Wireless Blade Sensor Communication for Wind Turbines

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Solution Overview

Problem

The use of slip rings in wind turbines for connecting rotating blade sensors to a central controller is costly, prone to mechanical failures, and increases the risk of lightning strikes, while existing wireless sensor solutions face battery life issues due to frequent data transmission.

Innovation Solution

Implementing a wireless communication system between rotor blade sensors and the central unit, where data is transmitted only when measurements are outside a predefined tolerance band, reducing the need for wiring and slip rings, and conserving battery power by minimizing unnecessary transmissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wireless communication is implemented between sensors and central controller, then reliability and resistance to lightning strikes are improved, but energy consumption increases due to data transmission

Engineering Contradiction:

Improvecommunication reliabilityVSAvoidbattery energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The sensor transmits data only when deflection exceeds the tolerance band threshold, rather than continuously or at every measurement cycle. This partial transmission approach maintains communication reliability for critical events while dramatically reducing energy consumption compared to continuous transmission.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The system changes the transmission parameter from continuous to event-driven based on the deflection threshold. When the structural characteristic (blade deflection) remains within the tolerance band, no transmission occurs. When it exceeds the threshold, transmission is triggered. This parameter change optimizes the balance between reliability and energy usage.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If slip rings are used for electrical connection between rotating blades and stationary tower, then continuous electrical contact is maintained, but mechanical wear and failure rate increase

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidconnector reliability

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent replaces the mechanical slip ring connection system with a wireless communication system. Sensors on the rotating blade communicate wirelessly with the central controller in the stationary tower, eliminating mechanical contact, friction, and wear entirely. This substitution maintains electrical connection functionality while dramatically improving reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of information

If sensors transmit data at every measurement cycle, then complete data availability is ensured, but battery life is reduced due to frequent transmissions

Engineering Contradiction:

Improvedata completenessVSAvoidbattery life

Core Design Contradiction:

Loss of informationVSDuration of action of moving object

Solution Approach 1:

The system uses a feedback mechanism where the sensor compares each measurement against the predefined tolerance band. Only when the measurement exceeds the threshold (indicating a significant event) does the sensor trigger data transmission. This feedback-based selective transmission ensures that critical information is communicated while minimizing unnecessary transmissions to preserve battery life.

Inventive Principle:

Principle #23Feedback

4Ease of manufacture

If slip rings are installed for electrical connection, then wired communication is achieved, but susceptibility to lightning strikes increases

Engineering Contradiction:

Improvewired connection implementationVSAvoidlightning strike susceptibility

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The wireless communication system replaces the wired electrical connection through slip rings. By using radio frequency or other wireless communication methods, the system eliminates the conductive path that would channel lightning strikes to the central controller. This substitution maintains communication functionality while providing protection against lightning damage.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP2734816B1Energy-efficient wireless communication scheme for wind turbines

Publication Date: 2019.10.30 ROBERT BOSCH GMBH

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AI summary

A method of operating a wind turbine includes providing a wind turbine having a plurality of blades. A respective sensor is attached to each of the blades. First measurements of a structural characteristic of each of the blades are repeatedly taken by use of the sensors. A tolerance band is established for the measurements. Signals indicative of the first measurements are wirelessly transmitted only if the first measurements are outside of the tolerance band. The transmitted signals are received at a controller. An actuator signal is sent from the controller to at least one actuator associated with the blades. The sending is in response to the receiving of the transmitted signals. At least one of the blades is actuated dependent upon the actuator signal. The actuating is performed by the at least one actuator. Second measurements of the structural characteristic of each of the blades are repeatedly taken by use of the sensors after the actuating step. The wirelessly transmitting, receiving, sending and actuating steps are repeated for the second measurements.