Wind Turbine Blade Add-On Control to Reduce Pitch-System Wear

Solution Overview

Problem

Conventional wind turbine control methods that adjust blade pitch angle to maintain nominal rotational speed above rated wind speed lead to high load on blade pitch bearings and hydraulic or electrical pitching systems, increasing costs and wear.

Innovation Solution

A method that adjusts blade add-ons, such as spoilers or flaps, to control rotational speed without simultaneously changing the blade pitch angle, reducing load on pitch systems by using active aerodynamic devices and controllers like PI controllers to manage rotational speed and torque.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If blade pitch angle is adjusted to control rotational speed above rated wind speed, then rotational speed control is achieved, but load on blade pitch bearings and hydraulic/electrical pitching systems increases

Engineering Contradiction:

Improverotational speedVSAvoidload on pitch system

Core Design Contradiction:

SpeedVSForce

Solution Approach 1:

The control function is segmented between two independent systems: blade pitch angle control and blade add-on control. The add-on (spoiler or flap) is segmented as a separate controllable element that can independently influence aerodynamic properties without affecting the pitch bearing load.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The blade add-on (spoiler or flap) acts as an intermediary element between the wind and the rotor blade. By adjusting the add-on, the aerodynamic characteristics are modified indirectly, achieving speed control without directly loading the pitch system.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Speed

If blade pitch angle is adjusted to maintain nominal rotational speed, then rotational speed control is achieved, but wear on pitch system components increases

Engineering Contradiction:

Improverotational speedVSAvoidlifetime of pitch system

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The control function is segmented between two independent systems: blade pitch angle control and blade add-on control. The add-on (spoiler or flap) is segmented as a separate controllable element that can independently influence aerodynamic properties without affecting the pitch bearing load.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The blade add-on system serves itself to perform the speed control function that would otherwise require pitch system intervention. By using the add-on for routine speed adjustments, the pitch system is freed from continuous operation, reducing wear and extending component lifetime.

Inventive Principle:

Principle #25Self-service

3Speed

If blade pitch angle is adjusted for speed control above rated wind speed, then rotational speed control is achieved, but system complexity and cost increase

Engineering Contradiction:

Improverotational speedVSAvoidpitching system complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The blade add-on serves multiple functions: it controls rotational speed, reduces pitch system load, and can be used in combination with pitch angle adjustment for optimized performance. This multi-functionality reduces the need for complex pitch system interventions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The blade add-on (spoiler or flap) acts as an intermediary element between the wind and the rotor blade. By adjusting the add-on, the aerodynamic characteristics are modified indirectly, achieving speed control without directly loading the pitch system.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Reduces wear and load on blade pitch systems, prolonging their lifetime and maintaining performance by primarily using blade add-ons for control, with minimal adjustments to the blade pitch angle when necessary.

Implementation Method 1

adjusting the setting of the add-on to meet a control objective while temporarily maintaining a setting of the blade pitch angle

Methodology Applied

Scientific EffectAerodynamic effect: Aerofoil

Implementation Method 2

Adjusting the blade add-on may have an effect on the driving impact of the impacting wind, meaning driving impact on the rotational speed or the torque of the rotor blade exerting on the rotor shaft of the wind turbine

Methodology Applied

Scientific EffectTorque generation: Torque

Data Source

PatentEP4097350B1Controlling a wind turbine using blade pitch angle setting and blade add-on setting

Publication Date: 2025.10.08 SIEMENS GAMESA RENEWABLE ENERGY AS

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AI summary

It is described a method of controlling a wind turbine (1060) by adjusting a blade pitch angle and at least one blade add-on of at least one wind turbine rotor blade (1063) having the blade add-on (1067), the method comprising: adjusting a setting of the add-on (1067) to meet a control objective while temporarily maintaining a setting of the blade pitch angle.