Yaw Actuator Torque Estimation Using Motor Current Mapping
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Solution Overview
Problem
Existing systems fail to accurately estimate the torque of yaw actuator shafts in wind turbines, leading to potential overload and inefficiencies.
Innovation Solution
A torque estimation device that utilizes strain sensors and current sensors to measure torque on yaw actuators, even when the drive unit is stopped, by generating and updating conversion tables based on measured current values and strain amounts, allowing for precise torque estimation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If torque is measured directly using a torque sensor, then measurement accuracy is improved, but device complexity and cost increase due to additional sensors and wiring
Solution Approach 1:
The patent replaces the mechanical torque sensor measurement system with an electrical measurement system. Instead of directly measuring torque mechanically, the system measures the current consumed by the drive unit's motor, which correlates with torque output. This substitution eliminates the need for physical torque sensors and their associated wiring, reducing device complexity while maintaining measurement capability through the relationship between electrical current and mechanical torque.
2Device complexity
If torque is calculated from drive unit current, then device complexity is reduced, but measurement precision deteriorates without direct torque sensing
Solution Approach 1:
The patent implements a feedback mechanism where the measured current value is continuously compared against stored correspondence information (calibration data) that maps current values to torque values. The estimation unit uses this feedback loop to adjust and refine torque estimates based on the actual current consumption patterns, improving measurement precision over time while maintaining the simplicity of the electrical measurement approach.
Solution Approach 2:
The patent changes the measurement parameter from direct mechanical torque to electrical current, which is easier to measure with high precision using standard electrical sensors. By establishing a correspondence relationship between current and torque through calibration data, the system achieves accurate torque estimation through parameter transformation, resolving the precision issue while maintaining device simplicity.
Data Source
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Figure 3~7
AI summary
A torque estimation device (8) includes: a current value obtaining unit (7) for obtaining a current value of a drive unit (30) of an actuator (3) included in a wind turbine (101); a storage unit (81) storing correspondence information representing correspondence between a torque occurring in a drive shaft (33) of the drive unit (30) and the current value; and an estimation unit (83) for estimating the torque occurring in the drive shaft (33) based on the current value obtained by the current value obtaining unit (7) and the correspondence information.