Wind Turbine Generator Torque Modulation for Gearbox Vibration

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Solution Overview

Problem

Wind turbines generate structure-borne vibrations and associated noise, particularly from gear tooth meshing in the gearbox, which can exceed allowable noise limits and disturb neighbors or animal life.

Innovation Solution

A method for controlling generator operation by generating a torque modulating signal based on gearbox vibrations, adjusting phase and amplitude to minimize resultant vibrations, and injecting this signal into the generator to cancel out gearbox vibrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the generator operates at high power output, then energy production increases, but gearbox vibrations from gear tooth meshing increase and exceed noise limits

Engineering Contradiction:

Improveenergy productionVSAvoidnoise emissions

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary anti-action by generating a torque modulating signal before the harmful vibrations occur, based on predicted gearbox vibrations from gear tooth meshing. This signal is injected into the generator to create counter-vibrations that cancel out the harmful vibrations in advance, allowing high power operation without exceeding noise limits

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The patent converts the harmful gearbox vibrations into a useful control signal. By predicting the vibrations from gear tooth meshing and using them to generate a torque modulating signal, the harmful vibrations are transformed into a basis for creating beneficial counter-vibrations that reduce overall noise emissions

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Object-affected harmful factors

If a torque modulating signal is injected into the generator to reduce gearbox vibrations, then noise emissions decrease, but the complexity of the control system increases

Engineering Contradiction:

Improvenoise emissionsVSAvoidcontrol system complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by predicting gearbox vibrations in advance based on operating parameters and gear tooth meshing characteristics. This prediction allows the control system to prepare the appropriate torque modulating signal before the vibrations occur, simplifying the control approach compared to reactive methods that would require complex real-time vibration measurement and response systems

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The control system uses the generator's own operational parameters and characteristics to generate the torque modulating signal. By leveraging existing sensor data and generator models, the system creates its own control signal without requiring external complex vibration measurement and analysis equipment, thereby reducing overall system complexity

Inventive Principle:

Principle #25Self-service

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

Reduces noise emissions from the wind turbine by minimizing vibrations from gear tooth meshing, providing valuable information for monitoring the condition of the turbine and enabling coordinated control across multiple turbines.

Implementation Method 1

obtaining a measure for vibrations originating from gear tooth meshing of a gearbox of the wind turbine, at the rotational speed of the generator

Methodology Applied

Scientific EffectVibration: Vibration

Implementation Method 2

determining at least one amplitude of a harmonic in the gearbox vibrations, generating a torque modulating signal for the generator by: selecting an initial phase angle and an initial amplitude, based on the rotational speed of the generator, on initial characteristics of the wind turbine, and on the at least one amplitude of the harmonic in the gearbox vibrations

Methodology Applied

Scientific EffectResonance: Resonance

Data Source

PatentUS20260063105A1Method for handling gearbox vibrations in a wind turbine

Publication Date: 2026.03.05 VESTAS WIND SYSTEMS AS

AI summary

A method and control system for controlling operation of a generator for a wind turbine is disclosed. The method and control system obtain a measure for a rotational speed of the generator and a measure for gearbox vibrations corresponding to a gearbox of the wind turbine; determine at least one amplitude of a harmonic in the gearbox vibrations; generate a torque modulating signal for the generator by: selecting an initial phase angle and an initial amplitude, based on the rotational speed of the generator and on the at least one amplitude of the harmonic in the gearbox vibrations, adjusting the initial phase angle and the initial amplitude, and generating a torque modulating signal based on the adjusted phase angle and the adjusted amplitude; and inject the torque modulating signal into the generator.