Wind Turbine Thrust Sensor Control System
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Solution Overview
Problem
Wind turbines face stress-related failures due to rapid variations in wind speed and direction, leading to delayed corrective actions that result in damage from excessive rotor speed and torque, as existing control systems respond too slowly to extreme gusts.
Innovation Solution
A control system that instantaneously detects increased thrust loads using axial load or combined torque/thrust sensors, activating a braking system to limit rotor speed overshoot or initiate shutdown, with the ability to modulate braking torque to prevent excessive deceleration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rotor speed sensor with braking system is used for shutdown control, then the turbine can be protected from over-speed damage, but the response is delayed due to rotor inertia causing stress-related failures
Solution Approach 1:
The thrust sensor detects increased axial loads on the rotor shaft before the rotor speed actually increases, allowing the control system to initiate corrective action (braking or pitch adjustment) in advance of the speed overshoot that would otherwise occur due to rotor inertia. This preliminary detection and action prevents the delayed response problem.
Solution Approach 2:
The thrust sensor acts as an intermediary measurement device that indirectly detects wind gust conditions by measuring axial load on the shaft, rather than directly measuring rotor speed. This intermediary measurement provides advance warning of upcoming speed increases, enabling faster control response.
2Reliability
If the over-speed set point is lowered to prevent damage from extreme gusts, then turbine safety is improved, but unwanted shutdowns occur during normal operation
Solution Approach 1:
By detecting thrust load increases before they translate into rotor speed increases, the system can initiate corrective braking or pitch action in advance, allowing for a higher over-speed set point that won't cause unwanted shutdowns during normal operation while still protecting against extreme gusts.
Solution Approach 2:
The thrust sensor provides continuous feedback on axial loads, allowing the control system to distinguish between normal operational variations and dangerous gust conditions. This feedback enables more nuanced control decisions rather than simple on/off shutdown based on speed thresholds.
3Speed
If a thrust sensor is added to detect increased axial loads instantaneously, then the response time to wind speed changes is improved, but the device complexity increases
Solution Approach 1:
The thrust sensor serves multiple functions: it enables faster gust detection, provides feedback for improved control algorithms, and can be used to monitor overall turbine loading conditions. This multi-functionality justifies the added device complexity by providing benefits beyond just faster response time.
Data Source
AI summary
A wind turbine control system includes a thrust sensor and a braking system, and allows an increase in wind rotor load to be detected instantaneously and corrective action to be initiated. The system includes additional features such as deceleration control. In one embodiment, a turbine controller regulates the rate of deceleration of the rotor shaft.