Wind Turbine Test Assembly Hydraulic Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current test benches for wind turbines lack the capability to simulate and measure the complex loads, including forces and moments, that wind turbines experience during operation, particularly in varying wind conditions, which limits the effectiveness of testing and design validation.
Innovation Solution
A test assembly incorporating a prime mover, actuator assembly with hydraulic bearings, and a torque transfer coupling that applies and measures forces and moments in multiple degrees of freedom, allowing for simulation of loads experienced by wind turbines, including axial, radial, and torque loads, using a system of hydraulic bearing assemblies and a controller to manage fluid pressure and control the application of loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional test bench is used for wind turbines, then the testing setup is simple, but it lacks the capability to simulate and measure complex loads including forces and moments in multiple degrees of freedom
Solution Approach 1:
The test bench is segmented into distinct functional modules: a prime mover for applying torque, an actuator assembly with multiple actuators for applying forces in different directions, hydraulic bearing assemblies for supporting the shaft and enabling controlled movement, and a measurement system with sensors. This modular segmentation allows each component to be optimized for its specific function while collectively providing comprehensive load simulation capabilities across multiple degrees of freedom.
Solution Approach 2:
The test bench is designed as a multi-functional system that can simultaneously apply and measure various types of loads including axial forces, radial forces, and torque moments. The hydraulic bearing assemblies serve multiple purposes: supporting the shaft, enabling controlled axial and radial movements, and facilitating rotation. This multi-functionality allows a single test bench to validate wind turbine components under diverse operational conditions without requiring multiple separate testing setups.
2Ease of operation
If hydraulic bearing assemblies are used to support the shaft for rotation, then the shaft can be supported with controlled movement in axial and radial directions, but the device complexity increases
Solution Approach 1:
Hydraulic bearing assemblies are employed to support the shaft, utilizing fluid pressure to provide controlled axial and radial positioning while allowing smooth rotation. The hydraulic system enables precise control of the shaft's movement in multiple directions through pressurized fluid acting on bearing surfaces, facilitating accurate simulation of operational loads and movements without requiring complex mechanical guidance mechanisms.
3Adaptability or versatility
If multiple actuators are used to apply forces and moments in up to 5 degrees of freedom, then the load simulation capability is enhanced, but the device complexity and number of components increase
Solution Approach 1:
Multiple actuators are integrated into a single actuator assembly that works in coordination to apply forces and moments across five degrees of freedom. The actuators are strategically positioned and configured to work together, with some actuators capable of applying forces in multiple directions. This merged assembly approach reduces the need for entirely separate mechanisms for each degree of freedom, consolidating control functions while maintaining the capability to simulate complex multi-axial loads including axial forces, radial forces, and torque moments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables comprehensive simulation and measurement of wind turbine loads, enhancing the testing and validation of wind turbine designs by accurately replicating operational conditions and allowing for the assessment of load limits.
Implementation Method 1
A first plurality of hydraulic bearings is configured to support the shaft of the actuator assembly for rotation
Implementation Method 2
A torque transfer coupling is connected to the primer mover and to the actuator assembly
Data Source
Figure 1
Figure 2
Figure 3
AI summary
One aspect of the invention is a test assembly comprising a prime mover (26), an actuator assembly (34, 34', 200, 250, 500, 550, 560, 570) and a torque transfer coupling (30, 400, 400', 400", 400'", 600). The actuator assembly (34, 34', 200, 250, 500, 550, 560, 570) has an end configured to be attached to a shaft of a portion of a test specimen such as a wind turbine assembly (22). The actuator assembly (34, 34', 200, 250, 500, 550, 560, 570) has a shaft (32) supported for rotation by hydraulic bearings. The torque transfer coupling (30, 400, 400', 400", 400'", 600) connects the primer mover (26) to the actuator assembly (34, 34', 200, 250, 500, 550, 560, 570).