Wind Turbine Drivetrain Torque Estimation for Early Failure Detection
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Solution Overview
Problem
Current wind turbine systems are unable to timely detect drivetrain failures, leading to potential catastrophic damage due to limitations in the accuracy and sampling rate of low-speed resolution sensors, which can result in delayed detection and reaction.
Innovation Solution
A method and system that involves a controller receiving speed measurements and determining electrical torque, estimating mechanical torque, and comparing it to an implausible torque threshold to initiate a control action, such as shutting down the turbine, when excessive torque values are detected, thereby preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If low-speed resolution speed sensor is used for detecting rotor speed, then device complexity is reduced, but measurement precision deteriorates leading to delayed failure detection
Solution Approach 1:
The patent introduces an intermediary computational model (mechanical torque estimation model) that processes data from the low-resolution speed sensor and combines it with electrical torque measurements. This intermediary model acts as a mediator that compensates for the low-resolution sensor's limitations by using the relationship between electrical and mechanical torque to detect drivetrain failures, thereby maintaining device simplicity while improving measurement precision through computational enhancement.
Solution Approach 2:
The patent transforms the detection parameter from direct speed measurement to mechanical torque estimation. By changing the parameter being monitored from speed (which has low measurement precision) to mechanical torque (which can be accurately estimated through computational modeling combining electrical torque and speed data), the system overcomes the sensor resolution limitation while maintaining simple hardware architecture.
2Device complexity
If low-speed resolution speed sensor with limited sampling rate is used, then device complexity is reduced, but detection timeliness deteriorates leading to delayed failure response
Solution Approach 1:
The patent implements a feedback mechanism where the mechanical torque estimation is continuously compared against expected torque values derived from electrical torque measurements. When discrepancies exceed thresholds, the system triggers immediate failure detection and shutdown. This feedback loop compensates for the limited sampling rate by using real-time electrical torque data to validate mechanical torque expectations, enabling timely failure detection without requiring high-speed sampling of the mechanical speed sensor.
Solution Approach 2:
The patent replaces reliance on high-speed mechanical speed sensing with an electrical-based torque measurement and computational estimation system. By substituting the mechanical detection approach (direct high-speed speed sensing) with an electrical measurement approach (electrical torque sensing combined with computational mechanical torque estimation), the system achieves timely failure detection without the complexity and cost of high-resolution mechanical sensors.
3Measurement precision
If comparison between low-speed and high-speed sensors is used for failure detection, then measurement precision is improved, but device complexity increases due to dual sensor requirements
Solution Approach 1:
The patent makes the electrical torque measurement system multi-functional by using it for both normal operational control and failure detection. The same electrical torque sensors and control systems used for turbine operation are also employed to estimate and validate mechanical torque, eliminating the need for separate dedicated failure detection sensors. This universal usage maintains measurement precision while avoiding additional hardware complexity.
Solution Approach 2:
The system uses its own existing electrical torque measurement capabilities to perform self-diagnosis and failure detection. Rather than requiring external or additional sensors, the turbine's control system leverages its inherent electrical measurements and computational models to monitor its own mechanical state, enabling the system to serve its own detection needs without additional hardware complexity.
Data Source
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AI summary
A method for preventing catastrophic damage in a drivetrain of a wind turbine includes receiving, via a controller, a speed measurement of the generator of the drivetrain. The method also includes determining an electrical torque of a generator of the drivetrain of the wind turbine. The method further includes estimating, via the controller, a mechanical torque of the rotor as a function of at least one of the electrical torque and the speed measurement of the generator. Further, the method includes comparing, via the controller, the estimated mechanical torque to an implausible torque threshold, wherein torque values above the implausible torque threshold speed values greater that the implausible speed threshold. Moreover, the method includes implementing, via the controller, a control action for the wind turbine when the estimated mechanical torque exceeds the implausible torque threshold.