Wind Turbine High Speed Shaft Brake Interlock Control
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Solution Overview
Problem
Traditional braking control methods in wind turbines fail to effectively manage extreme transient loads during overspeed fault conditions, potentially damaging mechanical and drive train components due to inaccurate speed detection leading to premature brake activation.
Innovation Solution
A system and method that utilize a low speed shaft sensor to determine rotational speed, a controller to generate an activate signal for the high speed shaft brake, and an interlock system to override the brake activation when the low speed shaft rotational speed exceeds a threshold, preventing damage by ensuring safe activation of the brake.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the mechanical brake is applied after the turbine faults at a defined rotor speed according to a time-dependent braking profile, then the brake activation timing is simplified, but extreme transient loads are not significantly eliminated and mechanical brake components can be significantly damaged
Solution Approach 1:
The system continuously monitors the actual rotational speed of the high-speed shaft using a speed sensor and compares it with the threshold value. This feedback mechanism ensures that the brake is activated only when the rotational speed is below the safe threshold, preventing premature activation that could cause damage to mechanical brake components while maintaining reliable operation.
Solution Approach 2:
The patent replaces the traditional time-dependent mechanical braking control with an electronic control system that uses speed sensor feedback and a controller to determine brake activation timing. This substitution allows for more precise and adaptive control of the brake activation based on actual operational conditions rather than fixed time profiles.
2Loss of time
If the brake is actuated too soon during overspeed fault conditions, then the response time to stop the rotor is reduced, but extreme transient loads damage the mechanical brake components and other drive train components
Solution Approach 1:
The speed sensor provides real-time feedback on the actual rotational speed of the high-speed shaft, allowing the controller to make informed decisions about brake activation timing. This ensures the brake is activated at the optimal moment - not too early to cause damage, and not too late to extend the duration of harmful transient loads.
Solution Approach 2:
The system changes the control parameter from fixed time-based activation to speed-based activation. By monitoring the actual rotational speed and comparing it with a threshold value, the system dynamically adjusts the brake activation timing based on the operational state, preventing activation during high-speed conditions that would cause component damage.
3Device complexity
If speed detection signal accuracy is insufficient, then the system is simpler, but the brake may be activated at shaft speeds that can damage the brake and other drive train components
Solution Approach 1:
The speed sensor provides continuous feedback on the actual rotational speed of the high-speed shaft, enabling the controller to accurately determine when the threshold value is reached. This feedback mechanism ensures reliable brake activation timing based on actual operational conditions rather than estimated or inaccurate speed signals.
Solution Approach 2:
The patent introduces a speed sensor as an intermediary device that accurately measures the rotational speed of the high-speed shaft and provides this information to the controller. This intermediary ensures that the brake activation decision is based on accurate speed data, preventing premature activation while maintaining system reliability.
Data Source
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AI summary
A wind turbine and associated control method includes a controller configured with a high speed shaft brake in the generator gear train. The controller receives an input signal corresponding to rotational speed of the high speed shaft, wherein upon the high speed shaft reaching a predefined rotational speed and under a braking condition that calls for the rotor to come to a complete standstill, the controller generates an activate signal to activate the brake. An interlock system is in communication with the low speed shaft sensor and the controller and is configured to override the activate signal when the rotational speed of the low speed shaft is above a threshold value.