Bearing Current Monitoring for Wind Turbine Fault Prediction

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Solution Overview

Problem

Current monitoring systems for large-scale rotating systems, such as wind turbines, fail to detect all potential failure modes in time, leading to reduced uptime and maintenance inefficiencies.

Innovation Solution

A monitoring arrangement that includes measurement devices to detect electrical current flow at the main bearing, comparing it with predetermined profiles to predict potential failures, using coils around the main shaft to measure current without interfering with the system and minimizing maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If current monitoring systems monitor vibrations and lubricant pressure parameters, then availability of wind turbines is improved, but failure modes are not detected in time

Engineering Contradiction:

ImproveavailabilityVSAvoiddetection capability

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent replaces mechanical monitoring systems (vibration sensors, pressure gauges) with an electrical measurement system that detects current flow through the bearing. This substitution enables detection of electrical discharge currents that cause bearing damage, providing earlier and more precise detection of failure modes while maintaining improved availability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If measurement devices are installed at the main bearing to detect current flow, then fault prediction capability is improved, but device complexity increases

Engineering Contradiction:

Improvefault prediction capabilityVSAvoidmonitoring arrangement complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces an intermediary measurement device that detects current flow in the proximity of the main bearing without requiring direct contact or disassembly of the bearing. This intermediary approach enables fault prediction through electrical measurement while minimizing structural complexity and interference with the existing bearing system.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If coils are arranged around the main shaft to measure current, then measurement capability is improved, but interference with the system increases

Engineering Contradiction:

Improvecurrent flow measurementVSAvoidsystem interference

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the measurement function from direct contact with the bearing and shaft by using coils arranged around the main shaft to detect current flow in the proximity of the bearing. This extraction enables accurate current measurement while minimizing physical interference and avoiding disruption to the rotating system's operation.

Inventive Principle:

Principle #2Taking out (Extraction)

4Reliability

If real-time monitoring is implemented to provide timely alarms, then uptime is improved, but maintenance needs increase

Engineering Contradiction:

ImproveuptimeVSAvoidmaintenance efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent implements preliminary detection of bearing degradation through continuous current flow monitoring and comparison with reference values. By detecting early signs of electrical discharge currents before actual bearing failure occurs, the system enables planned maintenance activities, improving uptime while optimizing maintenance scheduling rather than increasing unnecessary maintenance interventions.

Inventive Principle:

Principle #10Preliminary action

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

Enables real-time condition assessment and early fault prediction, increasing the efficiency and durability of rotating systems by providing timely alarms and reducing maintenance needs.

Implementation Method 1

a first measurement device configured to be arranged at a first location in proximity of the main bearing for determining a first measurement indicative of a current flow at the first location

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS9803618B2Monitoring and fault prediction in relation to a mechanical component of a rotating system

Publication Date: 2017.10.31 AB SKF SKF PATENT DEPARTMENT

AI summary

The present invention relates to a system configured to monitor a condition of a rotating system comprising a main bearing, the monitoring arrangement having a first measurement device configured to be arranged at a first location in proximity of the main bearing for determining a first measurement indicative of a current flow at the first location, and a control unit connected to the measurement device. The control unit is further configured to form a first parameter based on the first measurement, match the first parameter with a plurality of predetermined current flow profiles, each of the plurality of predetermined current flow profiles being indicative of a condition of the rotating system, determine, if a matching current flow profile is found, a relevance level for the corresponding condition, and provide an indication of an alarm if the relevance level is above a predetermined threshold.