Auxiliary Wind Turbine Controller for Low-Cost Component Upgrades

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Solution Overview

Problem

Upgrading wind turbine components to improve performance and extend operational lifetime is costly due to the need to adapt the existing wind turbine controller, which is prohibitively expensive.

Innovation Solution

Implementing an auxiliary controller that augments the wind turbine controller, allowing for the integration of new components without replacing or altering the existing controller, by receiving control signals, transmitting feedback, and substituting control signals as needed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the wind turbine controller is adapted to accommodate new components, then the performance and operational lifetime of the wind turbine can be improved, but the cost of upgrading becomes prohibitively expensive

Engineering Contradiction:
Improveoperational lifetimeVSAvoidcontroller adaptation cost
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The control system is segmented into two independent parts: the existing wind turbine controller and a new auxiliary controller. The auxiliary controller handles specific functionalities (such as pitch control) while the main controller continues to operate independently, eliminating the need to adapt the original controller and thus avoiding prohibitively expensive modifications while still enabling component upgrades

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The auxiliary controller acts as an intermediary between the main wind turbine controller and the control system. It receives control signals from the main controller, processes them according to new control strategies, and outputs modified control signals to the actuators. This intermediary approach allows integration of new components without altering the original controller

Inventive Principle:
Principle #24Intermediary (Mediator)

2Productivity

If the wind turbine controller is replaced to accommodate new components, then the performance can be improved, but the complexity and cost of the upgrade increases

Engineering Contradiction:
Improvepower productionVSAvoidcontroller replacement complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The control functionality is divided between the existing main controller and a new auxiliary controller. The auxiliary controller specifically handles power production optimization functions while the main controller maintains overall system management, allowing performance improvement without replacing the entire controller system

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The auxiliary controller is designed with multi-functionality to handle various control tasks (pitch control, power optimization, etc.) while working alongside the main controller. This universal approach allows a single auxiliary device to provide multiple performance enhancements without requiring multiple separate controller replacements

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentUS12473890B2Auxiliary controller for wind turbine control system
Publication Date: 2025.11.18 VESTAS WIND SYSTEMS AS
  • US12473890B2 patent drawing
  • US12473890B2 patent drawing
  • US12473890B2 patent drawing

AI summary

The disclosure relates to a method, as well as a related wind turbine and computer program product, for use with a wind turbine comprising a wind turbine controller. The method comprises determining the wind turbine to be in a first operational state, and operating a control system of the wind turbine using the wind turbine controller. The method further comprises determining the wind turbine to be in a second operational state, and operating the control system using an auxiliary controller. Operating the control system using the auxiliary controller comprises receiving a first control signal for the control system from the wind turbine controller, transmitting a feedback signal to the wind turbine controller in accordance with the first control signal, and transmitting a second control signal to the control system as a substitute for the first control signal.