Wind Turbine Rotor Lock Disengagement Using Counter-Torque Feedback

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Solution Overview

Problem

During wind turbine construction, deconstruction, and maintenance, the rotor lock may experience frictional interference due to minor movements, leading to potential damage from incorrect application of torque by the user, particularly affecting the rotor lock and bearings.

Innovation Solution

A method involving a sensor system to determine the direction of rotor torque, applying a rotor-drive counter-torque to oppose the rotor-lock counter-torque, and disengaging the rotor-lock mechanism, with a torque restriction preventing incorrect torque application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a user applies torque to the rotor using a rotor drive to reduce frictional interference, then the rotor lock can be unlocked, but the user may apply torque in the incorrect direction, increasing frictional interference and potentially damaging bearings

Engineering Contradiction:

Improverotor lock unlockingVSAvoiddamage to bearings and rotor lock

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The control system receives signals from sensors that detect the direction of rotor torque and the state of the rotor lock. Based on this feedback, the control system automatically determines the correct unlocking direction and applies torque through the rotor drive system only in that direction, preventing users from applying torque in the wrong direction and causing damage.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system uses sensors to automatically detect the rotor's current state and the direction of frictional interference, then the control system self-regulates the rotor drive system to apply torque in the correct direction without requiring user judgment or manual intervention to determine the proper unlocking direction.

Inventive Principle:

Principle #25Self-service

2Stability of the object's composition

If the rotor lock is used to fix the rotor in position during construction and maintenance, then the rotor is secured, but minor movements of the rotor create frictional interference that prevents unlocking

Engineering Contradiction:

Improverotor position stabilityVSAvoidrotor lock unlocking

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

Before attempting to unlock the rotor lock, the control system first detects the direction of frictional interference using sensors. Then, the rotor drive system applies a preliminary torque in the opposite direction to overcome the frictional interference and create the necessary movement clearance, enabling subsequent successful unlocking of the rotor lock.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If torque restriction is applied to prevent incorrect torque direction, then damage to components is prevented, but the system complexity increases due to sensor systems and control logic

Engineering Contradiction:

Improveprotection against component damageVSAvoidsensor system and control logic

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sensor system serves multiple functions: it detects the direction of rotor torque, determines the state of the rotor lock, identifies the correct unlocking direction, and provides feedback to the control system. This multi-functionality reduces the need for separate dedicated sensors and control logic for each function, thereby minimizing the increase in system complexity while maintaining comprehensive protection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Prevents damage to the wind turbine by ensuring the torque is applied in the correct direction, reducing frictional interference and safeguarding components like the rotor lock and bearings.

Implementation Method 1

the rotor comprising one or more blades, which due to the gravitational pull, generate a rotor torque which is opposed by a rotor-lock counter-torque from the rotor-lock

Methodology Applied

Scientific EffectGravitational pull: Gravitation

Implementation Method 2

the rotor lock may have a frictional interference with the rotor, which may prevent unlocking of the rotor lock

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12553417B2Rotor drive system assisted disengagement of the rotor-lock mechanism

Publication Date: 2026.02.17 VESTAS WIND SYSTEMS AS

AI summary

A method of disengaging a rotor-lock of a wind turbine, the rotor comprising one or more blades, which due to the gravitational pull, generates a rotor torque which is opposed by a rotor-lock counter-torque from the rotor-lock, the method comprising: a) determining a direction of the rotor torque with a sensor system; b) applying a rotor-drive counter-torque to the rotor with a rotor-drive system, wherein the rotor-drive counter-torque acts to oppose the determined rotor torque and causes the rotor-lock counter-torque to reduce; c) during or after the application of the rotor-drive counter-torque, disengaging the rotor-lock mechanism; wherein the step of determining a direction of the rotor torque comprises applying a torque restriction to the rotor-drive based on the determined direction of the rotor torque, the torque restriction preventing the application of torque to the rotor by the rotor-drive system in the same direction as the rotor torque.