Wind Turbine Pitch and Tip Speed Ratio Control Under Thrust Limits

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Solution Overview

Problem

Existing wind turbine control methods struggle to maximize power production while effectively limiting rotor thrust, leading to component fatigue and reduced electricity generation due to high aerodynamic forces.

Innovation Solution

A method and controller that utilize an iterative search algorithm to optimize pitch angle and tip speed ratio, determining optimal values that maximize power coefficient while adhering to thrust coefficient constraints, using predefined data structures and sensor feedback to adjust rotor speed and blade pitch in real-time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the wind turbine operates at high power output, then electricity generation is maximized, but thrust loads on the rotor increase causing component fatigue

Engineering Contradiction:
Improveelectricity generationVSAvoidcomponent fatigue resistance
Core Design Contradiction:
ProductivityVSStrength

Solution Approach 1:

The patent implements dynamic control of rotor speed and blade pitch angle based on real-time wind conditions and thrust measurements. The system continuously adjusts operating parameters to operate at optimal points that maximize power production while keeping thrust loads within safe limits, rather than using fixed operating modes

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent uses thrust measurements from sensors mounted on the rotor or blades to provide feedback to the control system. This feedback loop allows the controller to monitor actual thrust levels and adjust pitch angle and rotor speed accordingly to maintain thrust within acceptable ranges while maximizing power output

Inventive Principle:
Principle #23Feedback

2Strength

If the pitch angle is increased to limit thrust, then thrust loads are reduced, but power production decreases

Engineering Contradiction:
Improvethrust load reductionVSAvoidpower production
Core Design Contradiction:
StrengthVSProductivity

Solution Approach 1:

The patent changes multiple operating parameters simultaneously - both pitch angle and rotor speed - to achieve the desired balance. By adjusting both parameters together based on the power coefficient and thrust coefficient curves, the system can reduce thrust while maintaining or improving power production compared to adjusting pitch alone

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The system dynamically determines optimal pitch angle and rotor speed combinations based on current wind conditions and thrust measurements. The control algorithm continuously searches for operating points that maximize power production while keeping thrust below thresholds, adapting to changing conditions in real-time

Inventive Principle:
Principle #15Dynamics

3Productivity

If the rotor speed is increased to maximize power output, then electricity generation increases, but aerodynamic forces and thrust loads increase

Engineering Contradiction:
Improveelectricity generationVSAvoidaerodynamic forces
Core Design Contradiction:
ProductivityVSForce

Solution Approach 1:

The control system uses thrust measurements as feedback to adjust rotor speed. When thrust levels indicate high aerodynamic forces, the controller reduces rotor speed to bring thrust back within acceptable ranges, while still maintaining optimal power production points when conditions allow

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent implements dynamic rotor speed control that adapts to real-time wind conditions and thrust measurements. The system operates at variable speeds optimized for each moment's conditions rather than maintaining constant high speed, maximizing the balance between power production and force management

Inventive Principle:
Principle #15Dynamics

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 power production while protecting the wind turbine from excessive thrust loads, ensuring efficient operation and prolonged component lifespan by dynamically adjusting to varying wind conditions.

Implementation Method 1

converting the kinetic energy from incoming wind into electrical energy

Methodology Applied
Scientific EffectAerodynamic forces: Drag

Implementation Method 2

The blades and the rotor enable the wind turbine to deliver power to the grid by converting the kinetic energy from incoming wind into electrical energy

Methodology Applied
Scientific EffectWind power conversion: Wind Power

Data Source

PatentUS20250382942A1Wind turbine control to maximise power production with a thrust limit
Publication Date: 2025.12.18 VESTAS WIND SYSTEMS AS
  • US20250382942A1 patent drawing
  • US20250382942A1 patent drawing
  • US20250382942A1 patent drawing

AI summary

The invention relates to controlling a wind turbine. A predefined power coefficient data structure and a predefined thrust coefficient data structure respectively comprise values of a power coefficient and a thrust coefficient as functions of blade pitch angle and tip speed ratio. The invention includes using an iterative search algorithm to determine values of pitch angle and tip speed ratio that maximise the power coefficient value in the predefined power coefficient data structure subject to a constraint that the thrust coefficient value in the predefined thrust coefficient data structure is no greater than a maximum threshold thrust coefficient value. A rotor speed reference is determined based on the determined tip speed ratio value and on a received wind speed. The determined pitch angle value is set as a pitch angle reference. The wind turbine is controlled in accordance with the pitch angle and tip speed ration references.