Hydrostatic Jacking for Wind Turbine Bearing Wear
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Solution Overview
Problem
Current rolling element bearing systems in wind turbines lack adequate lifetime and robustness, leading to issues with wear and friction in plain/sliding bearings, especially during start-up and shut-down, and the stick-slip phenomenon due to high stiction and incomplete hydrodynamic film separation.
Innovation Solution
Implementing an intelligent and controlled hydrostatic jacking system that switches between hydrodynamic and hydrostatic modes based on turbine loading, lubricant conditions, and maintenance status, using sensors to monitor and adjust pressure and temperature for optimal bearing performance and extended lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If plain/sliding bearings are used to improve lifetime and robustness, then bearing durability is improved, but wear and friction increase during start-up and shut-down operations
Solution Approach 1:
The system applies hydrostatic pressure to the bearing surface before the rotor starts rotating, creating a lubricating film in advance. This preliminary action prevents direct contact between bearing surfaces during the critical start-up phase, eliminating wear and friction before they can occur.
Solution Approach 2:
The invention uses a hydraulic system to generate high pressure lubricant flow that forces a lubricating film between the bearing surfaces. This hydraulic approach creates sufficient pressure to separate the surfaces completely, eliminating solid contact and associated wear during start-up and shut-down operations.
2Object-generated harmful factors
If hydrodynamic bearing operation is used to reduce friction, then friction is reduced during normal operation, but stiction and stick-slip phenomenon occur during start-up and shut-down
Solution Approach 1:
The system establishes hydrostatic pressure support before motion begins, creating a lubricating film that eliminates stiction. This preliminary film formation allows the rotor to start rotating smoothly without the stick-slip phenomenon that plagues conventional hydrodynamic bearings during transition from static to dynamic operation.
Solution Approach 2:
The invention changes the operational parameters of the bearing by switching from pure hydrodynamic operation to hydrostatic support during start-up and shut-down. This parameter change involves applying external pressure to the lubricant to maintain film separation when the rotor speed is too low for hydrodynamic effects to occur naturally.
3Object-generated harmful factors
If bearing pressure is increased to maintain film separation, then wear is reduced, but system complexity increases
Solution Approach 1:
The system is designed to automatically activate hydrostatic pressure support when the rotor speed drops below the threshold for effective hydrodynamic operation. This self-service capability eliminates the need for complex external control systems, as the bearing intelligently switches between hydrostatic and hydrodynamic modes based on operating conditions.
Solution Approach 2:
The lubrication system is designed to perform multiple functions: it provides hydrostatic support during start-up and shut-down, transitions to hydrodynamic support during normal operation, and can operate in fault mode with reduced pressure. This multi-functionality reduces the need for separate systems for different operating conditions, simplifying the overall design.
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
This solution reduces wear and friction, increases load-carrying capacity, and allows operation with damaged or worn bearings by maintaining hydrostatic pressurization during start-up and shut-down, thereby extending the bearing's operational life and preventing unplanned maintenance.
Implementation Method 1
Operating the bearing as a hydrodynamic bearing in normal operation
Implementation Method 2
Operating the bearing as a hydrostatic bearing when the friction of the bearing reaches a threshold
Data Source
Figure 1
Figure 2(a)~2(c)
Figure 3(a)~3(b)
AI summary
Method for controlling a wind turbine (1) with a plain/sliding bearing (2) and bearing lubrication means (7), comprising the steps of: - Operating the bearing (2) as a hydrodynamic bearing (HD) in normal operation; and - Operating the bearing (2) as a hydrostatic bearing (HS) when the friction of the bearing (2) reaches a threshold.