Adjustable Radial Weight Test Rig for Wind Turbine Fatigue
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Solution Overview
Problem
Current test rigs for structural components like wind turbines face limitations in accurately simulating long-term loading effects due to resonant frequency issues, leading to incomplete and inaccurate data collection, which can result in unexpected material fatigue and damage.
Innovation Solution
An adjustable radial weight test rig with a rotatable shaft and adjustable center of mass allows continuous operation, simulating a wider range of loads by altering centrifugal forces without interruption, enabling more informative and accurate stress and fatigue testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If a test rig operates at resonant frequency to collect comprehensive loading data, then the quantity of useful loading information increases, but the test rig and test setup may suffer damage due to amplified lateral forces
Solution Approach 1:
The test rig dynamically adjusts the radial weight position during operation, transitioning from a static configuration to a dynamic one. This allows the system to modify centrifugal forces in real-time, enabling safe passage through resonant frequency ranges while collecting comprehensive loading data across the full operational spectrum.
Solution Approach 2:
The invention changes the physical parameter of centrifugal force by adjusting the radial weight's distance from the rotation axis. By varying this parameter, the system can reduce forces during resonant frequency operation to prevent damage, then increase forces during safe operation to maximize data collection, thus resolving the contradiction between information completeness and safety.
2Device complexity
If a test rig uses fixed radial weights to generate centrifugal forces, then the device complexity is reduced, but the ability to accurately simulate varying real-life loading conditions deteriorates
Solution Approach 1:
The radial weight arrangement transitions from a fixed static configuration to a dynamic adjustable system. The weight can move radially along the rotation axis, allowing the test rig to adapt to different loading scenarios while maintaining a relatively simple overall structure.
Solution Approach 2:
The adjustable radial weight mechanism serves multiple functions: it can simulate various loading conditions by changing its radial position, it can adjust centrifugal force magnitude, and it can adapt to different resonant frequency ranges. This multi-functionality increases versatility without proportionally increasing device complexity.
3Productivity
If the test rig operates continuously without interruption to reduce testing time, then the productivity increases, but the accuracy of fatigue testing deteriorates due to resonant frequency gaps in data collection
Solution Approach 1:
The system changes the centrifugal force parameter by adjusting the radial weight position during continuous operation. This allows the test rig to maintain safe operating conditions while passing through resonant frequency ranges, eliminating the need for interruptions and ensuring complete data collection for accurate fatigue testing.
Solution Approach 2:
The invention enables continuous testing operation by dynamically adjusting the radial weight to avoid resonant frequency damage. This maintains the continuity of useful action (data collection) while preventing harmful effects, thus achieving both high productivity and high measurement precision.
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 approach reduces testing costs and time while providing comprehensive data for design improvements, ensuring longer component lifetimes and reducing maintenance needs for large structures like wind turbines.
Implementation Method 1
The test rig can be used for stress testing and/or fatigue testing of the component under test, by transferring the forces in some suitable manner to the component under test. In the context of the invention, the 'radial weight' is to be understood as a mass or weight mounted to the shaft by means of a radial 'arm' such that the greater portion of the mass is offset ally outward from the shaft
Implementation Method 2
any large structure with one or more degrees of freedom or 'elasticity' will have one or more resonant frequencies. This applies also to such a test setup in which a test rig is mounted to such a structure. The lateral force that is actually applied to the component under test can therefore be much greater than the magnitude of the centrifugal force itself if the lateral force is 'amplified' by the resonant behaviour of the test rig
Data Source
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AI summary
The invention describes a test rig (1) for testing a component (20, 21), which test rig (1) comprises an adjustable radial weight arrangement (11, 12) mounted on a rotatable shaft (10); a driving means (13) for rotating the shaft (10) at a shaft rotational velocity (ω); and an adjusting means (15, 150) for adjusting the centre of mass (CM_RW) of the adjustable radial weight arrangement (11, 12) relative to the shaft (10) while the shaft (10) is rotating. The invention further describes a wind turbine test setup (2) for testing components (20, 21) of a wind turbine, which wind turbine test setup (2) comprises such a test rig (1) mounted to a component (21) such that centrifugal forces (Fc) generated by the rotating radial weights (11, 12) during operation of the test rig (1) are transferred as lateral forces (FWT) to the wind turbine component (21) under test. The invention also describes a method of testing a component (20, 21), which method comprises mounting such a test rig (1) to the component under test (20, 21) and operating the test rig (1).