outer body at a second axial location within the cavity, the inner body forming a cantilever, the cantilever extending at least axially between the at least one sensor at the second axial location.

[0042] Technical Solution 13. The component assembly according to Technical Solution 12, characterized in that the at least one sensor is at least one first sensor, and the assembly further includes:

[0043] At least one second sensor is attached to the internal body at a third axial location, the second axial location being located between the first axial location and the third axial location.

[0044] Technical Solution 14. The component assembly according to Technical Solution 8, characterized in that the wind turbine component is one of the rotor blades, high-speed shaft, low-speed shaft, rotatable hub, rotor support spindle, or tower of the wind turbine.

[0045] Technical Solution 15. A method for manufacturing a shaft assembly for a wind turbine, the method comprising:

[0046] A shaft body is formed, the shaft body defining a cavity extending in a radial direction and a load path for transmitting loads generated by the wind turbine in response to wind;

[0047] The internal body is configured within the cavity to be axially and rotationally aligned with the axis of the shaft body, wherein the internal body is non-load-bearing with respect to the load; and

[0048] At least one sensor is attached to the internal body within the cavity, the at least one sensor being configured to detect radial deflection of the shaft body in response to the load.

[0049] Technical Solution 16. The method according to Technical Solution 15, characterized in that the at least one sensor is connected to the internal body at a first axial location along the axis, the method further comprising:

[0050] The internal body is connected to the shaft body at a second axial location within the cavity to form a cantilever extending at least axially between the second axial location and the at least one sensor, wherein the at least one sensor has a first sensitivity at a first cantilever axial length and a second sensitivity corresponding to a second cantilever axial length, the second cantilever axial length being greater than the first cantilever axial length, and the second sensitivity being greater than the first sensitivity.

[0051] Technical Solution 17. The method according to Technical Solution 15, characterized in that, setting the inner body in the cavity includes at least one of the following: casting or additive manufacturing the inner body as a single body with respect to the shaft body, wherein there is no connecting part between the inner body and the shaft body.

[0052] Technical Solution 18. The method according to Technical Solution 15, characterized in that the shaft body comprises a first material, and wherein disposing the inner body within the cavity further comprises:

[0053] The internal body is formed of a second material different from the first material;

[0054] Insert the internal body into the cavity; and

[0055] The inner body is connected to the inner surface of the shaft body.

[0056] Technical Solution 19. The method according to Technical Solution 15, characterized in that connecting at least one sensor to the internal body includes:

[0057] The internal body is externally connected to a sensor array at an axial position, wherein the sensor array is equidistantly distributed around the circumference of the internal body.

[0058] Technical Solution 20. The method according to Technical Solution 15, characterized in that the method further includes:

[0059] An opening in the shaft body defined by the cavity is connected to a sealing component.

[0060] These and other features, aspects, and advantages of the present invention will become more readily understood with reference to the following description and the appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. Attached Figure Description

[0061] The complete and practicable disclosure of the invention, including its best mode for those skilled in the art, is set forth in the description with reference to the accompanying drawings, in which:

[0062] Figure 1 A perspective view showing one embodiment of a wind turbine according to the present disclosure;

[0063] Figure 2 A perspective interior view of one embodiment of the nacelle of a wind turbine according to the present disclosure is shown;

[0064] Figure 3 A schematic diagram of one embodiment of a wind turbine according to the present disclosure is shown;

[0065] Figure 4 A cross-sectional view is shown of one embodiment of a component assembly of a wind turbine according to the present disclosure;

[0066] Figure 5 An overlay cross-sectional side view of one embodiment of a component assembly of a wind turbine according to the present disclosure is shown.

[0067] Figure 6 A cross-sectional side view of one embodiment of a component assembly of a wind turbine according to the present disclosure is shown;

[0068] Figure 7 A cross-sectional view is shown of one embodiment of a component assembly of a wind turbine according to the present disclosure;

[0069] Figure 8 A cross-sectional view is shown of one embodiment of a component assembly of a wind turbine according to the present disclosure;

[0070] Figure 9 A schematic diagram showing one embodiment of a controller for use with a wind turbine according to the present disclosure; and

[0071] Figure 10 A flowchart illustrating one embodiment of a method for manufacturing a shaft assembly for a wind turbine according to the present disclosure is shown.

[0072] The repeated use of reference numerals in this specification and the accompanying drawings is intended to indicate the same or similar features or elements of the invention. Detailed Implementation

[0073] Reference will now be made in detail to embodiments of the invention, one or more of which are illustrated in the accompanying drawings. Each example is provided by way of illustration and not by way of limitation. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made in the invention without departing from the scope or spirit of the invention. For example, a feature shown or described as part of one embodiment may be used with another embodiment to produce yet another embodiment. Therefore, it is intended that the invention cover such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0074] As used in this article, the terms "first," "second," and "third" are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of an independent component.

[0075] The terms “connection,” “fixation,” “attachment to,” etc., refer to direct connection, fixation, or attachment, as well as indirect connection, fixation, or attachment of both through one or more intermediate components or features, unless otherwise specified herein.

[0076] As used herein, approximate language is applied to modify any quantitative expression that can be permissibly changed without causing a change in the essential function it relates to. Therefore, values ​​modified by one or more terms (such as "approximately," "approximately," and "roughly") are not limited to the specified precise values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value, or the precision of the method or machine used to construct or manufacture the component and / or system. For example, approximate language may refer to a margin of 10%.

[0077] Throughout this specification and claims, scope limitations are combined and / or interchanged, and such scopes are identified and include all subscopes contained therein, unless the context or language otherwise indicates. For example, all scopes disclosed herein include endpoints, and endpoints can be combined independently of each other.

[0078] Generally, this disclosure relates to components of a wind turbine (such as shaft assemblies) and methods of manufacturing thereof. Specifically, this disclosure includes wind turbine components such as rotor shafts, wind turbine blades, rotatable hubs, rotor support spindles, or towers. Wind turbine components may be hollow or otherwise define cavities. As structural elements of a wind turbine, wind turbine components may also define load paths for transmitting loads generated by the wind turbine in response to wind. For example, when constructed as wind turbine blades, the component may transmit loads generated by a portion of the blades to the rotating hub. Similarly, the component may transmit loads generated by the blades from the rotor to the gearbox and / or generator. Alternatively, the component may be a wind turbine tower, and thus may transmit loads to the foundation.

[0079] In addition to the external body, the component assembly may also include an internal body positioned within the cavity. The internal body may be non-load-bearing with respect to loads supported by the external body. For example, when constructed as a rotor shaft, the external body may transmit loads, but the loads may not be experienced by the internal body. Therefore, the internal body may not respond to loads. This could mean that the internal body does not bend or otherwise deflect in response to loads, even if the external body may bend / deflect in response to loads.

[0080] At least one sensor may be mounted on the inner body and positioned within a cavity of the outer body. Multiple sensors may be positioned to detect deflection of the outer body in response to a load. For example, since the inner body does not deflect in response to a load, the radial distance between the inner and outer bodies may vary as the outer body deflects in response to a load. This distance may indicate the degree of deflection / bending of the outer body and can therefore be used by a controller to control a wind turbine in response to wind.

[0081] Now refer to the attached diagram, Figure 1 A perspective view of one embodiment of a wind turbine 100 according to the present disclosure is shown. As shown, the wind turbine 100 generally includes a tower 102 extending from a support surface 104, a nacelle 106 mounted on the tower 102, and a rotor 108 coupled to the nacelle 106. The rotor 108 includes a rotatable hub 110 and at least one rotor blade 112 coupled to and extending outward from the hub 110. For example, in the illustrated embodiment, the rotor 108 includes three rotor blades 112. However, in alternative embodiments, the rotor 108 may include more or fewer than three rotor blades 112. Each rotor blade 112 may be spaced about the hub 110 to facilitate rotation of the rotor 108 such that kinetic energy can be converted from wind into usable mechanical energy, and subsequently into electrical energy. For example, the hub 110 may be rotatably coupled to an electrical system 150 located within the nacelle 106. Figure 2 ) generator 118 ( Figure 2 ), to allow the generation of electrical energy.

[0082] The wind turbine 100 may also include a controller 200 centered within the nacelle 106. However, in other embodiments, the controller 200 may be located within any other component of the wind turbine 100 or at a location outside the wind turbine. Furthermore, the controller 200 may be communicatively coupled to any number of components of the wind turbine 100 to control those components. In this regard, the controller 200 may include a computer or other suitable processing unit. Thus, in several embodiments, the controller 200 may include suitable computer-readable instructions that, when implemented, configure the controller 200 to perform various functions, such as receiving, sending, and / or executing wind turbine control signals.

[0083] Now refer to Figure 2 and Figure 3 A simplified interior view of one embodiment of cabin 106 is shown. Figure 1 The diagram shows an embodiment of the power transmission system 146 of the wind turbine 100. As shown, a generator 118 may be coupled to a rotor 108 to generate electrical power from rotational energy generated by the rotor 108. For example, as shown in the illustrated embodiment, the rotor 108 may include a rotor shaft 122 coupled to a hub 110 for rotating together with the hub 110. The rotor shaft 122 may be rotatably supported by a main bearing 144. The rotor shaft 122 may then be rotatably coupled to a high-speed shaft 124 of the generator 118 via an optional gearbox 126, which may be connected to a base support frame 136 by one or more torque arms 142. As generally understood, the rotor shaft 122 may provide a low-speed, high-torque input to the gearbox 126 in response to rotation of the rotor blades 112 and the hub 110. The gearbox 126 may then be configured with multiple gears to convert a low-speed, high-torque input into a high-speed, low-torque output to drive the high-speed shaft 124 and thus the generator 118. In an embodiment, the gearbox 126 may be configured with multiple gear ratios to produce varying rotational speeds of the high-speed shaft for a given low-speed input, or vice versa.

[0084] In embodiments, the electrical system 150 of the wind turbine 100 may include various components for converting the kinetic energy of the rotor 108 into an electrical output in an acceptable form to a connected power grid. For example, in an embodiment, the generator 118 may be a doubly-fed induction generator (DFIG). The generator 118 may provide multiphase power (e.g., three-phase power) to the electrical grid.

[0085] Still refer to Figure 3 And refer to Figure 4-8The image presents cross-sectional views of several embodiments of the component assembly 300 of a wind turbine 100. In these embodiments, the component assembly 300 may include wind turbine components such as rotor blades 112, tower 102, low-speed shaft 122, high-speed shaft 124, rotatable hub 108, and / or rotor support spindle. The wind turbine components may include an outer body 304. The outer body 304 may define a load path for transmitting loads of the wind turbine 100 in response to wind. In other words, the outer body 304 may be considered a load-bearing body. The outer body 304 may also define a cavity 306 therein. In these embodiments, an inner body 308 may be disposed within the cavity 306. The inner body 308 may be non-load-bearing with respect to loads. In other words, the inner body 308 may be formed to disconnect from the load path defined by the outer body 304, thereby isolating it from the loads of the wind turbine 100. Furthermore, at least one sensor 310 may be coupled to the inner body 308 and positioned within the cavity 306. Multiple sensors 310 may be configured to detect deflection of the external body 304 in response to loads. It should be understood that the external body 304 may support the weight of multiple blades 112, rotor 108, and / or nacelle 106. The external body 304 may also provide load paths for torsional, thrust, bending, and / or shear load components developed by the wind turbine 100 in response to wind.

[0086] In one embodiment, the sensors(s)310 may be located within the cavity 306, but may be coupled to the external body 304 rather than the internal body 308. In such an embodiment, the sensors(s)310 may be configured to detect the deflection of the external body 304 relative to the internal body 308. In other words, the internal body 308 may serve as a reference surface that does not deflect in response to load.

[0087] In one embodiment, the outer body 304 may have a plurality of generally circular cross-sections 305, such that the outer body 304 may be generally cylindrical. In an additional embodiment, the plurality of generally circular cross-sections 305 may have a plurality of varying diameters, such that the outer body 304 may include at least one tapered or flared portion. Figure 8 In another embodiment depicted, the outer body 304 may have multiple cross-sections 305 that are generally composed of straight lines. Therefore, the outer body 304 may be formed as a box beam or other similar structural component.

[0088] In an embodiment, the outer body 304 and the inner body 308 may be capable of rotating during wind turbine operation. In an embodiment, the outer body 304 and the inner body 308 may be concentric. Furthermore, the outer body 304 and the inner body 308 may have a synchronized rotational rate about an axis (A). The axis (A) may be the rotation axis of the outer body 304. Therefore, as... Figure 3 and Figure 4As specifically depicted herein, in embodiments, component assembly 300 may be shaft assembly 302 of wind turbine 100. In embodiments, shaft assembly 302 may be, for example, rotor shaft 122 or high-speed shaft 124. In such embodiments, outer body 304 may be shaft body 312. It should be understood that any operation or feature disclosed herein with reference to component assembly 300 and / or outer body 304 is equally applicable to embodiments having shaft assembly 302 and / or shaft body 312.

[0089] like Figure 4-6 As depicted, in one embodiment, cavity 306 may be axially aligned with outer body 304. Cavity 306 may be at least partially along the axial length (A) of outer body 304 in the axial direction. L (Extension). In embodiments, the cavity may be defined by a cavity wall 314, which may also be an inner surface of the outer body 304. In additional embodiments, the cavity 306 may define an opening 316 in the outer body 304. For example, the opening 316 may be formed in an axial surface 318 of the outer body 304 and / or in an outer surface 320 of the outer body 304. In at least one embodiment, the axial surface 318 may be defined by a flange 322 of the shaft body 312. Thus, in embodiments, the opening 316 may facilitate access to a component disposed within the cavity 306. In this regard, in at least one embodiment, a sealing member 324 may be coupled across the opening 316. It should be understood that when the sealing member 324 is coupled to the outer body 304, components of the assembly 300 within the cavity 306 may be seen, sensed, observed, monitored, measured, and / or otherwise detected in embodiments without being seen, sensed, observed, monitored, measured, and / or otherwise detected by a sensor disposed outside the outer body 304. In other words, the internal body 308 and the sensors(s) 310 can be completely encapsulated by the cavity 306 in an embodiment.

[0090] In an embodiment, the connection of the plurality of sensors 310 to the inner body 308 at a first axial location (A1) defines a physical distance (S1) between the plurality of sensors 310 and adjacent cavity walls 314 of the cavity 306 (such as adjacent cavity walls 314 in the radial direction (R)). In this respect, the plurality of sensors 310 can monitor the deflection of the outer body 304 without any physical contact with the inner surface of the outer body 304 and transmit the detected deflection to the controller 200. In this respect, in an embodiment, the plurality of sensors 310 may be proximity sensors (e.g., non-contact detectors) configured to indicate radial deflection of the shaft body 312 without requiring physical contact with the sensed surface. In an embodiment, the proximity sensor may be an inductive sensor, a capacitive sensor, an optical sensor, an ultrasonic sensor, and / or a magnetic sensor. Figure 4As depicted, in embodiments, the (multiple) sensors 310 may be communicatively coupled to the controller 200 via wired or wireless coupling. It should be understood that in embodiments in which the (multiple) sensors 310 are coupled to an external body 304, the physical distance (S1) may be defined between the (multiple) sensors 310 and the internal body 308.

[0091] In one embodiment, the (multiple) sensors 310 may be oriented toward the sensor target 330. The sensor target 330 may be integrated with the cavity wall 314. In another embodiment, the sensor target 330 may be a region of the cavity wall 314 having a plane parallel to the viewing plane of the (multiple) sensors 310. For example, the sensor target 330 may be a machined flat region of the cavity wall 314 parallel to a corresponding mounting region 332 of the internal body 308. The mounting region 332 is configured to securely attach the (multiple) sensors 310 thereto.

[0092] It should also be recognized that, as used herein, the term “monitor” and its variations indicate that the (multiple) sensors 310 of the wind turbine 100 may be configured to provide direct or indirect measurements of the monitored parameters. Thus, the sensors described herein may, for example, be used to generate signals relating to the monitored parameters, which may then be utilized by the controller 200 to determine the condition or response of the wind turbine 100.

[0093] In embodiments, the plurality of sensors 310 may also include additional sensors, such as those that can improve the detection of deflection of the external body 304 in response to loads along the load path. For example, in embodiments, the plurality of sensors 310 may include a temperature sensor, an accelerometer, and / or a hybrid sensor. It should be appreciated that including additional sensor types can improve the calibration and / or filtering of sensor signals by providing increased awareness of conditions affecting the proximity sensors.

[0094] Now refer to Figure 7 and Figure 8 In one embodiment, sensor 310 may be one sensor of sensor array 326. In another embodiment, sensor array 326 may include as few as two sensors 310. In a further embodiment, sensor array 326 may include three sensors spaced 120 degrees apart for alignment with the three-bladed rotor 108. However, in a further embodiment, sensor array 326 may include four or more sensors 310 (e.g., five sensors 310). For example, as... Figure 7 As shown, sensor array 326 may include six proximity sensors 310.

[0095] It should be recognized that increasing the number of sensors can provide several advantages to component 300. For example, increasing the number of sensors 310 can increase the accuracy of component 300 by increasing the number of deflection data collection points. When deflection indications are received from multiple sensors 310 of sensor array 326, controller 200 can correlate the reported deflection amplitudes to determine the focus and direction of the deflection. Furthermore, multiple indications can facilitate the detection of faulty sensors. Therefore, the number of sensors 310 in sensor array 326 provides system redundancy, thereby reducing potential maintenance intervals. Therefore, it should be recognized that sensor array 326 with at least five sensors 310 may be desirable.

[0096] In an embodiment, each sensor 310 of the sensor array 326 may define an angular spacing with at least one adjacent sensor 310. Angular spacing (A) S The sensor array 326 can be axially aligned about axis (A). Therefore, the sensor array 326 can be axially aligned at a first axial location (A1) along the axis (A) of the outer body 304. For example, in an embodiment, the sensor array can be externally attached to the inner body 308 such that each sensor 310 of the sensor array 326 defines a circumferential spacing (e.g., angular spacing (A1)) with at least one adjacent sensor 310 of the sensor array 326. S In one embodiment, the sensor array 326 may be equidistantly distributed around the circumference of the internal body 308.

[0097] like Figure 4 As depicted, in one embodiment, each sensor 310 of the sensor array 326 is communicatively coupled to a sensor junction box 328. In another embodiment, the sensor junction box 328 may be located outside the cavity 306. For example, in one embodiment, the sensor junction box 328 may be coupled to a sealing member 324 or the outer surface 320 of the outer body 304. The sensor junction box 328 may combine signals from the sensor array 326 for transmission to the controller 200. The combined signals may be transmitted to the controller 200 via a conduit 380 located within the outer body 304.

[0098] Refer again Figure 3-8In an embodiment, a stable reference point can be provided with respect to the unloaded inner body 308 from which the radial deformation of the outer body 304 can be observed. In an embodiment, the inner body 308 may have a cross-sectional shape corresponding to the cross-sectional shape of the cavity 306 defined by the cross-section 305 of the outer body 304. In an embodiment, the distance between the inner body 308 and the cavity wall 314 can be minimized by maximizing the diameter of the inner body 308. Maximizing the cross-sectional area of ​​the inner body 308 within the available space can result in an increase in the stiffness of the inner body 308. The increased stiffness of the inner body 308 can increase the accuracy of the sensors(s) ...

[0099] In one embodiment, the inner body 308 may be coupled to the outer body 304 at a second axial location (A2) within the cavity 306. The coupling of the inner body 308 at the second axial location (A2) forms a cantilever extending at least axially between the second axial location (A2) and the sensors(s) 310. It should be understood that the cantilever structure of the inner body 308 prevents the transfer of load from the load path defined by the outer body 304 and the inner body 308. Therefore, the inner body 308 can maintain the sensors(s) 310 at a relatively constant radial distance (RD1) from the axis, while the outer body 304 deflects in response to the load.

[0100] like Figure 5 As depicted in the embodiment, (a plurality of) sensors 310 may have a first cantilever axial length (CL). l The first sensitivity at the location (A2). The (multiple) sensors 310 may have a second sensitivity corresponding to the axial length (CL2) of the second cantilever. In an embodiment, the second cantilever axial length (CL1) may be greater than the first cantilever axial length (CL2). In such embodiments, the second sensitivity may be greater than the first sensitivity of the (multiple) sensors 310. In other words, the length of the cantilever can be customized to adjust the sensitivity of the (multiple) sensors 310. For example, the axial position of the second axial location (A2) can be customized to manage incidental movement of the (multiple) sensors 310 at the mounting location 332. It should be understood that incidental movement may be caused, for example, by vibration, changes in rotational speed, inertia, and / or other forces (not directly attributable to loads transmitted by the external body 304).

[0101] Still refer to Figure 5In one embodiment, the inner body 308 may be coupled to the outer body 304 via a mounting element 334. In another embodiment, the mounting element 334 may be, for example, an expandable plug disposed within the cavity 306. In yet another embodiment, the mounting element 334 may be generally annular and may be coaxial with the outer body 304. The axial positioning of the mounting element 334 may be determined by the cantilever axial length required to achieve the desired sensitivity, fidelity, and / or accuracy of the sensors(s)(s)310.

[0102] In one embodiment, component 300 may further include at least one second sensor 336. Multiple second sensors 336 may be coupled to the inner body 308 at a third axial location (A3). In this embodiment, the second axial location (A2) may be located between the first axial location (A1) and the third axial location (A3). In other words, the inner body 308 may form a cantilever extending from the support element 334 in two axial directions. In this embodiment, the use of axially displaced sensors 310 may increase the fidelity of the sensor input to the controller 200 and provide indication of the lateral and / or vertical displacement of the outer body 304.

[0103] Refer again Figure 4 As depicted, in the embodiment, the outer body 304 and the inner body 308 may be a single body without a connection between them. Therefore, the outer body 304 and the inner body 308 can be manufactured simultaneously. For example, the single body can be formed by casting, milling, and / or additive manufacturing. It should be recognized that simultaneously forming a single body eliminates the possibility of displacement and / or misalignment at the connection between the inner body 308 and the outer body 304.

[0104] In additional embodiments, such as in Figure 6 As specifically depicted, the outer body 304 and the inner body 308 are formed separably. In an embodiment, the inner body 308 may be formed within the cavity 306 to be fused with the outer body 304. For example, in an embodiment, the inner body 308 may be additively manufactured directly within the recess 306 after the formation of the outer body 304. In an additional embodiment, the outer body 304 and the inner body 308 may be formed independently using known manufacturing techniques. After their formation, the inner body 308 may be inserted into the cavity 306 and secured therein by chemical, material, and / or mechanical means.

[0105] In embodiments where the outer body 304 and the inner body 308 can be formed independently, the outer body 304 may be formed of a first material. In such embodiments, the inner body 308 may be formed of a second material different from the first material. It should be recognized that the selection of the first and second materials can be driven by the operational design of the component. For example, the first material may be selected to support the definition of load paths for the transfer of loads for the wind turbine 100, while the second material may be selected to balance the desired stiffness of the inner body 308 with the desired lightweight structure.

[0106] Now refer to Figure 9 This diagram illustrates one embodiment of a controller communicatively coupled to sensor(s) 310. As shown, controller 200 includes one or more processor(s) 206 and associated storage(s) 208 configured to perform various computer-implemented functions (e.g., performing methods, steps, calculations, etc., and storing related data, as disclosed herein). Furthermore, controller 200 may also include a communication module 210 to facilitate communication between controller 200 and various components of wind turbine 100. Additionally, communication module 210 may include sensor interface 212 (e.g., one or more analog-to-digital converters) to allow signals transmitted from sensor(s) 310 to be converted into signals that can be understood and processed by processor 206. It should be appreciated that sensor(s) 310 may be communicatively coupled to communication module 210 using any suitable means. For example, sensor(s) 310 may be coupled to sensor interface 212 via a wired connection. However, in other embodiments, sensor(s) 310 may be coupled to sensor interface 212 via a wireless connection, such as by using any suitable wireless communication protocol known in the art. In addition, the communication module 210 may also be operatively coupled to the operation state control module 214, which is configured to change the operation state of at least one wind turbine.

[0107] As used herein, the term "processor" refers not only to integrated circuits known in the art as included in a computer, but also to controllers, microcontrollers, microcomputers, programmable logic controllers (PLCs), application-specific integrated circuits (ASICs), and other programmable circuits. Furthermore, the storage device(s) 208 may generally include storage elements, including but not limited to computer-readable media (e.g., random access memory (RAM)), computer-readable non-volatile media (e.g., flash memory), floppy disks, optical disc read-only memory (CD-ROM), magneto-optical disc (MOD), digital versatile optical disc (DVD), and / or other suitable storage elements. Such storage devices(s) 208 may be generally configured to store suitable computer-readable instructions that, when implemented by the processor(s) 206, configure the controller 200 to perform various functions (including, but not limited to, detecting anonymous operational events and initiating enhanced braking modes for the wind turbine 100, as described herein), and various other suitable computer-implemented functions.

[0108] Reference Figure 10 The flowchart presents an embodiment of a method 400 for manufacturing a shaft assembly for a wind turbine. Method 400 can be implemented to manufacture the above-described reference. Figure 3-8 The load-bearing component 300 and / or shaft assembly 302 are discussed. For illustrative and explanatory purposes, Figure 10 The steps are described in a specific order. Those skilled in the art will understand using the disclosure provided herein that the various steps of method 400 or any other method disclosed herein can be adapted, modified, rearranged, performed concurrently, or modified in various ways without departing from the scope of this disclosure.

[0109] As shown at (402), method 400 includes forming a shaft body defining a cavity extending in a radial direction and a load path for transmitting a load generated by a wind turbine in response to wind. As shown at (404), method 400 includes arranging an inner body within the cavity in axial and rotational alignment with the axis of the shaft body, the inner body being non-load-bearing with respect to the load. Furthermore, as shown at (406), method 400 includes coupling at least one sensor to the inner body within the cavity, the at least one sensor being configured to detect radial deflection of the shaft body in response to the load.

[0110] This written description uses examples to disclose the invention (including the best mode) and also enables those skilled in the art to practice the invention (including making and using any apparatus or system and performing any incorporated methods). The patentable scope of the invention is defined by the claims and may include other examples that may occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that are not distinct from the literal language of the claims, or if they include equivalent structural elements that are not significantly different from the literal language of the claims. Furthermore, those skilled in the art will recognize the interchangeability of various features from different embodiments. Similarly, the various method steps and features described in accordance with the principles of this disclosure, and other known equivalents of each such method and feature, may be mixed and matched by those skilled in the art to construct additional systems and techniques. It will be understood, of course, that not all such objects or advantages described above may be achieved according to any particular embodiment. Therefore, for example, those skilled in the art will recognize that the systems and techniques described herein may be implemented or practiced in a manner that achieves or optimizes one or a set of advantages as taught herein, without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0111] Further aspects of the invention are provided by the subject matter of the following provisions:

[0112] Clause 1. A shaft assembly for a wind turbine, the shaft assembly comprising: a shaft body defining a cavity therein and a load path for transmitting a load generated by the wind turbine in response to wind; an inner body disposed within the cavity and coupled to the shaft body, the inner body being non-load-bearing with respect to the load, wherein the shaft body and the inner body are concentric and have a synchronous rotational rate about an axis; and at least one sensor coupled to the inner body and positioned within the cavity for detecting deflection of the shaft body in response to the load.

[0113] Clause 2. The shaft assembly according to Clause 1, wherein the connection of the at least one sensor to the inner body defines a physical distance in the radial direction between the at least one sensor and an adjacent wall of the cavity.

[0114] Clause 3. The shaft assembly according to any of the preceding clauses, wherein the at least one sensor includes a proximity sensor configured to indicate radial deflection of the shaft body.

[0115] Clause 4. The shaft assembly according to any of the preceding clauses, wherein the at least one sensor comprises a sensor array disposed at a first axial location on the axis, the sensor array being external to the internal body, each sensor of the sensor array defining a circumferential spacing with at least one adjacent sensor of the sensor array.

[0116] Clause 5. The shaft assembly according to any of the preceding clauses, wherein the at least one sensor is coupled to the inner body at a first axial location along the axis, and the inner body is coupled to the shaft body at a second axial location within the cavity, the inner body forming a cantilever that extends at least axially between the at least one sensor and the second axial location.

[0117] Clause 6. The shaft assembly described in any of the foregoing clauses, wherein the shaft body and the inner body are a single body in which there is no connection between them.

[0118] Clause 7. A shaft assembly according to any of the preceding clauses, wherein the inner body is coupled within the cavity after formation, the shaft body comprising a first material, and the inner body comprising a second material different from the first material.

[0119] Clause 8. A component assembly of a wind turbine, the assembly comprising: a wind turbine component including: an outer body defining a cavity therein, the outer body defining a load path for transmitting a load of the wind turbine therethrough; an inner body disposed within the cavity of the outer body, the inner body being non-load-bearing with respect to the load; and at least one sensor coupled to the inner body and positioned within the cavity for detecting deflection of the outer body in response to the load.

[0120] Clause 9. A component assembly according to any of the preceding clauses, wherein the outer body and the inner body are rotatable during operation of the wind turbine, and wherein the outer body and the inner body are concentric and have a synchronous rotational rate about an axis.

[0121] Clause 10. The component assembly according to any of the preceding clauses, wherein the connection of the at least one sensor to the internal body defines a physical distance between the at least one sensor and an adjacent wall of the cavity.

[0122] Clause 11. The component assembly according to any of the preceding clauses, wherein the at least one sensor comprises a sensor array disposed at a first axial location along the axis of the outer body, each sensor of the sensor array defining an angular spacing with respect to the axis of at least one adjacent sensor of the sensor array.

[0123] Clause 12. A component assembly according to any of the preceding clauses, wherein the at least one sensor is coupled to the inner body at a first axial location along the axis of the outer body, and the inner body is coupled to the outer body at a second axial location within the cavity, the inner body forming a cantilever that extends at least axially between the at least one sensor at the second axial location.

[0124] Clause 13. The component assembly according to any of the preceding clauses, wherein the at least one sensor is at least one first sensor, the component further comprising: at least one second sensor, the at least one second sensor being coupled to the internal body at a third axial location, the second axial location being disposed between the first axial location and the third axial location.

[0125] Clause 14. The component assembly described in any of the preceding clauses, wherein the wind turbine component is one of the rotor blades, high-speed shaft, low-speed shaft, rotatable hub, rotor support spindle, or tower of the wind turbine.

[0126] Clause 15. A method for manufacturing a shaft assembly for a wind turbine, the method comprising: forming a shaft body defining a cavity extending in a radial direction and a load path for transmitting a load generated by the wind turbine in response to wind; arranging an inner body within the cavity in axial and rotational alignment with an axis of the shaft body, the inner body being non-load-bearing with respect to the load; and coupling at least one sensor to the inner body within the cavity, the at least one sensor being configured to detect radial deflection of the shaft body in response to the load.

[0127] Clause 16. The method according to any of the preceding clauses, wherein the at least one sensor is coupled to the internal body at a first axial location along the axis, the method further comprising: coupling the internal body to the axis body at a second axial location within the cavity to form a cantilever extending at least axially between the second axial location and the at least one sensor, wherein the at least one sensor has a first sensitivity at a first cantilever axial length and a second sensitivity corresponding to a second cantilever axial length, the second cantilever axial length being greater than the first cantilever axial length, and the second sensitivity being greater than the first sensitivity.

[0128] Clause 17. The method according to any of the preceding clauses, wherein placing the inner body within the cavity comprises at least one of: casting or additive manufacturing the inner body as a single body with respect to the shaft body, wherein there is no connection between the inner body and the shaft body.

[0129] Clause 18. The method according to any of the preceding clauses, wherein the shaft body comprises a first material, and wherein disposing the inner body within the cavity further comprises: forming the inner body from a second material different from the first material; inserting the inner body into the cavity; and coupling the inner body to an inner surface of the shaft body.

[0130] Clause 19. The method according to any of the preceding clauses, wherein attaching at least one sensor to the internal body comprises: externally attaching the internal body to a sensor array at an axial position, wherein the sensor array is equidistantly distributed around the circumference of the internal body.

[0131] Clause 20. The method described under any of the foregoing clauses further includes: an opening connecting a sealing member across the shaft body defined by the cavity.

Claims

1. A shaft assembly for a wind turbine, the shaft assembly comprising: A shaft body, the shaft body defining a cavity therein and a load path for transmitting loads generated by the wind turbine in response to wind; An internal body is disposed within the cavity and connected to the shaft body, the internal body being non-load-bearing with respect to the load, wherein the shaft body and the internal body are concentric and have a synchronous rotational speed about an axis. as well as At least one sensor, coupled to the internal body and positioned within the cavity, is used to detect the deflection of the shaft body in response to the load.

2. The shaft assembly according to claim 1, characterized in that, The connection between the at least one sensor and the internal body defines a physical distance in the radial direction between the at least one sensor and the adjacent wall of the cavity.

3. The shaft assembly according to claim 2, characterized in that, The at least one sensor includes a proximity sensor configured to indicate radial deflection of the shaft body.

4. The shaft assembly according to claim 1, characterized in that, The at least one sensor includes a sensor array disposed at a first axial location on the axis, the sensor array being external to the internal body, each sensor in the sensor array defining a circumferential spacing with at least one adjacent sensor in the sensor array.

5. The shaft assembly according to claim 1, characterized in that, The at least one sensor is coupled to the inner body at a first axial location along the axis, and the inner body is coupled to the shaft body at a second axial location within the cavity, the inner body forming a cantilever that extends at least axially between the at least one sensor and the second axial location.

6. The shaft assembly according to claim 1, characterized in that, The shaft body and the internal body are single bodies with no connecting parts between them.

7. The shaft assembly according to claim 1, characterized in that, The inner body is attached to the cavity after it is formed. The shaft body includes a first material, and the inner body includes a second material different from the first material.

8. A method for manufacturing a shaft assembly for a wind turbine, the method comprising: A shaft body is formed, the shaft body defining a cavity extending in a radial direction and a load path for transmitting loads generated by the wind turbine in response to wind; The internal body is configured within the cavity to be axially and rotatably aligned with the axis of the shaft body, wherein the internal body is non-load-bearing with respect to the load. as well as At least one sensor is attached to the internal body within the cavity, the at least one sensor being configured to detect radial deflection of the shaft body in response to the load.

9. The method according to claim 8, characterized in that, The at least one sensor is coupled to the internal body at a first axial location along the axis, and the method further includes: The internal body is connected to the shaft body at a second axial location within the cavity to form a cantilever extending at least axially between the second axial location and the at least one sensor, wherein the at least one sensor has a first sensitivity at a first cantilever axial length and a second sensitivity corresponding to a second cantilever axial length, the second cantilever axial length being greater than the first cantilever axial length, and the second sensitivity being greater than the first sensitivity.

10. The method according to claim 8, characterized in that, The internal body is disposed within the cavity by at least one of the following: the internal body is cast or additively manufactured as a single body with respect to the shaft body, and there is no connection between the internal body and the shaft body.

11. The method according to claim 8, characterized in that, The shaft body includes a first material, and the arrangement of the inner body within the cavity further includes: The internal body is formed of a second material different from the first material; Insert the internal body into the cavity; and The inner body is connected to the inner surface of the shaft body.

12. The method according to claim 8, characterized in that, Connecting at least one sensor to the internal body includes: The internal body is externally connected to a sensor array at an axial position, wherein the sensor array is equidistantly distributed around the circumference of the internal body.

13. The method according to claim 8, characterized in that, The method further includes: An opening in the shaft body defined by the cavity is connected to a sealing component.

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