Wind Turbine Damage Assessment Using Cumulative Load Histograms
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Solution Overview
Problem
Conventional wind turbines rely on simulated data for maintenance and operation, which can lead to inefficient maintenance schedules and increased costs due to under- or over-maintenance, as well as potential damage from extreme loads, highlighting the need for a system that utilizes actual operational data to optimize maintenance and extend the lifespan of wind turbine components.
Innovation Solution
A method and system that determine loading and travel metrics for wind turbine components during operation, generate cumulative load histograms, and apply life or damage models to estimate actual damage accumulation, enabling adaptive corrective actions such as adjusting power output or scheduling maintenance based on real-time data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If simulated data is used for maintenance scheduling, then maintenance can be planned in advance, but the accuracy of damage assessment deteriorates leading to under- or over-maintenance
Solution Approach 1:
The system implements feedback by continuously monitoring actual operational parameters (loads, speeds, temperatures) from sensors during wind turbine operation and using this real-time data to update and refine the damage accumulation assessment, replacing static simulated data with dynamic actual operational data for accurate maintenance scheduling
Solution Approach 2:
The patent replaces the mechanical/simulation-based damage assessment system with an actual measurement-based system using sensors and data processing to directly measure operational parameters and calculate damage accumulation from real operational data rather than simulated conditions
2Reliability
If preventive maintenance is scheduled at predetermined intervals, then component reliability can be maintained, but operational downtime and costs increase due to over-maintenance
Solution Approach 1:
The system transitions from static predetermined maintenance intervals to dynamic condition-based maintenance scheduling, where maintenance timing is continuously adjusted based on real-time monitoring of actual damage accumulation from operational data, allowing maintenance to be performed only when actually needed
Solution Approach 2:
The patent changes the parameter basis for maintenance scheduling from fixed time intervals to variable damage accumulation metrics calculated from actual operational data, enabling maintenance decisions to be made based on actual component condition rather than predetermined schedules
3Ease of manufacture
If simulated lifetime load histograms are used for design, then component design can be completed before operation, but the design may not reflect actual operational conditions leading to suboptimal maintenance planning
Solution Approach 1:
The system performs preliminary damage assessment calculations during the design phase using simulated data, but then continuously updates these assessments during operation with actual operational data, maintaining the benefit of advance planning while adapting to real conditions
Solution Approach 2:
The wind turbine system performs self-monitoring and self-assessment of its own damage accumulation using onboard sensors and data processing capabilities, enabling the system to automatically adapt its maintenance needs based on its actual operational experience without external intervention
Data Source
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AI summary
A method for operating a wind turbine includes determining one or more loading and travel metrics or functions thereof for one or more components of the wind turbine during operation of the wind turbine. The method also includes generating, at least in part, at least one distribution of cumulative loading data for the one or more components using the one or more loading and travel metrics during operation of the wind turbine. Further, the method includes applying a life model of the one or more components to the at least one distribution of cumulative loading data to determine an actual damage accumulation for the one or more components of the wind turbine to date. Moreover, the method includes implementing a corrective action for the wind turbine based on the damage accumulation.