Wind Turbine Gear Backlash Measurement Using Optical Scale Markings
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Solution Overview
Problem
Conventional methods for measuring backlash in wind turbines, particularly between ring gears and pinions, are inadequate as they do not allow for easy and frequent measurements, which is crucial for maintaining optimal performance and preventing wear-related issues.
Innovation Solution
A backlash measuring apparatus and method that includes a rotation amount calculating unit to determine the amount of rotation of a target pinion from a contact state with a ring gear, allowing for the measurement of backlash between the ring gear and the pinion, and can be used at multiple times to diagnose the condition of the wind turbine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional backlash measuring methods are used, then measurement can be performed, but the measurement process is complex and cannot be easily performed at multiple different times
Solution Approach 1:
The patent replaces complex mechanical measurement systems with an optical measurement system. A camera captures images of scale markings on the pinion and ring gear, and image processing algorithms calculate backlash from these images. This substitution of mechanical methods with optical/electronic methods simplifies the measurement system while maintaining or improving measurement precision, enabling easy repeated measurements at different times.
2Reliability
If frequent backlash measurements are implemented, then wear monitoring and timely maintenance are enabled, but the measurement process becomes more time-consuming and operationally complex
Solution Approach 1:
The patent prepares the measurement system in advance by attaching scale markings to the pinion and ring gear during manufacturing or initial setup. These pre-prepared markings enable rapid subsequent measurements without requiring complex preparation each time. The camera and image processing system are also pre-configured, allowing quick capture and analysis of backlash values at different operational times, thus reducing measurement time while improving reliability through frequent monitoring.
3Loss of information
If detailed backlash measurement is performed, then wear condition can be accurately diagnosed, but the measurement and analysis process becomes more complex
Solution Approach 1:
The patent introduces scale markings as intermediary elements attached to the pinion and ring gear. These markings serve as mediators that translate the physical backlash (relative position between gear teeth) into measurable optical patterns (relative positions of scale markings). A camera captures these patterns, and image processing algorithms convert them into quantitative backlash values. This intermediary approach simplifies the detection process while preserving detailed wear condition information, making accurate diagnosis easier without increasing measurement complexity.
Data Source
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AI summary
A backlash measuring method is provided for measuring backlash at a plurality of different times. The backlash measuring method includes: a rotation amount calculating step of braking a ring gear relative to a second portion while contact between a target tooth and the ring gear achieved in a contacting step is maintained, causing a target pinion to rotate toward a second side in a rotation direction opposite to the first side with a driving force less than a braking force applied to brake the ring gear relative to the second portion until the target tooth touches the ring gear at a tooth surface facing the second side, and calculating an amount of rotation of the target pinion; and a measuring step of measuring backlash between the ring gear and the target pinion based on the amount of rotation of the target pinion calculated in the rotation amount calculating step.