Wind Turbine Azimuth Drive Pinion Alignment Monitoring
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Solution Overview
Problem
Wind turbines experience high loads and frequent load peaks in turbulent winds, leading to misalignment of the drive pinion in the azimuth bearing, which can cause wear and damage to the pinion shaft bearing, resulting in uneven load distribution and potential tooth breakage, necessitating costly repairs and extended downtimes.
Innovation Solution
Incorporation of sensor units, such as inductive and mechanical sensors, to detect deviations in the alignment of the pinion axis relative to a reference alignment, allowing for early detection of misalignment and potential faults, thereby preventing further damage to the yaw gearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the drive pinion operates under high loads and frequent load peaks in turbulent winds, then the wind turbine can generate power in various wind conditions, but the drive pinion deviates from its reference alignment causing wear and damage to the pinion shaft bearing
Solution Approach 1:
The sensor unit continuously monitors the alignment of the drive pinion before serious damage occurs, enabling early detection of misalignment. This preliminary monitoring allows maintenance to be performed before the bearing wear progresses to tooth breakage, preventing catastrophic failures while maintaining productivity.
2Duration of action of stationary object
If the pinion shaft bearing becomes defective allowing the drive pinion to deflect, then the wind turbine can continue operating with bearing wear, but the gearing of the drive pinion can no longer mesh properly leading to tooth breakage
Solution Approach 1:
The sensor unit provides continuous feedback on the alignment status of the drive pinion. When misalignment exceeds a threshold indicating bearing defects, the system generates an alarm signal that triggers maintenance intervention. This feedback loop prevents the progression from bearing wear to gear tooth breakage by enabling timely maintenance while maintaining operational continuity.
3Ease of repair
If early detection of pinion shaft bearing damage is implemented through sensor units, then repair costs and downtime are reduced, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical monitoring systems with a simple sensor unit that uses electromagnetic or capacitive fields to detect alignment deviations. This substitution maintains ease of repair by providing clear, actionable alarm signals while minimizing the complexity of the monitoring system itself, requiring only basic sensor installation and threshold-based evaluation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Early detection of misalignment enables proactive maintenance, reducing the risk of serious damage and downtime by allowing for timely repairs, minimizing repair costs and ensuring optimal power transmission.
Implementation Method 1
at least one sensor unit (160) which is configured to detect a deviation in the alignment of the pinion axis (R) relative to the reference alignment
Implementation Method 2
sensor units, such as inductive and mechanical sensors, to detect deviations in the alignment of the pinion axis
Data Source
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AI summary
The invention relates to a wind turbine (100) with an azimuth bearing (120) having an azimuth toothing (124) and at least one azimuth drive (112) coupled to an azimuth gearbox (144) corresponding to the azimuth toothing (124), wherein the azimuth gearbox (144) has a drive pinion (140) rotatable about a pinion axis, the drive pinion (140) being configured to engage with the corresponding azimuth toothing (124) of the azimuth bearing (120), the pinion axis having a predetermined reference orientation. The invention proposes that the wind turbine (100) has at least one sensor unit (160) configured to detect a deviation of the pinion axis's orientation relative to the reference orientation.