Systems and methods for controlling a wind turbine

Abstract

A system and method for controlling a wind turbine are provided. Accordingly, components of the wind turbine are monitored by at least one sensor of a sensor system. An output indicating a fault of the sensor is received from the sensor system. A fault adjustment response is generated by a fault module. The fault adjustment response includes an adjustment signal that replaces the output signal of the faulty sensor.

Description

Technical Field

[0001] The present disclosure generally relates to wind turbines, and more particularly, to systems and methods for controlling a wind turbine using a fault regulation signal in response to a sensor failure. Background Art

[0002] Wind power is considered to be one of the cleanest and most environmentally friendly energy sources currently available, and wind turbines have received increasing attention in this regard. Modern wind turbines typically include a tower, a generator, a gearbox, a nacelle, and one or more rotor blades. The nacelle includes a rotor assembly coupled to the gearbox and the generator. The rotor assembly and the gearbox are mounted on a platen support frame located within the nacelle. The one or more rotor blades capture the kinetic energy of the wind using known airfoil principles. The rotor blades transfer kinetic energy in the form of rotational energy to rotate a shaft that couples the rotor blades to the gearbox, or directly to the generator if no gearbox is used. The generator then converts the mechanical energy into electrical energy, and the electrical energy can be transmitted to a converter and / or transformer housed within the tower and subsequently deployed to the utility grid. Modern wind power systems typically take the form of a wind farm having multiple such wind turbine generators that are operable to supply power to a transmission system that provides power to the grid.

[0003] Typically, modern wind turbines employ a component monitoring system to monitor the operating conditions of the various components of the wind turbine. Thus, the component monitoring system typically includes one or more sensors operably coupled to the various components of the wind turbine. The output of the sensors can be utilized by a controller to adjust the operating parameters of the wind turbine to maximize power generation and prevent or limit damage to the wind turbine. However, over the life of the wind turbine, the sensors may fail. Thus, the output of the component monitoring system may be incomplete and / or incorrect.

[0004] Typically, when the turbine controller receives unacceptable information from the component monitoring system, the controller will implement an alternative control scheme. Typically, such a control scheme includes significantly derating or stopping the wind turbine to protect the components from overloading conditions. However, derating also results in a decrease in the power generation of the wind turbine. Thus, there is a need for systems and methods to facilitate wind turbine operation in the presence of sensor failures while minimizing the derating of the wind turbine.

[0005] Accordingly, the art is constantly seeking new and improved systems for controlling wind turbines. Thus, the present disclosure relates to systems and methods for controlling a wind turbine via fault regulation. Summary of the Invention

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

[0007] In one aspect, the present disclosure relates to a system for controlling a wind turbine. The system can include a sensor system having at least one sensor operably coupled to a component of the wind turbine to detect an operating condition of the component. The system can also include a controller communicatively coupled to the sensor system. The controller can include at least one processor configured to perform a plurality of operations. The plurality of operations can include detecting, via a fault module, an output signal of the sensor indicative of a sensor fault. The plurality of operations can also include generating, via the fault module, a fault adjustment signal. Additionally, the plurality of operations can include replacing the output signal of the sensor with the fault adjustment signal to cause a change in an operating state of the wind turbine.

[0008] In another aspect, the present disclosure relates to a method for controlling a wind turbine. The method can include receiving, via a controller, data indicative of an operating condition of a component of the wind turbine from a sensor system. The sensor system can include a sensor operably coupled to the component. The method can also include detecting, via a fault module, an output signal from the sensor indicative of a sensor fault. Additionally, the method can include generating, via the fault module, a fault adjustment response. The fault adjustment response can include an adjustment signal that replaces the output signal indicative of the sensor fault. Further, the method can include causing, via the controller, a change in an operating state of the wind turbine based at least on the adjustment signal. It should be understood that the method can further include any of the additional features and / or steps described herein.

[0009] In yet another aspect, the present disclosure relates to a wind turbine. The wind turbine can include a tower fastened to a foundation; a nacelle mounted on top of the tower; a rotor mounted to the nacelle; at least one rotor blade mounted to the rotor; and a blade monitoring system operably coupled to the rotor blade. The blade monitoring system can include a sensor system including a sensor operably coupled to the rotor blade to detect an operating condition of the component. The blade monitoring system can also include a controller communicatively coupled to the sensor system. The controller can include at least one processor configured to perform a plurality of operations. The plurality of operations can include detecting, via a fault module, an output signal of the sensor indicative of a sensor fault. The plurality of operations can include generating, via the fault module, a fault adjustment signal. Additionally, the plurality of operations can include replacing the output signal of the sensor with the fault adjustment signal to cause a change in an operating state of the wind turbine. It should be understood that the wind turbine can further include any of the additional features described herein.

[0010] These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and 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. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] In this specification, a complete and enabling disclosure of the present invention, including the best mode thereof, for a person of ordinary skill in the art is set forth with reference to the accompanying drawings, in which:

[0012] Figure 1 A perspective view of an embodiment of a wind turbine in accordance with the present disclosure is shown;

[0013] Figure 2 An interior perspective view of an embodiment of a nacelle of a wind turbine in accordance with the present disclosure is shown;

[0014] Figure 3A A perspective view of an embodiment of a rotor blade equipped with a blade monitoring system in accordance with the present disclosure is shown;

[0015] Figure 3B A cross-sectional view of a rotor blade in accordance with the present disclosure Figure 3A is shown;

[0016] Figure 4 A schematic view of an embodiment of a controller for use in a wind turbine in accordance with the present disclosure is shown; and

[0017] Figure 5 A schematic view of an embodiment of the control logic of a system for controlling a wind turbine in accordance with the present disclosure is shown.

[0018] The repeated use of reference characters in this specification and drawings is intended to represent the same or analogous features or elements of the present invention. DETAILED DESCRIPTION

[0019] Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, and not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still further embodiments. Accordingly, it is intended that the present invention cover such modifications and variations that come within the scope of the appended claims and their equivalents.

[0020] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to denote the position or importance of individual components.

[0021] Unless otherwise specified herein, the terms "coupled," "fixed," "attached to," etc. refer to both direct coupling, fixing, or attachment, as well as indirect coupling, fixing, or attachment through one or more intermediate components or features.

[0022] As used throughout this specification and the claims, approximate language is applied to modify any quantitative representation that can permissibly vary without resulting in a change in the basic function to which it relates. Thus, a value modified by one or more terms such as "about," "approximately," and "substantially" will not be limited to the precise value specified. In at least some instances, the 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, the approximate language may refer to within a 10% margin.

[0023] Here and throughout the specification and claims, ranges are combined and interchanged, and such ranges are recognized and include all subranges subsumed therein unless the context or language indicates otherwise. For example, all ranges disclosed herein include the endpoints, and the endpoints are combined independently of each other.

[0024] Generally, the present disclosure relates to systems and methods for controlling a wind turbine. In particular, the present disclosure includes systems and methods for facilitating operation of a wind turbine in the event of a failure of at least one sensor. Specifically, the present disclosure may include a system for detecting an output signal indicative of a failure of one or more sensors. The system may generate a fault adjustment signal in response to an indication of the failed sensor(s). Thus, the fault adjustment signal can be used to replace the fault signal to maintain continuous control of the wind turbine. More specifically, the fault adjustment signal can be generated by leveraging sensor redundancy to simulate a lost signal by modifying signals from additional sensors coupled to the same component. Additionally, inputs from additional sensor systems coupled to the wind turbine or additional components of the wind turbine can also be employed to model the signals that would be received from the sensors if the sensors were operative. Thus, it should be appreciated that the use of the fault adjustment signal permits the wind turbine to continue operating in a configuration that maximizes power generation in the presence of sensor failures.

[0025] Now referring to the drawings, Figure 1A perspective view of a wind turbine 100 according to an embodiment of 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, the at least one rotor blade 112 being coupled to the hub 110 and extending outwardly 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 than three or less than three rotor blades 112. Each rotor blade 112 may be spaced about the hub 110 to facilitate rotation of the rotor 108, enabling kinetic energy to be converted from the wind into useful mechanical energy and subsequently into electrical energy. For example, the hub 110 may be rotatably coupled to a generator 118 located within the nacelle 106 ( Figure 2 ) to permit the generation of electrical energy.

[0026] The wind turbine 100 may also include a controller 200 centralized 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 external to the wind turbine. Additionally, the controller 200 may be communicatively coupled to any number of components of the wind turbine 100 to control those components. Accordingly, 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 different functions, such as receiving, transmitting, and / or executing wind turbine control signals.

[0027] Now referring to Figure 2 is shown Figure 1Simplified internal view of an embodiment of the nacelle 106 of the wind turbine 100 shown in the figure. As shown, the generator 118 can be coupled to the rotor 108 to generate electrical power from the rotational energy generated by the rotor 108. For example, as shown in the illustrated embodiment, the rotor 108 can include a rotor shaft 122 coupled to the hub 110 to rotate therewith. The rotor shaft 122 can be rotatably supported by a main bearing 144. The rotor shaft 122 can in turn be rotatably coupled to the high-speed shaft 124 of the generator 118 through an optional gearbox 126, and the gearbox 126 is connected to the platen support 136 through one or more torque arms 142. As generally understood, the rotor shaft 122 can provide a low-speed, high-torque input to the gearbox 126 in response to the rotation of the rotor blades 112 and the hub 110. Then, the gearbox 126 can be configured to convert the low-speed, high-torque input into a high-speed, low-torque output to drive the high-speed shaft 124 and thus drive the generator 118. In one embodiment, the transmission 126 can be configured with multiple gear ratios to produce a varying rotational speed of the high-speed shaft for a given low-speed input, or vice versa.

[0028] Each rotor blade 112 can also include a pitch control mechanism 120 configured to rotate each rotor blade 112 about its pitch axis 116. The pitch control mechanism 120 can include a pitch controller 150 configured to receive at least one pitch setpoint command from the controller 200. In addition, each pitch control mechanism 120 can include a pitch drive motor 128 (e.g., any suitable electric, hydraulic, or pneumatic motor), a pitch drive gearbox 130, and a pitch drive pinion 132. In such embodiments, the pitch drive motor 128 can be coupled to the pitch drive gearbox 130 such that the pitch drive motor 128 applies a mechanical force to the pitch drive gearbox 130. Similarly, the pitch drive gearbox 130 can be coupled to the pitch drive pinion 132 to rotate therewith. The pitch drive pinion 132 can in turn be in rotational engagement with a pitch bearing 134 coupled between the hub 110 and the corresponding rotor blade 112 such that rotation of the pitch drive pinion 132 causes rotation of the pitch bearing 134. Thus, in such embodiments, rotation of the pitch drive motor 128 drives the pitch drive gearbox 130 and the pitch drive pinion 132, thereby rotating the pitch bearing 134 and the (one or more) rotor blades 112 about the pitch axis 116. Similarly, the wind turbine 100 can include one or more yaw drive mechanisms 138 communicatively coupled to the controller 200, each (multiple) yaw drive mechanism 138 being configured to change the angle of the nacelle 106 relative to the wind (e.g., by engaging the yaw bearing 140 of the wind turbine 100).

[0029] Still referring to Figure 2, the wind turbine 100 may include a component monitoring system, such as at least one sensor system 160, the sensor system 160 having one or more sensors 156, 158 that may monitor the performance of the wind turbine 100 and / or environmental conditions affecting the wind turbine 100. In a particular embodiment, as will be discussed in Figure 5 , the sensor system 160 may be a first sensor system 176, and the wind turbine 100 may further include a second sensor system 178.

[0030] For example, in one embodiment, the sensor system 160 may include a plurality of sensors configured to monitor a single property or multiple properties of one or more wind turbine components. For example, in one embodiment, a first set of sensors may be configured as strain gauges configured to detect tensile loads on a component, while another set of sensors may be configured to monitor temperature changes within the component. It should also be appreciated that, as used herein, the term "monitor" and its variants indicate that the various sensors of the wind turbine 100 may be configured to provide either direct measurements of the parameters being monitored or indirect measurements of such parameters. Thus, the sensors described herein may be used, for example, to generate signals related to the parameters being monitored, which may then be utilized by the controller 200 to determine the condition of the wind turbine 100.

[0031] For example, in one embodiment, the wind turbine 100 may include an environmental sensor 156 configured to collect data indicative of at least one environmental condition. The environmental sensor 156 may be operatively coupled to the controller 200. Thus, in one embodiment, the (one or more) environmental sensors 156 may be, for example, a wind vane, an anemometer, a lidar sensor, a thermometer, a barometer, or other suitable sensors. Data collected by the (one or more) environmental sensors 156 may include measures of wind speed, wind direction, wind shear, gusts, wind veer, atmospheric pressure, and / or temperature. In at least one embodiment, the (one or more) environmental sensors 156 may be mounted on the nacelle 106 in a downwind position of the rotor 108. In an alternative embodiment, the (one or more) environmental sensors 156 may be coupled to or integrated with the rotor 108. It should be appreciated that the (one or more) environmental sensors 156 may include a network of sensors and may be located at positions remote from the turbine 100.

[0032] Additionally, the wind turbine 100 may include one or more operating sensors 158. The (one or more) operating sensors 158 may be configured to detect the performance of the wind turbine 100 in response to environmental conditions. Additionally, the (one or more) operating sensors 158 may be, for example, sensors configured to monitor electrical characteristics of the output of the generator 118 of the wind turbine 100, such as current sensors, voltage sensors, temperature sensors, or power sensors that directly monitor power output based on current and voltage measurements.

[0033] In another embodiment, the (one or more) operating sensors 158 may include any other sensors that may be used to monitor the operating state of the wind turbine 100. More specifically, the (one or more) operating sensors 158 may be a rotational speed sensor operably coupled to the controller 200. The (one or more) operating sensors 158 may be for the rotor shaft 122 of the wind turbine 100. The (one or more) operating sensors 158 may collect data indicative of the rotational speed of the rotor shaft 122 and, thus, may collect data indicative of the rotational speed of the rotor 108. In one embodiment, the (one or more) operating sensors 158 may be an analog tachometer, a D.C. tachometer, an A.C. tachometer, a digital tachometer, a contact tachometer, a non-contact tachometer, or a time and frequency tachometer.

[0034] In an additional embodiment, the (one or more) operating sensors 158 may be a pitch sensor. Thus, the controller 200 may receive an indication of the pitch setpoint of the rotor 108 of the wind turbine 100 via the (one or more) operating sensors 158 operably coupled to the pitch control mechanism 120. The controller 200 may consider the pitch setpoint indication in accordance with environmental conditions in order to determine whether the pitch of the rotor 108 is an operating state that may be changed to meet the desired power generation.

[0035] Now referring to Figure 3A and Figure 3B , the rotor blade 112 may include an outer surface 146 that defines a pressure side 148 and a suction side 152 extending in a chordwise (C) direction between a leading edge 154 and a trailing edge 162. A thickness (T) of the rotor blade 112 may be defined in a flapping (F) direction between the pressure side 148 and the suction side 152. The rotor blade 112 may also extend in a spanwise (S) direction between a root 164 and a tip 166. In at least one embodiment, the rotor blade 112 may be a segmented rotor blade having at least a tip portion 168 and a root portion 170.

[0036] In addition, as shown, rotor blade 112 may be equipped with the sensor system 160 described herein. In such embodiments, the sensor system 160 may be configured as a blade monitoring system. When configured as a blade monitoring system, sensor 158 may be a strain gauge configured to detect bending moments within rotor blade 112 during operation. In such embodiments, the sensor(s) of sensor system 160 may be positioned at different locations around rotor blade 112. For example, as shown, a first sensor 172 may be positioned at a first spanwise location near leading edge 154, while a second sensor 174 may be positioned at a second spanwise location near leading edge 154. In such embodiments, sensors 172, 174 may be particularly adapted to detect bending moments caused by loads along leading edge 154 of rotor blade 112. In an additional embodiment, first sensor 172 may be positioned as previously described; however, second sensor 174 may be positioned at the same spanwise location, but at different chordwise and flap positions. In a further embodiment, two sensors 158 may be positioned at different spanwise locations along leading edge 154, and two additional sensors 158 may be positioned at different spanwise locations along suction side 152. It should be appreciated that any suitable number of sensors may be used at any suitable locations to improve the fidelity of the output of sensor system 160 and the redundancy of sensor system 160.

[0037] Now referring to Figures 4 - 5 , there is presented a schematic diagram of various embodiments of a system 300 for controlling a wind turbine 100 according to the present disclosure, the system 300 including, for example, a sensor system 160. As Figure 4 particularly shown in, there is presented a schematic diagram of one embodiment of suitable components that may be included within system 300. For example, as shown, system 300 may include a controller 200 communicatively coupled to sensor system 160. In addition, as shown, controller 200 includes one or more processors 206 and associated memory devices 208 configured to perform various computer-implemented functions (e.g., as disclosed herein, execute methods, steps, calculations, etc. and store related data). Additionally, controller 200 may further include a communication module 210 to facilitate communication between controller 200 and various components of wind turbine 100. In addition, communication module 210 may include a sensor interface 212 (e.g., one or more analog-to-digital converters) to allow signals transmitted from sensor(s) 156, 158 to be converted into signals understandable and processable by processor 206. It should be appreciated that sensor(s) 156, 158 may be communicatively coupled to communication module 210 using any suitable method. For example, as Figure 4As shown, one or more sensors 156, 158 are coupled to sensor interface 212 via a wired connection. However, in other embodiments, one or more sensors 156, 158 may be coupled to sensor interface 212 via a wireless connection (such as by using any suitable wireless communication protocol known in the art). Additionally, communication module 210 may also be operatively coupled to an operation state control module 214, which is configured to change at least one wind turbine operation state.

[0038] As used herein, the term "processor" refers not only to integrated circuits referred to in the art as included in a computer, but also to controllers, microcontrollers, microcomputers, programmable logic controllers (PLCs), application specific integrated circuits, and other programmable circuits. Additionally, one or more memory devices 208 generally may include one or more memory 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, compact disk-read only memory (CD-ROM), magneto-optical disks (MOD), digital versatile disks (DVD), and / or other suitable memory elements. Such one or more memory devices 208 generally may be configured to store suitable computer-readable instructions that, when implemented by one or more processors 206, cause controller 200 to be configured to perform various functions including, but not limited to: detecting, via fault module 302, an output signal of sensor 158 indicative of a sensor fault; and generating, via fault module 302, a fault regulation signal as described herein, as well as various other suitable computer-implemented functions. In at least one embodiment, fault module 302 may include a fault detection module 338 and a fault regulation module 340. In one embodiment, fault detection module 338 may be configured to detect a sensor fault of sensor 158. In an additional embodiment, fault regulation module 340 may be configured to generate a fault regulation response that may include a fault regulation signal.

[0039] Still referring to Figure 4 , in one embodiment, system 300 may include a fault module 302, which may be a software module of controller 200. In an additional embodiment, fault module 302 may be a distributed controller 200 or a hardware card.

[0040] Specifically referring to Figure 5, as shown at 304, the fault module 302 of the system 300 can be configured to detect the output signal 306 of the sensor system 160 indicating a sensor fault. For example, the output signal 306 can include a sensor output (or lack of sensor output) indicating a sensor fault. Thus, the sensor output 306 can be considered unacceptable to the system 300 for controlling the wind turbine 100. Additionally, a sensor fault can be indicated by a lack of signal from one or more sensors and / or poor signal quality / resolution. In an additional embodiment, a sensor fault can be indicated by the sensor output 306 being out of range and / or a lack of azimuth signal. Additional sensor faults can include, but are not limited to, zero calibration low fault, strain sensor drift, temperature sensor fault, additive fault, multiplicative fault, output stuck fault, and / or slow drift fault.

[0041] As shown at 308, the system 300 can also be configured to generate a fault adjustment signal via the fault module 302. Additionally, as shown at 310, the system 300 can replace the output signal 306 of the sensor 158 with the fault adjustment signal. Thus, as shown at 312, replacing the faulty output signal 306 with the fault adjustment signal can cause a change in the operating state of the wind turbine 100. As shown at 334, where generation of the fault adjustment signal is not feasible, the system 300 can reduce the operating limit of the wind turbine 100. For example, when a sensor fault is detected but the adjustment signal is not available, the system 300 can reduce the rating of the wind turbine 100 by establishing a thrust limit that is a percentage of the nominal thrust limit of the wind turbine 100.

[0042] In such as Figure 3A and Figure 3BIn embodiments such as embodiments of, the first sensor 172 of the sensor system 160 may be positioned in a first position relative to the component and may malfunction, while the second sensor 174 may be operative. Thus, in response to detecting a sensor fault at 304, the system 300 may be configured to utilize sensor redundancy to generate a fault adjustment signal at 308. Additionally, the system 300 may receive data 328 indicative of an operating condition from the second sensor 174 positioned in a second position relative to the component at 314. As shown at 316, the system 300 may apply a weighting factor to the data received from the second sensor 174 to simulate acceptable data indicative of the operating condition from the first sensor 172. For example, the first sensor 172 may be positioned between the root 164 of the rotor blade 112 and the second sensor 174 in a region of the rotor blade 112 that is subject to a greater bending moment than the region monitored by the second sensor 174. Thus, the weighting factor may be multiplied by the output of the second sensor 174 to simulate the output of the operative first sensor 172. In an additional embodiment, the weighting factor may also be combined with a bias term to simulate acceptable data indicative of the operating condition from the first sensor. It should be appreciated that the weighting factor may be derived from a historical data set of the rotor blade 112, where the outputs of the plurality of sensors 158 are individually recorded as a time series - data set.

[0043] In an additional embodiment, where the system 300 may be configured to utilize sensor redundancy to generate a fault adjustment signal at 308, the first sensor 172 may be configured to monitor a first property of the component and may malfunction. In such embodiments, the system 300 may be configured to receive data indicative of a second monitored property from the second sensor 174. As shown at 316, the system 300 may apply a conversion factor to the data indicative of the second monitored property to simulate acceptable data indicative of the first monitored property from the first sensor 172. For example, in one embodiment, the first property may be strain indicative of a bending moment, while the second property may be temperature, vibration, or acceleration. In such embodiments, the system 300 may utilize the conversion factor to extrapolate the bending moment that would be indicated by the operative first sensor 172 at the measured second property. It should be appreciated that the conversion factor may be derived from a historical data set of the rotor blade 112, where the outputs of the plurality of sensors 158 are individually recorded as a time series - data set.

[0044] In another embodiment, system 300 may be configured to simulate or use modeling to simulate the operating conditions of a component. Thus, as shown at 318, system 300 may receive data 330 from second sensor system 178 indicative of the operating conditions of wind turbine 100. As shown at 320, system 300 may simulate the operating conditions of a component based on the operating conditions of the wind turbine as detected by second sensor system 178. Based on the results of the simulation, as shown at 322, system 300 may emulate data indicative of the operating conditions of the component. It should be appreciated that controller 200 may use the measured operating conditions to extrapolate the expected output from first sensor system 176 of the operation.

[0045] In one embodiment, wherein system 300 may be configured to simulate or use modeling to simulate the operating conditions of a component, second sensor system 178 may include environmental sensor 156 and one or more operating sensors 158. Based on these inputs, as shown at 320, system 300 may correlate the operating conditions of a component with the performance of the wind turbine for detected environmental conditions 332 based on a historical data set. The historical data set may include wind turbine performance points in response to various environmental conditions and the corresponding operating conditions of the component at each wind turbine performance point. For example, second sensor system 178 may indicate the power output of generator 118 at a wind speed 332 detected by environmental sensor 156. Controller 200 may then use the measured power output and wind speed to determine the amount of thrust from rotor 108 necessary to result in the measured performance. This determination may in turn allow controller 200 to determine the loads experienced by rotor blades 112 when generating the calculated thrust. Additionally, controller 200 may emulate the output of first sensor system 176 for component operation at the calculated loads.

[0046] In a further embodiment, system 300 may correlate the monitored operating conditions of a first component with the monitored operating conditions of a second component. For example, in one embodiment, the two components may correspond to two of the rotor blades 112. Thus, system 300 may use the output of second sensor system 178 as a substitute for a fault signal from first sensor system 176. It should be appreciated that the output of second sensor system 178 may be time-shifted relative to the desired output from first sensor system 176. Thus, in at least one embodiment, system 300 may employ time-shift logic to account for the time shift and correlate the output of second sensor system 178 with the desired output from first sensor system 176.

[0047] Still referring to Figure 5, as shown at 308, system 300 may be configured to generate a fault accommodation signal via one of the sensor redundancy methods or modeling methods described herein. For example, in one embodiment, system 300 may receive data indicating a first sensor system fault from a first sensor system 176. A first sensor system fault may indicate a lack of sensor data within the first sensor system 176 that is available to simulate acceptable data from at least one of the plurality of sensors 158. Thus, as shown at 324, system 300 may determine whether the number and / or type of sensors 158 operating in the first sensor system 176 is sufficient to simulate data from the failed sensor. In one embodiment, where the operating sensors provide sufficient redundancy to compensate for the failed sensor, system 300 may employ a sensor redundancy method. In one embodiment, where system 300 determines that there is not sufficient sensor redundancy in the first sensor system 176, system 300 may employ a modeling method as discussed herein.

[0048] If system 300 determines that the first sensor system 176 lacks sufficient sensor redundancy to simulate the missing sensor data from the failed sensor, then as shown at 326, system 300 may determine whether modeling inputs are available from the operating sensor systems. Thus, as shown at 334, system 300 may determine that there are not sufficient modeling inputs available and may reduce the operating limits of the wind turbine 100. As shown at 336, system 300 may also reduce the operating limits of the wind turbine 100 when a fault accommodation signal is provided. It should be appreciated that a potential degradation in signal accuracy may result from the modeling and simulation of the failed sensor output 306 as compared to data received via direct measurement. This in turn may lead to a degradation in the accuracy of the control system of the wind turbine 100. Thus, in one embodiment, the operating limits of the wind turbine 100 may be reduced to prevent component overload. It should be further appreciated that in embodiments where an accommodation signal is generated, the reduction in operating limits may be less than in embodiments where no accommodation signal is generated.

[0049] In addition, those skilled in the art will recognize the interchangeability of various features from different embodiments. Similarly, the various method steps and features described, as well as other known equivalents for each such method and feature, may be mixed and matched by those of ordinary skill in the art to construct additional systems and techniques in accordance with the principles of the present disclosure. Of course, it is to be understood that not necessarily all such objectives or advantages described above can be achieved in accordance with any particular embodiment. Thus, 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 advantage or a group of advantages taught herein, without necessarily achieving other objectives or advantages taught or suggested herein.

[0050] This written description uses examples to disclose the invention, including the best mode, and also enables any person skilled in the art to practice the invention, including making and using any device or system and performing any incorporated method. The patentable scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. If such other examples include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ materially from the literal language of the claims, then it is intended that such other examples be within the scope of the claims.

[0051] A further aspect of the invention is provided by the subject matter of the following clauses:

[0052] Clause 1. A system for controlling a wind turbine, the system comprising: a sensor system including at least one sensor operably coupled to a component of the wind turbine to detect an operating condition of the component; and a controller communicatively coupled to the sensor system, the controller including at least one processor configured to perform a plurality of operations, the plurality of operations including: detecting, via a fault module, an output signal of the at least one sensor indicative of a sensor fault, generating, via the fault module, a fault adjustment signal, and replacing the output signal of the at least one sensor with the fault adjustment signal so as to cause a change in an operating state of the wind turbine.

[0053] Clause 2. The system of any preceding clause, wherein the sensor system includes a plurality of sensors operably coupled to the component, a first sensor of the plurality of sensors being located at a first location and being in a fault state, a second sensor of the plurality of sensors being in an operating state, and wherein generating the fault adjustment signal further includes: receiving data indicative of the operating condition from the second sensor located at a second location relative to the component, wherein the second location is different from the first location; and applying a weighting factor to the data received from the second sensor so as to simulate acceptable data indicative of the operating condition from the first sensor, wherein the weighting factor adjusts a positional difference between the first and second sensors.

[0054] Clause 3. The system of any preceding clause, wherein the sensor system includes a plurality of sensors operably coupled to the component, a first sensor of the plurality of sensors being configured to monitor a first attribute of the component and being faulty, and wherein generating the fault adjustment signal further includes: receiving data indicative of a second monitored attribute from a second sensor of the plurality of sensors, the first attribute being an attribute different from the second attribute; and applying a conversion factor to the data indicative of the second monitored attribute so as to simulate acceptable data indicative of the first monitored attribute from the first sensor.

[0055] Clause 4. The system of any preceding clause, wherein the sensor system is a first sensor system, the system further comprising a second sensor system having at least one sensor, and wherein generating the fault conditioning signal further comprises: receiving data indicative of the operating condition of the wind turbine from the second sensor system; simulating the operating condition of the component based on the operating condition of the wind turbine as detected by the second sensor system; and emulating data indicative of the operating condition of the component from the first sensor system based on the simulation.

[0056] Clause 5. The system of any preceding clause, wherein the second sensor system has at least one environmental sensor configured to detect environmental conditions acting on the wind turbine and at least one operating sensor configured to detect the performance of the wind turbine in response to the environmental conditions, and wherein simulating the operating condition of the component comprises: correlating the operating condition of the component with the performance of the wind turbine for the detected environmental conditions based on a historical data set, wherein the historical data set includes wind turbine performance points in response to various environmental conditions and the corresponding operating conditions of the component at the various wind turbine performance points.

[0057] Clause 6. The system of any preceding clause, wherein the component is a first component, and wherein the second sensor system is configured to monitor the operating condition of a second component of the wind turbine, and wherein simulating the operating condition of the first component comprises: correlating the operating condition of the first component with the operating condition of the second component of the wind turbine.

[0058] Clause 7. The system of any preceding clause, wherein generating the conditioning signal further comprises: receiving data indicative of a first sensor system fault from the first sensor system, wherein the first sensor system fault indicates a lack of sensor data within the first sensor system available for emulating acceptable data from at least one of the plurality of sensors.

[0059] Clause 8. The system of any preceding clause, wherein the system includes a blade monitoring system, and wherein the component includes a blade of the wind turbine.

[0060] Clause 9. The system of any preceding clause, wherein the first component is a first blade of the wind turbine, and wherein the second component is a second blade of the wind turbine.

[0061] Clause 10. The system of any preceding clause, the plurality of operations further comprising: reducing the load limit of the wind turbine in response to the generation of the fault conditioning signal.

[0062] Clause 11. A method for controlling a wind turbine, the method comprising: receiving, via a controller, data indicative of an operating condition of a component of the wind turbine from a sensor system, the sensor system including at least one sensor operatively coupled to the component; detecting, via a fault module, an output signal of the at least one sensor indicative of a sensor fault; generating, via the fault module, a fault adjustment response, the fault adjustment response including an adjustment signal that replaces the output signal indicative of the sensor fault; and causing, via the controller, a change in an operating state of the wind turbine based at least on the adjustment signal.

[0063] Clause 12. The method of any preceding clause, wherein the sensor system includes a plurality of sensors operatively coupled to the component, a first sensor of the plurality of sensors is located in a first position and is faulty, a second sensor of the plurality of sensors is operative, and wherein generating the fault adjustment signal further comprises: receiving data indicative of the operating condition from the second sensor located in a second position relative to the component, wherein the second position is different from the first position; and applying a weighting factor to the data received from the second sensor in order to simulate acceptable data indicative of the operating condition from the first sensor, wherein the weighting factor adjusts a positional difference between the first and second sensors.

[0064] Clause 13. The method of any preceding clause, wherein the sensor system includes a plurality of sensors operatively coupled to the component, a first sensor of the plurality of sensors is configured to monitor a first attribute of the component and is in a fault state, and wherein generating the fault adjustment signal further comprises: receiving data indicative of a second monitored attribute from a second sensor of the plurality of sensors, the first attribute being an attribute different from the second attribute; and applying a conversion factor to the data indicative of the second monitored attribute in order to simulate acceptable data indicative of the first monitored attribute from the first sensor.

[0065] Clause 14. The method of any preceding clause, wherein the sensor system is a first sensor system, the system further including a second sensor system having at least one sensor, and wherein generating the fault adjustment signal further comprises: receiving data indicative of an operating condition of the wind turbine from the second sensor system; simulating the operating condition of the component based on the operating condition of the wind turbine as detected by the second sensor system; and simulating the data indicative of the operating condition of the component from the first sensor system based on the simulation.

[0066] Clause 15. The method of any preceding clause 14, wherein the component is a first component, and wherein the second sensor system is configured to monitor an operating condition of a second component of the wind turbine, and wherein simulating the operating condition of the first component includes correlating the operating condition of the first component with the operating condition of the second component of the wind turbine.

[0067] Clause 16. A method according to any preceding clause, wherein the first component is a first blade of a wind turbine and wherein the second component is a second blade of the wind turbine.

[0068] Clause 17. A method according to any preceding clause, wherein generating the adjustment signal further comprises: receiving data indicative of a failure of a first sensor system from the first sensor system, wherein the first sensor system failure indicates a lack of sensor data within the first sensor system that is acceptable for simulating data from at least one of the plurality of sensors.

[0069] Clause 18. A wind turbine comprising: a tower fastened to a foundation; a nacelle mounted on top of the tower; a rotor mounted to the nacelle; at least one rotor blade mounted to the rotor; and a blade monitoring system operatively coupled to the at least one rotor blade, the blade monitoring system comprising: a sensor system including at least one sensor operatively coupled to the at least one rotor blade to detect an operating condition of a component; and a controller communicatively coupled to the sensor system, the controller including at least one processor configured to perform a plurality of operations, the plurality of operations including: detecting, via a fault module, an output signal of the at least one sensor indicative of a sensor failure, generating, via the fault module, a fault adjustment signal, and replacing the output signal of the at least one sensor with the fault adjustment signal so as to cause a change in an operating state of the wind turbine.

[0070] Clause 19. A wind turbine according to any preceding clause, wherein the sensor system includes a plurality of sensors operatively coupled to the at least one rotor blade, a first sensor of the plurality of sensors is in a first location and in a failed state, a second sensor of the plurality of sensors is in an operating state, and wherein generating the fault adjustment signal further comprises: receiving data indicative of the operating condition from a second sensor located in a second location relative to the at least one rotor blade, wherein the second location is different from the first location; and applying a weighting factor to the data received from the second sensor so as to simulate acceptable data indicative of the operating condition from the first sensor, wherein the weighting factor adjusts a positional difference between the first and second sensors.

[0071] Clause 20. A wind turbine of any of the previous clauses, wherein the at least one rotor blade is a first rotor blade, wherein the sensor system is a first sensor system, the system further comprising a second sensor system having at least one sensor operably coupled to a second rotor blade, and wherein generating a fault regulation signal further comprises: receiving data indicative of an operating condition of the second rotor blade from the second sensor system; simulating an operating condition of the first rotor blade based on the operating condition of the second rotor blade as detected by the second sensor system; and emulating data indicative of the operating condition of the first rotor blade from the first sensor system based on the simulation.

Claims

1. A system for controlling a wind turbine, the system comprises: a sensor system including at least one sensor operably coupled to a component of the wind turbine to detect an operating condition of the component; and a controller communicatively coupled to the sensor system, the controller including at least one processor configured to perform a plurality of operations including: detecting, via a fault module, an output signal of the at least one sensor indicating a sensor fault; generating, via the fault module, a fault adjustment signal; and replacing the output signal of the at least one sensor with the fault adjustment signal so as to cause a change in an operating state of the wind turbine, wherein the at least one sensor includes a plurality of sensors operably coupled to the component, a first sensor of the plurality of sensors is located in a first position and is in a fault state, a second sensor of the plurality of sensors is located in a second position relative to the component and is in an operating state, wherein the second position is different from the first position, and wherein generating the fault adjustment signal further includes: receiving data indicating the operating condition from the second sensor; and applying a weighting factor to the data received from the second sensor so as to simulate acceptable data indicating the operating condition from the first sensor, wherein the weighting factor adjusts a positional difference between the first and second sensors.

2. The system according to claim 1, wherein the sensor system includes a plurality of sensors operably coupled to the component, a first sensor of the plurality of sensors is configured to monitor a first attribute of the component and is faulty, and wherein generating the fault adjustment signal further includes: receiving data indicating a second monitored attribute from a second sensor among the plurality of sensors, the first attribute being an attribute different from the second attribute; and applying a conversion factor to the data indicating the second monitored attribute so as to simulate acceptable data indicating the first monitored attribute from the first sensor.

3. The system according to claim 1, wherein the sensor system is a first sensor system, the system further includes a second sensor system having at least one sensor, and wherein generating the fault adjustment signal further includes: receiving data indicating an operating condition of the wind turbine from the second sensor system; simulating an operating condition of the component based on the operating condition of the wind turbine detected by the second sensor system; and simulating data indicating the operating condition of the component from the first sensor system based on the simulation.

4. The system according to claim 3, wherein the second sensor system has at least one environmental sensor configured to detect environmental conditions acting on the wind turbine and at least one operating sensor configured to detect a performance of the wind turbine in response to the environmental conditions, and wherein simulating the operating condition of the component includes: Based on a historical data set, for a detected environmental condition, correlate an operating condition of the component with a performance of the wind turbine, wherein the historical data set includes wind turbine performance points in response to various environmental conditions and corresponding operating conditions of the component at the various wind turbine performance points.

5. The system of claim 3, wherein, the component is a first component, and wherein the second sensor system is configured to monitor an operating condition of a second component of the wind turbine, and wherein simulating the operating condition of the first component includes: correlating the operating condition of the first component with the operating condition of the second component of the wind turbine.

6. The system of claim 3, wherein, generating the adjustment signal further includes: receiving data indicating a failure of the first sensor system from the first sensor system, wherein the first sensor system failure indicates a lack of sensor data within the first sensor system that can be used to simulate acceptable data from at least one of the plurality of sensors.

7. The system of claim 1, wherein, the system includes a blade monitoring system, and wherein the component includes a blade of the wind turbine.

8. The system of claim 5, wherein, the first component is a first blade of the wind turbine, and wherein the second component is a second blade of the wind turbine.

9. The system of claim 1, the plurality of operations further includes: reducing a load limit of the wind turbine in response to the generation of the fault adjustment signal.

10. A method for controlling a wind turbine, the method includes: receiving, via a controller, data indicating an operating condition of a component of the wind turbine from a sensor system, the sensor system including at least one sensor operably coupled to the component; detecting, via a fault module, an output signal of the at least one sensor indicating a sensor fault; generating, via the fault module, a fault adjustment response, the fault adjustment response including an adjustment signal that replaces the output signal indicating the sensor fault; causing, via the controller, a change in an operating state of the wind turbine at least based on the adjustment signal, wherein the at least one sensor includes a plurality of sensors operably coupled to the component, a first sensor of the plurality of sensors is located in a first position and is faulty, a second sensor of the plurality of sensors is located in a second position relative to the component and is in an operating state, wherein the second position is different from the first position, and wherein generating the fault adjustment signal further includes: receiving data indicating the operating condition from the second sensor; and applying a weighting factor to the data received from the second sensor to simulate acceptable data indicating the operating condition from the first sensor, wherein the weighting factor adjusts the positional difference between the first and second sensors.

11. The method of claim 10, wherein, The sensor system includes a plurality of sensors operably coupled to the component, a first sensor of the plurality of sensors being configured to monitor a first property of the component and being in a fault state, and wherein generating the fault adjustment signal further includes: Receiving data indicative of a second monitored property from a second sensor of the plurality of sensors, the first property being a property different from the second property; and Applying a conversion factor to the data indicative of the second monitored property so as to simulate acceptable data indicative of the first monitored property from the first sensor.

12. The method according to claim 10, wherein, the sensor system is a first sensor system, the system further includes a second sensor system having at least one sensor, and wherein generating the fault adjustment signal further includes: Receiving data indicative of the operating condition of the wind turbine from the second sensor system; Simulating the operating condition of the component based on the operating condition of the wind turbine detected by the second sensor system; and Based on the simulation, simulating data indicative of the operating condition of the component from the first sensor system.

13. The method according to claim 12, wherein, the component is a first component, and wherein the second sensor system is configured to monitor the operating condition of a second component of the wind turbine, and wherein simulating the operating condition of the first component includes: Correlating the operating condition of the first component with the operating condition of the second component of the wind turbine.

14. The method according to claim 13, wherein, the first component is a first blade of the wind turbine, and wherein the second component is a second blade of the wind turbine.

15. The method according to claim 12, wherein, generating the adjustment signal further includes: Receiving data indicative of a first sensor system fault from the first sensor system, wherein the first sensor system fault indicates a lack of sensor data within the first sensor system that is available for simulating acceptable data from at least one of the plurality of sensors.

16. A wind turbine, comprising: A tower fastened to a foundation; A nacelle mounted on top of the tower; A rotor mounted to the nacelle; At least one rotor blade mounted to the rotor; And A blade monitoring system operably coupled to the at least one rotor blade, the blade monitoring system including: A sensor system including at least one sensor operably coupled to the at least one rotor blade for detecting the operating condition of a component, and A controller communicatively coupled to the sensor system, the controller including at least one processor configured to perform a plurality of operations, the plurality of operations including: Detecting, via a fault module, an output signal of the at least one sensor indicative of a sensor fault, Generating, via the fault module, a fault adjustment signal, and Replace the output signal of the at least one sensor with the fault adjustment signal so as to cause a change in the operating state of the wind turbine, wherein the at least one sensor includes a plurality of sensors operatively coupled to the at least one rotor blade, a first sensor of the plurality of sensors is located in a first position and is in a fault state, a second sensor of the plurality of sensors is located in a second position relative to the at least one rotor blade and is in an operating state, wherein the second position is different from the first position, and wherein generating the fault adjustment signal further includes: Receiving data indicating the operating condition from the second sensor; and Applying a weighting factor to the data received from the second sensor so as to simulate acceptable data indicating the operating condition from the first sensor, wherein the weighting factor adjusts the positional difference between the first and second sensors.

17. The wind turbine according to claim 16, wherein, the at least one rotor blade is a first rotor blade, wherein the sensor system is a first sensor system, the system further includes a second sensor system having at least one sensor operatively coupled to a second rotor blade, and wherein generating the fault adjustment signal further includes: Receiving data indicating the operating condition of the second rotor blade from the second sensor system; Simulating the operating condition of the first rotor blade based on the operating condition of the second rotor blade detected by the second sensor system; and Simulating data indicating the operating condition of the first rotor blade from the first sensor system based on the simulation.

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