Rotor-Mounted Air Gap Measurement for Wind Turbine Stator Alignment
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Solution Overview
Problem
Existing methods for measuring the stator of a gearless wind turbine are inconvenient, time-consuming, and do not allow for direct measurement of adjustments, as they require frequent manual positioning of the rotor and lack the ability to determine the stator's circumferential position.
Innovation Solution
A measuring system and method where the air gap measuring unit and position determination unit are mounted on the rotor, allowing for detection of the air gap during rotation, eliminating the need for manual repositioning and enabling precise measurement of the stator and rotor runout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement methods are used with the turbine locked in place, then measurement accuracy can be achieved, but the measurement process becomes time-consuming and inconvenient
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated optical measurement system. A laser scanner or capacitive sensor automatically measures the air gap between rotor and stator, eliminating the need for technicians to manually measure distances while the turbine is locked in various positions. The measurement unit rotates with the rotor to continuously capture stator inner surface geometry.
Solution Approach 2:
The measurement system is pre-mounted on the rotor before measurement begins, with the sensor positioned to face the stator inner surface. The rotor is rotated to a measurement position in advance, and the measurement is automatically executed without requiring the turbine to be locked and unlocked multiple times for different measurement positions.
2Ease of operation
If the turbine is locked in place for manual measurement, then technicians can access the rotor hub, but the measurement process becomes inconvenient and requires frequent startup/locking
Solution Approach 1:
The measurement system performs measurements automatically without requiring technician intervention during the measurement process. The measurement unit on the rotor automatically scans the stator inner surface as the rotor rotates, and the evaluation unit processes the data to determine stator roundness and circumferential position, eliminating the need for technicians to repeatedly access the rotor hub.
Solution Approach 2:
The patent replaces manual measurement operations with an automated optical/electrical measurement system that operates independently of technician presence, allowing measurements to be taken without locking the turbine or requiring technician access to the rotor hub area.
3Measurement precision
If manual measurement at multiple positions is performed, then stator roundness can be assessed, but circumferential position information is lost
Solution Approach 1:
The measurement unit includes a position determination component that continuously tracks the circumferential position of the rotor during rotation. This position information is fed back to the evaluation unit, which correlates each measurement point with its specific circumferential position on the stator, enabling both roundness assessment and precise location identification of out-of-round areas.
Solution Approach 2:
The system adds a positional dimension to the measurements by incorporating circumferential position tracking. Instead of merely measuring air gap distances at unspecified positions, the system records both the distance measurement and the corresponding angular/circumferential position, creating a two-dimensional measurement dataset that enables precise localization of stator imperfections.
4Productivity
If the measurement unit is mounted on the rotor, then continuous measurement during rotation is possible, but the system complexity increases
Solution Approach 1:
The measurement unit mounted on the rotor serves multiple functions: it measures the air gap distance, determines the circumferential position, and enables continuous measurement during rotor rotation. This multi-functional design achieves high productivity through a single integrated system rather than multiple separate measurement devices.
Solution Approach 2:
The patent uses a laser scanner or capacitive sensor as an intermediary measurement device that can non-contactly measure the air gap between rotor and stator. This intermediary sensor enables accurate measurement without requiring direct physical contact or complex mechanical linkages, simplifying the overall system while maintaining high measurement efficiency.
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
Enables simplified and precise measurement of the stator and rotor, allowing for real-time adjustment without requiring technicians to access the rotor hub, and providing accurate data for stator alignment and correction of out-of-round areas.
Implementation Method 1
the air gap measuring unit (210) comprises a holding device (212) and a distance sensor (214)
Data Source
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AI summary
The invention relates to a measuring system (200) and an associated measuring method (300) for the measurement of a stator (132) of a gearless wind turbine (100), wherein the measuring system (100) has an air gap measuring unit (210) and a position determining unit (220), wherein the air gap measuring unit (210) has a holding device (212) and a distance sensor (214), wherein the holding device (212) is designed for mounting the air gap measuring unit (210) on a rotor (132) of the wind turbine (100), wherein the distance sensor (214) is designed to provide a signal which is indicative of an extent of an air gap (154) between stator (132) and rotor (134), wherein the position determining unit (220) is designed to be mounted on the rotor (134) of the wind turbine (100) and to detect the signal of the distance sensor (214) at multiple rotational positions during a rotation of the rotor (134). The measuring system (200) and the associated measuring method (300) permit simplified measurement of a stator.