Wind Turbine Yaw Rotation Limit Detector
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Solution Overview
Problem
Existing wind turbine yaw systems face challenges in accurately detecting the rotation limit of the toothed ring, leading to potential damage from excessively twisted power cables due to incorrect yaw corrections.
Innovation Solution
A rotation limit detector is configured to monitor the rotation of a toothed ring in a wind turbine yaw assembly, using a pinion and transmission system to convert primary shaft rotation into secondary shaft rotation, and incorporates switch actuators and switches to detect rotation limits and direction, enabling precise corrective actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a yaw encoder is used to monitor rotation, then angular position can be detected, but the encoder may fail undetected and report erroneous data leading to incorrect corrective actions
Solution Approach 1:
A mechanical cam follower acts as an intermediary between the rotating assembly and the detection system. The cam follower physically tracks the rotation through cam surface contact, providing a reliable mechanical reference that is independent of electronic encoders. This mechanical intermediary ensures accurate rotation tracking even when electronic sensors fail.
Solution Approach 2:
The patent replaces reliance on electronic yaw encoders with a mechanical cam-based detection system. The cam profile mechanically encodes rotation information that can be read by a follower, substituting electronic measurement with a purely mechanical system that is more reliable and less prone to undetected failures.
2Measurement precision
If a rotation tracker with mechanical cam follower is used, then rotation can be tracked, but a cam count event may go undetected if the follower fails
Solution Approach 1:
The system incorporates feedback mechanisms where the cam follower's position is continuously monitored and compared against expected cam profile positions. When a cam count event occurs, the system receives feedback about the follower's position and can detect anomalies or failures in the follower mechanism, alerting operators to potential issues before they cause undetected tracking errors.
3Productivity
If excessive corrective yaw manoeuvres are performed, then cable twist may be reduced, but severe damage to power cables can occur
Solution Approach 1:
The cam-based detection system performs preliminary detection of the actual rotation state before corrective yaw maneuvers are executed. By accurately determining the current angular position and rotation direction through the mechanical cam profile, the system can calculate the precise corrective action needed, avoiding excessive maneuvers that would damage cables while ensuring sufficient correction to resolve the twist.
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
The rotation limit detector effectively identifies the direction of rotation at the limit, allowing for accurate corrective measures to prevent further damage, thereby reducing downtime and maintenance costs associated with twisted power cables.
Implementation Method 1
a transmission system that is configured to convert rotation of the primary shaft into rotation of a secondary shaft according to a gear ratio. The transmission system of the inventive rotation limit detector applies an inverse gear ratio to convert a full rotation of the primary shaft into a fraction of a full rotation of the secondary shaft.
Data Source
AI summary
A rotation limit detector, wind turbine and method to detect a limit of rotation of a toothed ring of a rotating assembly includes a pinion mounted on a primary shaft to engage with the toothed ring; a transmission system configured to convert rotation of the primary shaft into rotation of a secondary shaft; a first switch actuator mounted on the secondary shaft, and a first switch for inclusion in a control circuit, wherein the first switch actuator is configured to actuate the first switch when the extent of rotation of the toothed ring has reached a predefined limit in a clockwise direction; and a second switch actuator mounted on the secondary shaft, and a second switch for inclusion in the control circuit, wherein the second switch actuator actuates the second switch when the extent of rotation of the toothed ring has reached a predefined limit in a counter-clockwise direction.