Wind Turbine Control Software Validation by Parallel Output Comparison

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for validating wind turbine control software updates are cumbersome, potentially expensive, and may introduce production loss or suboptimal performance during testing, especially when comparing different operating conditions and requiring significant manual handling.

Innovation Solution

A method where two versions of the wind turbine control software run simultaneously on a controller, with identical input, allowing direct comparison of their outputs under identical conditions, ensuring no production loss and automatic validation without manual handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional A-B testing is used to validate new software versions, then validation can be performed, but production loss and suboptimal performance occur during testing

Engineering Contradiction:

Improvesoftware validation reliabilityVSAvoidwind turbine production continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system segments the software validation process by running multiple software versions (new version and previous version) simultaneously on separate processors within the controller. This allows independent execution and comparison of different software versions without interrupting overall system operation, resolving the contradiction between validation reliability and production continuity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system introduces an intermediary comparison mechanism that automatically compares outputs from different software versions against each other and against expected values. This intermediary validation layer enables continuous monitoring and verification without requiring manual intervention or system shutdown, maintaining both reliability and productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If traditional A-B testing is used, then validation can be performed, but significant manual handling is required

Engineering Contradiction:

Improvesoftware validation reliabilityVSAvoidvalidation process automation

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

The system implements self-service validation where the controller automatically executes multiple software versions, collects their outputs, performs comparisons, and determines validation results without external intervention. The system serves its own validation needs by autonomously managing the entire validation process, eliminating manual handling while maintaining reliability.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system incorporates feedback mechanisms where validation results from automated comparisons are fed back into the control system. This feedback loop enables continuous automatic validation and decision-making, enhancing both automation extent and validation reliability through iterative self-verification.

Inventive Principle:

Principle #23Feedback

3Productivity

If digital twin approach is used, then validation can be performed without downtime, but model-based limitations prevent accounting for all real conditions

Engineering Contradiction:

Improvewind turbine production continuityVSAvoidcoverage of operating conditions

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

Instead of using an abstract digital twin model, the system creates actual runtime copies of the wind turbine control system by executing multiple software versions simultaneously on separate processors. These live copies process real sensor data and produce actual control outputs, providing both continuity and comprehensive condition coverage through genuine parallel operation rather than simulation.

Inventive Principle:

Principle #26Copying

4Productivity

If new software version is installed without validation, then productivity is maintained, but compliance with certifications and legal requirements cannot be ensured

Engineering Contradiction:

Improvewind turbine production continuityVSAvoidsoftware compliance with certifications

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary validation actions by automatically testing the new software version against expected values and comparing it with the previous version before full deployment. This preliminary verification ensures compliance with certifications and legal requirements is satisfied prior to installation, maintaining both productivity and reliability through advance validation.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP4273701B1A method for validating an upgraded version of wind turbine control software

Publication Date: 2025.11.12 VESTAS WIND SYSTEMS AS

Figure 1~2
Figure 3~4
Figure 5

AI summary

A method for validating a version of wind turbine control software is disclosed. A first version (7) of the wind turbine control software and a second version (8) of the wind turbine control software are running simultaneously on a controller (1), by applying identical control input to the first version (7) and to the second version (8), and the first (7) and the second (8) versions of the wind turbine control software each generating control output (9, 10), based on the received control input. The wind turbine (5) or wind farm (4) is controlled based on the control output (9) generated by the first version (7) of the wind turbine control software. The control output (9, 10) generated by the first version (7) and by the second version (8) of the wind turbine control software are compared, during a time interval, and the second version (8) of the wind turbine control software is validated, based on the comparison.