Dual-Circuit Cooling Layout for Fault-Tolerant Wind Turbines
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Solution Overview
Problem
Conventional cooling systems for wind turbines, especially offshore units, fail to meet reliability requirements, leading to increased maintenance costs and power generation losses due to complex and difficult-to-maintain layouts.
Innovation Solution
A dual-circuit cooling system with independent cooling circuits that allow for fault-tolerant operation, where one circuit can operate in standby mode to ensure continuous operation even if the other fails, utilizing a heat exchange module with separate passages for coolant exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional cooling system is used, then the structure is simple, but the reliability is insufficient
Solution Approach 1:
The cooling system is divided into two independent cooling circuits (first cooling circuit and second cooling circuit), each capable of operating independently to cool the wind turbine components. This segmentation ensures that if one circuit fails, the other can continue to provide cooling, thereby improving reliability without requiring a completely complex system architecture.
Solution Approach 2:
The patent implements a redundant cooling circuit design where a standby cooling circuit is prepared in advance. When the active cooling circuit fails, the standby circuit can immediately take over, providing prior cushioning against cooling system failures. This approach enhances reliability by having backup capacity ready before failures occur.
2Reliability
If a redundant cooling system is implemented, then the reliability is improved, but the maintenance difficulty increases
Solution Approach 1:
By segmenting the cooling system into two independent circuits with separate heat exchangers and coolant loops, the patent enables isolated maintenance of individual components. Each circuit can be serviced independently without shutting down the entire cooling system, reducing maintenance complexity despite the redundant architecture.
Solution Approach 2:
The standby cooling circuit automatically takes over cooling functions when the active circuit requires maintenance or fails, enabling the system to service itself without external intervention. This self-service capability reduces maintenance difficulty by eliminating the need for complex manual switching or system shutdowns during routine maintenance.
3Productivity
If offshore wind turbines are used, then the power generation capacity increases, but the maintenance difficulty increases due to special environment
Solution Approach 1:
The redundant cooling circuit design provides prior cushioning against failures in offshore environments where maintenance access is difficult. The standby circuit ensures continuous cooling operation even when one circuit fails, preventing shutdowns and reducing the need for costly offshore maintenance interventions.
Solution Approach 2:
The automated failover capability between cooling circuits enables the offshore wind turbine to service its own cooling system without external assistance. When one circuit fails, the other automatically assumes the cooling load, eliminating the need for immediate maintenance personnel intervention in the challenging offshore environment.
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
Enhances reliability and reduces shutdowns, improving wind turbine availability and maintaining cooling efficiency through redundant circuit design and simplified layout.
Implementation Method 1
a first coolant in the first cooling circuit and/or a second coolant in the second cooling circuit is configured to flow through the first passage of the heat exchange module, to exchange heat with a third coolant which flows through the second passage of the heat exchange module
Data Source
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AI summary
A cooling system, comprising: a heat exchange module, wherein the heat exchange module at least comprises a first channel and a second channel that are independent from each other; a first cooling circuit, wherein the first cooling circuit is connected to the first channel of the heat exchange module; and a second cooling circuit, wherein the second cooling circuit is connected to the first channel of the heat exchange module, and a first coolant in the first cooling circuit and/or a second coolant in the second cooling circuit can flow through the first channel of the heat exchange module so as to be used for performing heat exchange with a third coolant that flows through the second channel of the heat exchange module. According to the cooling system, the reliability of the cooling system can be improved by means of the design of dual cooling circuits.