Rotor Speed Detection Using Redundant Sensor Units
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Solution Overview
Problem
Existing systems for detecting and monitoring rotor speed in wind turbines are maintenance-intensive and difficult to calibrate, with a risk of overspeed detection failures leading to system destruction, and require dedicated components for reliable operation.
Innovation Solution
A system utilizing at least three sensor units with acceleration sensors and gyroscopes, each capable of independent speed and position determination, with communication between units for fail-safe monitoring and automatic shutdown initiation based on sensor unit failures, eliminating the need for manual calibration and dedicated components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If centrifugal electromechanical switches are used for overspeed detection, then reliability of overspeed detection is improved, but maintenance effort and calibration complexity increase
Solution Approach 1:
The patent replaces the mechanical centrifugal electromechanical switch system with an electronic sensor-based detection system. The sensor unit measures rotor speed electronically, eliminating the need for mechanical centrifugal forces and electromechanical switching components. This substitution maintains reliable overspeed detection while eliminating the maintenance and calibration issues associated with mechanical systems.
Solution Approach 2:
The sensor unit is designed to be self-contained with integrated electronics that automatically process measurement signals without requiring external calibration or adjustment. The system performs self-diagnosis and continues operation even when individual components fail, reducing maintenance effort while maintaining detection reliability.
2Reliability
If centrifugal electromechanical switches are used for overspeed detection, then reliability of overspeed detection is improved, but device complexity increases
Solution Approach 1:
The patent combines the overspeed detection function with the existing rotary encoder used for power control into a single integrated sensor unit. The same sensor that measures rotational speed for control purposes also detects overspeed conditions, eliminating the need for separate centrifugal switches and reducing overall system complexity while maintaining reliability.
Solution Approach 2:
The sensor unit performs multiple functions: it measures rotational speed for power control, detects overspeed conditions for safety, and provides position information. This multi-functional approach replaces the dedicated centrifugal overspeed switch, reducing device complexity while maintaining or improving reliability through unified measurement.
3Measurement precision
If rotary encoders are used for speed measurement, then power control accuracy is improved, but safety risk from single point of failure increases
Solution Approach 1:
The patent divides the speed measurement system into multiple independent sensor units distributed around the rotor. Each sensor unit independently measures rotational speed and position. This segmentation creates redundancy so that if one sensor fails, others continue to provide accurate measurements, maintaining both measurement precision and system safety.
Solution Approach 2:
The system incorporates redundant sensor units as a preventive measure against sensor failure. By having multiple independent sensors before any failure can occur, the system cushions against the risk of single-point failures, ensuring continuous safe operation and maintaining measurement accuracy even when individual sensors fail.
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 reliable and fail-safe detection of rotor speed and overspeed without dedicated components, reducing maintenance effort and preventing system damage through autonomous operation and redundancy, achieving a low probability of critical failures.
Implementation Method 1
Each sensor unit has an accelerometer and a gyroscope and is configured to determine the rotational speed and position of the rotor
Implementation Method 2
Each sensor unit has an accelerometer and a gyroscope and is configured to determine the rotational speed and position of the rotor
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a system for detecting and monitoring a speed of a rotor (106), more particularly a wind turbine (100) rotor, comprising: at least three sensor units (10), each sensor unit (10) having an acceleration sensor (12) and a gyroscope (14) and each sensor unit being configured to determine the speed and the position of the rotor (106) independently of the other sensor units (10), and each sensor unit (10) also having a communication component (16, 18) for communicating with the other sensor units (10). The system (1) is configured for fail-safe monitoring of the speed of the rotor by comparing the speeds and positions determined by the sensor units (10). The system and the associated method permit a reliable, fail-safe determination of a speed and an overspeed of a rotor.