Wind Turbine Blade Alignment Sensor System
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Solution Overview
Problem
Manual alignment of wind turbine blades introduces high variance and error, leading to energy loss, increased vibration, and reduced service life due to misalignment, which can result in significant annual energy output loss and component damage.
Innovation Solution
A sensor is embedded in the wind turbine blade to measure the installation angle and compare it to a known twist angle, with a controller adjusting the blade position to ensure alignment, using a processing unit to determine and execute necessary adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment method is used, then alignment process is simple, but alignment precision is poor leading to high error rate
Solution Approach 1:
The patent replaces the manual mechanical alignment method with an automated sensor-based measurement system. Sensors mounted on the blade and hub automatically measure alignment angles, eliminating manual marking and visual alignment. This substitution dramatically improves measurement precision while the automated calculation system handles the complexity, resolving the contradiction between precision and operational simplicity.
Solution Approach 2:
The patent introduces sensors as intermediary devices between the blade-hub assembly and the alignment measurement process. These sensors serve as mediators that automatically capture angular position data, which is then processed by a calculation unit to determine alignment accuracy. This intermediary system bridges the gap between physical alignment and measurement, achieving high precision without requiring complex manual procedures.
2Loss of energy
If manual alignment is performed, then alignment operation is easy, but energy loss increases due to misalignment
Solution Approach 1:
The patent replaces manual alignment operations with an automated sensor-based system that precisely measures and calculates blade-hub alignment. This automation eliminates the high error rates associated with manual methods, ensuring optimal alignment that maximizes energy capture. The system reduces annual energy output loss by preventing misalignment-related efficiency degradation, justifying the increased automation level.
Solution Approach 2:
The patent implements a feedback mechanism where sensors continuously measure alignment angles, the calculation unit processes this data to determine alignment accuracy, and the results guide any necessary adjustments. This closed-loop feedback system ensures the blade remains optimally aligned with the hub, minimizing energy loss from misalignment while maintaining straightforward operational procedures through automated control.
3Object-affected harmful factors
If manual alignment method is used, then alignment process is simple, but vibration increases due to misalignment
Solution Approach 1:
The patent replaces simple manual alignment with an automated sensor-based measurement and calculation system. This system precisely determines blade-hub alignment angles and detects any misalignment that would cause vibration. By automating the measurement process, the system achieves high alignment accuracy that eliminates vibration-causing misalignment, while the calculation unit manages the computational complexity, resolving the contradiction between vibration reduction and system simplicity.
Solution Approach 2:
The patent introduces sensors and calculation units as intermediary systems between the blade-hub assembly and the vibration problem. These intermediaries automatically measure alignment parameters and provide data for determining optimal alignment, preventing misalignment-induced vibration before it occurs. The intermediary system handles the measurement complexity, allowing the physical alignment process to remain straightforward while effectively reducing harmful vibrations.
4Duration of action of stationary object
If manual alignment is performed, then alignment operation is straightforward, but component service life reduces due to misalignment damage
Solution Approach 1:
The patent replaces manual alignment operations with an automated sensor-based system that precisely measures and calculates blade-hub alignment. This automation ensures consistent, accurate alignment that prevents misalignment-related stress and damage to turbine components. By eliminating manual errors, the system extends component service life, justifying the increased automation level required to achieve and maintain this protective alignment accuracy.
Solution Approach 2:
The patent implements a feedback mechanism where sensors measure alignment angles, the calculation unit determines alignment accuracy, and the results guide adjustments to achieve optimal alignment. This continuous feedback loop ensures components remain properly aligned throughout operation, preventing misalignment-induced damage and extending service life. The automated feedback system manages the complexity of maintaining precise alignment over time, making the extended service life achievable through systematic control.
Data Source
AI summary
The present subject matter is directed to a wind turbine blade alignment method. A sensor provided on the blade at a blade station with a known twist angle is used to measure an installation angle of the blade station. The installation angle is adjusted if the installation angle measured by the sensor is not equal to the known twist angle. A wind turbine with such a sensor for measuring an installation angle used for blade alignment is also provided.