Decentralized Actuator Bracing for Wind Turbine Drive Units
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Solution Overview
Problem
Existing adjustment and drive units for wind turbines and large slewing gears face issues with dynamic effects due to mobility and elasticity in the drive train, leading to increased wear, overloading, and prolonged downtimes, especially under unfavorable conditions.
Innovation Solution
The implementation of intelligent actuators that communicate directly with each other to distribute drive torque and provide auxiliary torque to prevent overloading, using decentralized control modules to evaluate load signals and adjust torque levels dynamically, reducing the need for central control intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If actuators are braced against one another with high tension to suppress dynamic effects, then dynamic stability improves, but actuator load and wear increase
Solution Approach 1:
The patent implements dynamic bracing where the tension between actuators is continuously adjusted based on actual operating conditions. The control system monitors load signals and dynamically modifies the bracing force, allowing high stability when needed while reducing unnecessary loads during normal operation. This transforms the static bracing concept into a dynamic, adaptive system that optimizes the trade-off between stability and actuator loading.
Solution Approach 2:
The invention changes the bracing parameter from a fixed high tension state to a variable state that adapts to operating conditions. By modifying the tension parameter dynamically based on load signals and operational phase, the system achieves high stability when required while minimizing actuator wear and loading during normal operation, effectively resolving the contradiction between stability and strength requirements.
2Stability of the object's composition
If service brake is applied to suppress dynamic fluctuations, then dynamic effects are controlled, but wear on brakes and actuators increases
Solution Approach 1:
The patent replaces the mechanical service brake system with an intelligent actuator bracing system. Instead of using friction-based brakes to suppress dynamic effects, the invention uses controlled electromagnetic or hydraulic actuators that can apply precise counter-forces without the wear associated with mechanical braking. This substitution eliminates brake wear while maintaining dynamic control capability.
Solution Approach 2:
The actuators serve dual functions: they perform the primary adjustment function and simultaneously provide dynamic suppression through their bracing action. This self-service capability eliminates the need for separate brake components, reducing overall system wear and maintenance requirements while maintaining effective dynamic control.
3Force
If actuators are oversized to overcome braking force, then adjustment capability is maintained, but device complexity and space requirements increase
Solution Approach 1:
The invention extracts the braking function from the actuator system, separating it into a distinct control mechanism. This allows actuators to be sized only for their primary adjustment function without the excessive capacity needed to overcome brake forces. The braking action is provided independently through the control system's ability to coordinate actuators, eliminating the need for oversized components.
4Speed
If decentralized control is implemented for rapid response, then control speed improves, but system complexity increases
Solution Approach 1:
The control system is segmented into decentralized control units, each responsible for specific actuators. This segmentation enables parallel processing of control decisions, dramatically improving response speed. Each control unit can independently evaluate load signals and adjust actuator bracing without waiting for central controller approval, while the modular architecture manages complexity through standardized interfaces and protocols.
Data Source
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Figure 3~4(a)
AI summary
The invention relates to adjustment and/or drive units that can be used in wind turbines to set the azimuth angle of the wind turbine nacelle or the pitch angle of the rotor blades. Such an adjustment and/or drive unit has at least two actuating drives for rotating two assemblies, which are mounted for rotation relative to each other, and has a control device for controlling the actuating drives, which control device controls the actuating drives in such a way that the actuating drives are braced in relation to each other during the rotation of the two assemblies and/or at a standstill of the assemblies. The invention further relates to a wind turbine having such an adjustment and/or drive unit and to a method for controlling such an adjustment and/or drive unit. According to the invention, the actuating drives are connected for communication with other each other and each have a control module for the decentralized adjustment of the provided torque in accordance with load signals of load-determining devices, which determine the individual load of each actuating drive, wherein said control modules of the actuating drives are configured to change, upon receipt of a load signal from another actuating drive that indicates that overloading of said other actuating drive has been reached, its own torque by an auxiliary torque amount in order to relieve said other actuating drive.