Wind Turbine Load Decoupling for Six-DOF Transmission Testing
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Solution Overview
Problem
Existing wind turbine testing methods, particularly for offshore installations, struggle to accurately simulate and apply six degree-of-freedom (DOF) loads, including torques and non-torsional forces, due to the complexity of the marine environment, leading to high failure rates in transmission chains and gearboxes.
Innovation Solution
A load decoupling and loading apparatus for wind turbines that includes multiple actuators, a first and second loading bearing, and a rotation shaft, with actuators connected through spherical hinges to provide five DOF loads, and a motor to apply torque loads, enabling synchronized loading of six DOF loads on a test prototype.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a loading apparatus only provides mechanical structure forces in vertical direction, then the device complexity is reduced, but the measurement precision of six DOF loads is insufficient
Solution Approach 1:
The loading apparatus is segmented into multiple independent actuator systems: vertical actuators for Fx/Fy forces, horizontal actuators for Fz force, and a motor system for Mx torque. Each actuator group independently controls one dimension of the six DOF loads, allowing complex six DOF loading to be achieved through coordinated operation of simpler modular components, thus resolving the contradiction between device complexity and measurement precision
Solution Approach 2:
A decoupling mechanism is introduced as an intermediary between the actuators and the main shaft. This decoupling mechanism separates the torque loading path (through the rotation shaft) from the non-torsional loading path (through loading bearings), enabling independent control of torque and non-torsional forces. This intermediary structure allows precise six DOF load simulation without requiring a monolithic complex system
2Device complexity
If torque load is not considered in load simulation, then the device complexity is reduced, but the manufacturing precision of load simulation is insufficient
Solution Approach 1:
The loading control system is segmented into independent torque control (motor + rotation shaft) and non-torsional control (vertical + horizontal actuators). This segmentation allows the torque loading function to be added without complicating the overall control architecture, as each segment can be controlled independently through its own actuators and sensors
Solution Approach 2:
The rotation shaft serves as an intermediary component that introduces torque loading capability into the system. By placing the motor-driven rotation shaft between the decoupling mechanism and the main shaft, torque can be applied independently of the non-torsional forces, enabling precise six DOF load simulation including torque without requiring a complete redesign of the control system
Data Source
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AI summary
The application relates to, but is not limited to the technical field of testing and detecting a wind turbine, and in particular to a load decoupling and loading apparatus, method and system for a wind turbine, and a control system. The loading apparatus includes multiple actuators, a first loading bearing, a rotation shaft and a second loading bearing. The rotation shaft is arranged horizontally with a ground, the first loading bearing and the second loading bearing are sleeved at both ends of the rotation shaft respectively, an end of the first loading bearing away from the rotation shaft is connected to an external motor, and an end of the second loading bearing away from the rotation shaft is connected to an external test prototype. Multiple actuators are connected to the first loading bearing and the second loading bearing respectively. The actuators provide five degree-of-freedom (DOF) loads for the test prototype through the first loading bearing and the second loading bearing. The motor provides a torque load for the test prototype. According to the five DOF loads, the application achieves control of multiple actuators in the loading apparatus, enhances accuracy of loading control of a transmission chain of the wind turbine, and improves experimental accuracy of the wind turbine.