Wind Turbine T-Connector Fault Detection via Remote Cable Temperature

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Solution Overview

Problem

Wind turbine T-connectors are prone to failure due to high voltage and current stresses, leading to arcing, heating, and mechanical damage, which can result in extended downtime and high repair costs, especially in offshore installations.

Innovation Solution

A wind turbine cable connector monitoring method that uses temperature sensors to measure the temperature at a known distance along the cable from the connector, allowing for the identification of potential fault conditions based on temperature data, thereby enabling proactive maintenance and minimizing downtime.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If temperature sensors are installed directly on the connector, then measurement precision is improved, but device complexity and safety requirements increase

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidmonitoring system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses the cable as an intermediary medium to transfer thermal information from the connector to a remote sensor. Instead of placing the sensor directly on the high-voltage connector, the system measures temperature at a remote location on the cable and uses thermal conduction models to infer the connector temperature, thereby avoiding direct contact with high-voltage components while maintaining measurement capability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces direct mechanical contact measurement (temperature sensor on connector) with indirect thermal field measurement through the cable. By substituting the mechanical/electrical contact approach with thermal conduction-based remote sensing, the system reduces complexity and safety requirements while preserving the ability to detect connector faults

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If T-connectors are inspected during routine maintenance, then reliability is improved, but loss of time for maintenance operations increases

Engineering Contradiction:

Improveconnector reliabilityVSAvoidmaintenance downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent implements continuous temperature monitoring that detects fault conditions before they lead to connector failure. By performing preliminary detection of thermal anomalies during normal operation, the system enables proactive maintenance scheduling rather than reactive maintenance after failure, reducing unplanned downtime while maintaining reliability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors cable temperature and provides feedback about connector health status. This real-time feedback mechanism allows operators to track connector conditions over time and schedule maintenance based on actual degradation patterns rather than fixed intervals, optimizing the balance between reliability and maintenance time

Inventive Principle:

Principle #23Feedback

3Loss of time

If a fault is detected early through remote monitoring, then loss of time is reduced, but measurement precision may be compromised

Engineering Contradiction:

Improvedowntime before fault detectionVSAvoidconnector temperature measurement accuracy

Core Design Contradiction:

Loss of timeVSMeasurement precision

Solution Approach 1:

The patent transforms the measurement parameter from direct connector temperature to cable temperature at a remote location. By changing the measured parameter and using thermal conduction relationships, the system achieves early fault detection through remote sensing while accounting for the indirect measurement through mathematical modeling of heat transfer

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system creates a thermal copy or proxy measurement of the connector condition by measuring temperature at a remote cable location. This indirect measurement serves as a surrogate that correlates with connector health, enabling early fault detection without direct contact with the connector while maintaining sufficient precision for predictive maintenance

Inventive Principle:

Principle #26Copying

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

The method allows for the early detection of potential faults in T-connectors, enabling proactive maintenance and reducing the risk of uncontrolled breakdowns, thereby minimizing downtime and repair costs.

Implementation Method 1

sensing a measured temperature at a position on the cable a known distance along the cable from the connector

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250146883A1Wind turbine cable connector monitoring method and device

Publication Date: 2025.05.08 ORSTED WIND POWER AS

AI summary

Wind turbine cable connector monitoring method and device for monitoring a connector (1) attached to cable (4). A temperature sensor (6) is provided for sensing a measured temperature at a position a known distance along the cable (4) from the connector (1). A controller (8,19) records the measured temperature from the temperature sensor (6) while the connector (4) is in use, and identifies a potential fault condition in the connector (4) based on the measured temperature and the position the known distance along the cable (4) from the connector (1).