Wind Turbine Over-Rating Control Under Extreme Load Limits

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Solution Overview

Problem

Wind turbines face limitations in over-rating control due to the risk of exceeding ultimate design loads, particularly extreme loads, which restricts the potential increase in power output and leads to early component failure.

Innovation Solution

A method and system for calculating a maximum safe over-rated power demand for wind turbines in non-standard operating conditions, using a look-up table populated with simulations of various wind conditions to determine the highest power level that can be achieved without exceeding ultimate design loads, incorporating stochastic calculations and real-time data for precise control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If wind turbines operate at higher power levels through over-rating control, then energy capture and productivity are improved, but the risk of exceeding ultimate design loads increases, leading to component failure

Engineering Contradiction:

Improvepower outputVSAvoidrisk of component failure

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary calculations of maximum safe over-rated power demand based on current operating conditions (wind speed, turbulence intensity, air density) before allowing over-rating operation. This prevents exceeding ultimate design loads by establishing safe operating limits in advance through stochastic load calculations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The control system dynamically adjusts the power demand parameter based on changing environmental conditions. By continuously monitoring wind speed, turbulence intensity, and air density, the system modifies the maximum safe over-rated power demand to maintain reliability while maximizing energy capture

Inventive Principle:

Principle #35Parameter changes

2Reliability

If wind turbines operate at rated power under standard conditions, then ultimate design loads are not exceeded, but the potential for energy capture is limited

Engineering Contradiction:

Improvedesign load complianceVSAvoidenergy capture

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system transitions from static rated power operation to dynamic over-rating control. The maximum safe power demand is continuously adjusted based on real-time environmental conditions, allowing the turbine to operate at higher power levels when conditions permit while maintaining design load compliance

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The control system modifies the power demand parameter from fixed rated power to variable over-rated power. By changing operating parameters based on environmental conditions (wind speed, turbulence, air density), the system achieves both reliability and improved productivity

Inventive Principle:

Principle #35Parameter changes

3Productivity

If over-rating control is implemented without considering extreme loads, then power output increases, but extreme loads may exceed ultimate design loads causing early component failure

Engineering Contradiction:

Improvepower outputVSAvoidextreme loads

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system applies preliminary anti-action by calculating and preventing extreme loads from exceeding ultimate design loads. Through stochastic load calculations, the system identifies and counteracts potential harmful effects before they cause damage, allowing safe over-rating operation

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The system converts the potentially harmful effect of extreme loads into a beneficial control mechanism. By using stochastic load calculations to predict extreme load behavior, the system transforms uncertainty into a tool for optimizing over-rating control while maintaining safety

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentEP3317516B1Extreme load control

Publication Date: 2021.12.08 VESTAS WIND SYSTEMS AS

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AI summary

Methods for calculating a maximum safe over-rated power demand for a wind turbine operating in non-standard conditions include the steps of determining a value indicative of a risk of exceeding an ultimate design load during operation in a standard operating condition, and establishing a maximum over-rated power demand corresponding to a maximum power that the turbine may produce under the non-standard operating condition without incurring an increased risk of exceeding the ultimate design load, with respect to operation in the standard condition. A method of over-rating a wind turbine, a wind turbine controller, a wind turbine and a wind power plant are also claimed.