High-pressure variable pitch system and wind generating set

Abstract

The invention provides a high-voltage variable-pitch system and a wind generating set. The high-voltage variable-pitch system comprises a variable-pitch controller module, an integrated driver, a variable-pitch motor module, a capacitor backup power supply and a cooling module, the variable pitch controller module is connected with the integrated driver through a controller local area network open interface, the integrated driver is connected with the variable pitch motor module through a three-phase power line, the integrated driver is connected with the capacitor back-up power source through a direct-current power line, and the capacitor back-up power source is connected with the power management module arranged in the integrated driver. And the cooling module is arranged near the capacitor back-up power supply. The problems that a traditional low-pressure variable pitch system is high in failure rate, high in maintenance cost, low in intelligent degree and the like are solved. By adopting the technical means such as the variable-pitch motor module and the capacitor backup power supply, high integration and intelligent control of the system are realized, and the stability and reliability of the system are improved.

Description

Technical Field

[0001] This invention relates to the field of wind power generation, and more particularly to a high-voltage pitch system and a wind turbine generator set. Background Technology

[0002] In the field of wind power technology, the pitch system, as the core control unit of a wind turbine generator, directly determines the generator's power generation efficiency, safety and stability, and operation and maintenance costs. Low-voltage pitch systems, due to their high technological maturity, have been used in the industry for many years. However, traditional low-voltage pitch systems have gradually revealed many inherent defects in long-term actual operation, mainly in three aspects: First, the failure rate is relatively high, with core components susceptible to failure due to operating conditions, leading to an increase in unplanned shutdowns; second, maintenance costs are high, with troubleshooting and component replacement requiring significant human and material resources, and power generation losses during downtime further exacerbating economic costs; third, the level of intelligence is low, lacking accurate condition monitoring and prediction capabilities, making it difficult to adapt to the development needs of intelligent operation and maintenance in wind farms. Especially for older wind turbine generators with long service lives, their pitch systems generally use AC motors as drive components and batteries as backup power. This configuration has two major problems: First, the AC motor has poor output stability under low voltage conditions, and the battery has a limited charge-discharge cycle life and is easily affected by ambient temperature, which together lead to insufficient overall system stability and may cause safety accidents in extreme cases. Second, the battery needs to be tested for capacity and maintained by charging and discharging regularly, and the fault diagnosis of the AC motor relies on manual on-site inspection, which significantly increases the workload and operational risks of maintenance personnel.

[0003] To address these issues, several improved pitch control system solutions have been proposed in recent years. However, existing solutions still have significant shortcomings: in terms of system stability improvement, reliability issues have not been thoroughly resolved through the coordinated optimization of drive components and backup power; in terms of failure rate reduction, effective monitoring methods for the entire lifecycle status of key components are lacking; and in terms of intelligent control, dynamic and precise matching of pitch control actions with wind speed and turbine load has not been achieved. Therefore, current improved pitch control systems still cannot meet the actual needs of efficient, safe, and low-cost operation of wind turbine generators (especially in the retrofitting of older units) in terms of stability, reliability, and intelligence. Summary of the Invention

[0004] To address the above problems, this invention proposes a high-voltage pitch control system and a wind turbine generator set. The novel high-voltage pitch control system proposed in this invention solves the problems of high failure rate, high maintenance cost, and low level of intelligence inherent in traditional low-voltage pitch control systems. By employing pitch motor modules and capacitor backup power supplies, this invention achieves high system integration and intelligent control, improving system stability and reliability. Implementing this invention can significantly reduce the failure rate of wind turbine generator sets, increase unit availability, and thus reduce operation and maintenance costs. Simultaneously, the high-voltage pitch control system of this invention also has higher energy density and faster charging speed, ensuring the system's emergency feathering capability in the event of grid outages or anomalies, thereby improving unit safety.

[0005] This invention proposes a high-voltage pitch system, comprising:

[0006] Pitch controller module, integrated driver, pitch motor module, capacitor backup power supply, cooling module;

[0007] The pitch controller module is connected to the integrated driver via the Controller Area Network (CAN) open interface. The integrated driver is connected to the pitch motor module via a three-phase power line and to the capacitor backup power supply via a DC power line. The capacitor backup power supply is connected to the power management module built into the integrated driver. The cooling module is located near the capacitor backup power supply.

[0008] In addition, the pitch controller module integrates a pitch safety chain module.

[0009] In addition, the system also includes an independent impeller speed monitoring device, which is installed on the main shaft gear side of the impeller corresponding to the high-pressure pitch system. The independent impeller speed monitoring device is connected to the integrated drive.

[0010] In addition, the independent impeller speed monitoring device is connected to the integrated drive via an encoder signal line.

[0011] In addition, the sensors inside the independent impeller speed monitoring device are either magnetoelectric or photoelectric sensors.

[0012] In addition, the pitch motor module is a permanent magnet synchronous motor.

[0013] In addition, the cooling module includes: a heat sink, a fan, and a cold plate;

[0014] The radiator is connected to the fan, which uses forced convection to remove heat from the components in the high-voltage pitch system through the cold plate.

[0015] In addition, the high-voltage pitch system also includes the high-voltage pitch system cabinet;

[0016] The pitch controller module, integrated driver, pitch motor module, and capacitor backup power supply are located in the upper part of the high-voltage pitch system cabinet, while the cooling module is located in the lower part of the high-voltage pitch system cabinet.

[0017] The present invention also proposes a wind turbine generator set employing the high-voltage pitch system described in any of the preceding claims.

[0018] In addition, the high-voltage pitch system is located inside the hub of the wind turbine generator set or in the shaft control cabinet near the hub.

[0019] This invention proposes a novel high-voltage pitch control system that solves the problems of high failure rate, high maintenance cost, and low intelligence level of traditional low-voltage pitch control systems. By employing pitch motor modules and capacitor backup power supplies, this invention achieves high system integration and intelligent control, improving system stability and reliability. Implementing this invention can significantly reduce the failure rate of wind turbine generators, increase generator availability, and thus reduce operation and maintenance costs. Simultaneously, the high-voltage pitch control system of this invention also has higher energy density and faster charging speed, ensuring emergency feathering capability in the event of grid outages or anomalies, and improving generator safety. Attached Figure Description

[0020] Figure 1 This is an overall connection diagram of a high-voltage pitch system provided in one embodiment of the present invention;

[0021] Figure 2 An overall connection diagram of a high-voltage pitch system provided in another embodiment of the present invention;

[0022] Figure 3 This is a partial connection diagram of a high-pressure pitch system provided in another embodiment of the present invention. Detailed Implementation

[0023] The present invention will be further described in detail below with reference to specific embodiments and accompanying drawings. This description is intended only to illustrate the specific embodiments of the invention and does not constitute any limitation on the invention. The scope of protection of the invention is defined by the claims.

[0024] Reference Figure 1 This invention proposes a high-pressure pitch system, comprising:

[0025] Pitch controller module, integrated driver, pitch motor module, capacitor backup power supply, cooling module;

[0026] The pitch controller module is connected to the integrated driver via the Controller Area Network (CAN) open interface. The integrated driver is connected to the pitch motor module via a three-phase power line and to the capacitor backup power supply via a DC power line. The capacitor backup power supply is connected to the power management module built into the integrated driver. The cooling module is located near the capacitor backup power supply.

[0027] The controller LAN open interface corresponds to the CANopen interface. The pitch controller module communicates with the integrated driver through the CANopen interface to send angle commands and receive status feedback.

[0028] The integrated driver connects to the pitch motor module via a three-phase power line. Optionally, the pitch motor module is a permanent magnet synchronous motor, and the integrated driver is used to provide servo control.

[0029] The integrated driver connects to a capacitor backup power supply via a DC power line to achieve charge and discharge management.

[0030] The capacitor backup power supply is connected to the power management module built into the integrated drive, and provides control power and emergency feathering energy to the high-voltage pitch system through the power management module. The control power supply is, for example, 24V. The capacitor backup power supply is a supercapacitor backup power supply.

[0031] Optionally, the capacitor backup power supply is a supercapacitor backup power supply: using a supercapacitor as a backup power supply has higher energy density, longer service life and faster charging speed compared to traditional batteries, thus ensuring the system's emergency feathering capability in the event of a power grid failure or anomaly.

[0032] Optionally, the integrated driver, a highly integrated type of driver, integrates AC servo drive, PLC control, backup power supply charging and discharging management, and 24V power supply function, realizing a high degree of system integration and intelligent control.

[0033] The high-voltage pitch system operates as follows:

[0034] During normal pitch control: The pitch controller module sends a target angle command to the integrated driver via the CANopen interface based on the wind speed signal. The integrated driver controls the pitch motor module (optionally a permanent magnet synchronous motor) to rotate, adjusting the blade angle to the optimal wind capture state.

[0035] In emergency feathering: When the power grid fails or overspeed occurs, the capacitor backup power supply (optionally, a supercapacitor backup power supply) immediately supplies power to the integrated drive. The integrated drive triggers the pitch motor module to reverse, quickly turning the blades to a preset angle, such as 91°, to avoid the wind. At the same time, the pitch controller module (optionally, the pitch safety chain module inside the pitch controller module) disconnects the EFC (Emergency Feather Control) signal to ensure mechanical braking.

[0036] The novel high-voltage pitch control system proposed in this invention solves the problems of high failure rate, high maintenance cost, and low level of intelligence in traditional low-voltage pitch control systems. By employing pitch motor modules and capacitor backup power supplies, this invention achieves a high degree of system integration and intelligent control, thereby improving the system's stability and reliability.

[0037] Implementing this invention can significantly reduce the failure rate of wind turbine generator sets, improve the availability of the units, and thus reduce operation and maintenance costs. Simultaneously, the high-voltage pitch system of this invention also features higher energy density and faster charging speed, ensuring the system's emergency feathering capability in the event of grid outages or anomalies, thereby improving the safety of the unit.

[0038] This invention replaces low-voltage pitch with mature high-voltage pitch technology, thereby increasing the system's voltage level and enhancing its stability and anti-interference capabilities.

[0039] This system integrates AC servo drive, PLC control, backup power supply charging and discharging management, and 24V power supply functions through a highly integrated driver, thereby greatly improving the stability and reliability of the system.

[0040] In one embodiment, the pitch controller module integrates a pitch safety chain module.

[0041] The pitch safety chain module is integrated inside the pitch controller module. It uses hardware logic to detect system faults and triggers emergency feathering.

[0042] Reference Figure 3 In one embodiment, the system further includes an independent impeller speed monitoring device installed on the main shaft gear side of the impeller corresponding to the high-pressure pitch system. The independent impeller speed monitoring device is connected to the integrated drive. The integrated drive is shown in the figure as an integrated pitch drive.

[0043] By setting up an independent impeller speed monitoring device to measure the impeller speed in real time and automatically disconnecting the EFC signal when overspeed occurs, the safety of the system is improved.

[0044] In the closed-loop control of the system: the independent impeller speed monitoring device feeds back the speed to the integrated driver in real time. After comparing the speed with the target value, the motor torque of the pitch motor module is dynamically adjusted to achieve stable power output.

[0045] In one embodiment, the independent impeller speed monitoring device is connected to the integrated driver via an encoder signal line.

[0046] Optionally, an RS485 encoder signal cable (0.5mm diameter, 90% shielding coverage) is used for connection. One end of the encoder signal cable is connected to the encoder output port of the independent impeller speed monitoring device, and the other end is connected to the encoder input port of the integrated driver. Both ends of the encoder signal cable's shielding layer are grounded to reduce electromagnetic interference.

[0047] In one embodiment, the sensor inside the independent impeller speed monitoring device is a magnetoelectric sensor or a photoelectric sensor.

[0048] The magnetoelectric sensor can operate stably in a temperature range of -40℃ to 120℃ and is suitable for the internal environment of wheel hubs with a lot of dust and high humidity. It realizes speed acquisition by detecting the change in magnetic flux generated by the alternating changes of the tooth tip and tooth valley of the main shaft gear.

[0049] Photoelectric sensors calculate rotational speed by emitting light and receiving changes in the on / off state of reflected light. They are suitable for clean, dry shaft control cabinet environments and have a measurement accuracy 10% higher than that of magnetoelectric sensors.

[0050] In one embodiment, the pitch motor module is a permanent magnet synchronous motor.

[0051] Using a permanent magnet synchronous motor as the pitch motor module has advantages such as high power density, high operating efficiency, and self-heating, which reduces the system's energy consumption and heat generation.

[0052] Reference Figure 2 In one embodiment, the cooling module includes: a heat sink, a fan, and a cold plate;

[0053] The radiator is connected to the fan, which uses forced convection to remove heat from the components in the high-voltage pitch system through the cold plate.

[0054] The heatsink is directly connected to the fan, and forced convection is used to dissipate the heat from components such as integrated drivers through the cold plate, ensuring the stability of the system in high-temperature environments.

[0055] Optionally, the radiator, fan, and cold plate are all integrated into the high-voltage pitch system cabinet, located in the lower part of the cabinet, forming a closed-loop cooling system.

[0056] In one embodiment, the high-voltage pitch system also includes a high-voltage pitch system cabinet;

[0057] The pitch controller module, integrated driver, pitch motor module, and capacitor backup power supply are located in the upper part of the high-voltage pitch system cabinet, while the cooling module is located in the lower part of the high-voltage pitch system cabinet.

[0058] During installation, pay attention to the safe electrical distance between various electrical components, and reduce the space occupied by integrating various electrical components together.

[0059] The present invention also proposes a wind turbine generator set employing the high-voltage pitch system described in any of the preceding claims.

[0060] The novel high-voltage pitch control system proposed in this invention solves the problems of high failure rate, high maintenance cost, and low level of intelligence in traditional low-voltage pitch control systems. By employing pitch motor modules and capacitor backup power supplies, this invention achieves a high degree of system integration and intelligent control, thereby improving the system's stability and reliability.

[0061] Implementing this invention can significantly reduce the failure rate of wind turbine generator sets, improve the availability of the units, and thus reduce operation and maintenance costs. Simultaneously, the high-voltage pitch system of this invention also features higher energy density and faster charging speed, ensuring the system's emergency feathering capability in the event of grid outages or anomalies, thereby improving the safety of the unit.

[0062] This invention replaces low-voltage pitch with mature high-voltage pitch technology, thereby increasing the system's voltage level and enhancing its stability and anti-interference capabilities.

[0063] This system integrates AC servo drive, PLC control, backup power supply charging and discharging management, and 24V power supply functions through a highly integrated driver, thereby greatly improving the stability and reliability of the system.

[0064] In one embodiment, the high-voltage pitch system is located inside the hub of the wind turbine or in a shaft control cabinet near the hub.

[0065] The high-voltage pitch system is installed inside the hub of the wind turbine generator set. The output shaft of the pitch motor module is directly connected to the pitch bearing of the blade, reducing energy loss in the transmission process.

[0066] The high-voltage pitch system is located in the shaft control cabinet near the hub inside the wind turbine generator set, which makes it convenient for maintenance personnel to inspect and maintain the high-voltage pitch system from inside the nacelle without having to enter the hub, thus reducing maintenance risks.

[0067] As needed, the above technical solutions can be combined to achieve the best technical effect.

[0068] The above description is merely the principle and preferred embodiment of the present invention. It should be noted that, for those skilled in the art, several other modifications can be made based on the principle of the present invention, and these modifications should also be considered within the scope of protection of the present invention.

Claims

1. A high-voltage pitch control system, characterized in that, include: Pitch controller module, integrated driver, pitch motor module, capacitor backup power supply, cooling module; The pitch controller module is connected to the integrated driver via the Controller Area Network (CAN) open interface. The integrated driver is connected to the pitch motor module via a three-phase power line and to the capacitor backup power supply via a DC power line. The capacitor backup power supply is connected to the power management module built into the integrated driver. The cooling module is located near the capacitor backup power supply.

2. The high-voltage pitch system according to claim 1, characterized in that, The pitch controller module integrates a pitch safety chain module.

3. The high-voltage pitch system according to claim 1, characterized in that, The system also includes an independent impeller speed monitoring device, which is installed on the main shaft gear side of the impeller corresponding to the high-pressure pitch system. The independent impeller speed monitoring device is connected to the integrated drive.

4. The high-voltage pitch system according to claim 3, characterized in that, The independent impeller speed monitoring device is connected to the integrated driver via an encoder signal line.

5. The high-voltage pitch system according to claim 3, characterized in that, The sensors inside the independent impeller speed monitoring device are either magnetoelectric or photoelectric sensors.

6. The high-voltage pitch system according to claim 1, characterized in that, The pitch motor module is a permanent magnet synchronous motor.

7. The high-voltage pitch system according to claim 1, characterized in that, The cooling module includes: a heat sink, a fan, and a cold plate; The radiator is connected to the fan, which uses forced convection to remove heat from the components in the high-voltage pitch system through the cold plate.

8. The high-voltage pitch system according to claim 1, characterized in that, The high-voltage pitch system also includes the high-voltage pitch system cabinet; The pitch controller module, integrated driver, pitch motor module, and capacitor backup power supply are located in the upper part of the high-voltage pitch system cabinet, while the cooling module is located in the lower part of the high-voltage pitch system cabinet.

9. A wind turbine generator set, characterized in that, The high-pressure pitch system as described in any one of claims 1-8 is adopted.

10. The wind turbine generator set according to claim 9, characterized in that, The high-voltage pitch system is installed inside the hub of the wind turbine generator set or in the shaft control cabinet near the hub.

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