Wind Turbine Gearbox Meshing Angle Tracking for Tonal Noise Control

Solution Overview

Problem

Existing methods for tracking the gear tooth meshing angle in wind turbine gearboxes require cumbersome and technically challenging measurements inside the gearbox, which are difficult to implement effectively.

Innovation Solution

A method that tracks the gear tooth meshing angle by monitoring the angular position of high speed and low speed shafts, estimating a virtual gear tooth meshing angle based on the monitored positions and gearbox topology, and resetting the reference angle after a calculated number of full rotations to maintain accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If measurements are taken inside the gearbox to track gear tooth meshing angle, then measurement precision is improved, but device complexity and ease of operation deteriorate

Engineering Contradiction:

Improvegear tooth meshing angle measurement precisionVSAvoidmeasurement system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses shaft position sensors as intermediary measurement points outside the gearbox to indirectly determine the gear tooth meshing angle. Instead of placing sensors inside the gearbox to directly measure gear tooth positions, the system measures the angular positions of the input and output shafts and uses these measurements to calculate the meshing angle through mathematical relationships, thereby avoiding the complexity of internal gearbox instrumentation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces direct mechanical measurement of gear tooth positions with an electrical/electronic measurement system that monitors shaft rotational positions. By substituting direct mechanical contact measurement inside the gearbox with non-contact shaft position sensing and computational calculation, the system achieves accurate meshing angle tracking while significantly reducing device complexity and improving ease of operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If measurements are taken inside the gearbox to track gear tooth meshing angle, then measurement precision is improved, but ease of operation worsens

Engineering Contradiction:

Improvegear tooth meshing angle measurement precisionVSAvoidmeasurement system operation ease

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent uses shaft position sensors as intermediary measurement points outside the gearbox to indirectly determine the gear tooth meshing angle. Instead of placing sensors inside the gearbox to directly measure gear tooth positions, the system measures the angular positions of the input and output shafts and uses these measurements to calculate the meshing angle through mathematical relationships, thereby avoiding the complexity of internal gearbox instrumentation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces direct mechanical measurement of gear tooth positions with an electrical/electronic measurement system that monitors shaft rotational positions. By substituting direct mechanical contact measurement inside the gearbox with non-contact shaft position sensing and computational calculation, the system achieves accurate meshing angle tracking while significantly reducing device complexity and improving ease of operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If virtual gear tooth meshing angle estimation is used instead of direct measurement, then device complexity is reduced, but measurement precision may worsen

Engineering Contradiction:

Improvemeasurement system complexityVSAvoidgear tooth meshing angle measurement precision

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent implements a feedback mechanism where the estimated virtual gear tooth meshing angle is continuously compared with actual gear meshing information when available. The system uses this feedback to correct and refine the estimation, ensuring that the calculated meshing angle maintains high precision despite being derived from indirect shaft position measurements rather than direct gear tooth sensing.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces direct mechanical measurement of gear tooth positions with an electrical/electronic measurement system that monitors shaft rotational positions. By substituting direct mechanical contact measurement inside the gearbox with non-contact shaft position sensing and computational calculation, the system achieves accurate meshing angle tracking while significantly reducing device complexity and improving ease of operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12264647B1Method for tracking a gear tooth meshing angle of a gearbox of a wind turbine

Publication Date: 2025.04.01 VESTAS WIND SYSTEMS AS

AI summary

A method for tracking a gear tooth meshing angle of a gearbox of a wind turbine is disclosed. An initial reference virtual gear tooth meshing angle of the gearbox is selected, and an angular position of a high speed shaft and/or a low speed shaft of the gearbox is monitored. A virtual gear tooth meshing angle relative to the reference virtual gear tooth meshing angle is estimated, based on the monitored angular position of the high speed shaft and/or the low speed shaft and on information regarding topology of the gearbox. A number of full rotations of the high speed shaft and/or the low speed shaft which corresponds to an integer number of full periods of gear meshing of the gearbox is calculated, and the reference virtual gear tooth meshing angle is reset each time the high speed shaft and/or the low speed shaft has performed the calculated number of full rotations. The estimated virtual gear tooth meshing angle is applied to a periodic noise signal of the wind turbine.