System and Method for Detecting a Pitch Fault in a Wind Turbine Via Voltage, Current, Torque, or Force Monitoring
20200025173 ยท 2020-01-23
Inventors
Cpc classification
F05B2270/309
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D17/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2270/328
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D7/0224
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D7/0264
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D7/0212
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/72
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
F03D7/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A method for reducing loads of a wind turbine includes determining an operational state of the wind turbine. The method also includes commanding a predetermined pitch event. Further, the method includes monitoring at least one operating condition of a pitch drive mechanism of a rotor blade of the wind turbine during the predetermined pitch event. If the operational state corresponds to a predetermined operational state and the operating condition(s) follows a pitch fault pattern during the predetermined pitch event, the method also include yawing a nacelle of the wind turbine away from an incoming wind direction.
Claims
1. A method for reducing loads of a wind turbine, the method comprising: determining, via a controller, an operational state of the wind turbine; commanding, via the controller, a predetermined pitch event for a pitch drive mechanism of a rotor blade of the wind turbine; monitoring, via the controller, at least one operating condition of the pitch drive mechanism of the rotor blade during the predetermined pitch event; and, if the operational state corresponds to a predetermined operational state and at least one operating condition follows a pitch fault pattern during the predetermined pitch event, yawing a nacelle of the wind turbine away from an incoming wind direction.
2. The method of claim 1, wherein monitoring the at least one operating condition of the pitch drive mechanism of the rotor blade further comprises monitoring at least one operating condition of a pitch actuator of the pitch drive mechanism.
3. The method of claim 2, wherein the pitch actuator comprises at least one of a rotary actuator or a linear actuator.
4. The method of claim 3, wherein the predetermined pitch event comprises at least one of acceleration to a first speed, dwelling at a predetermined speed for a predetermined time period, and/or deceleration to a second speed.
5. The method of claim 4, wherein an acceleration rate of the acceleration requires full motor current of the rotary actuator or actuator force of the linear actuator.
6. The method of claim 1, wherein the at least one operating condition comprises at least one of voltage, current, torque, force, pressure, or flow rate of the pitch drive mechanism.
7. The method of claim 1, wherein the predetermined operational state of the wind turbine comprises at least one of an idling state, a parked state, turbine shutdown, or a maintenance state.
8. The method of claim 1, wherein the pitch fault pattern comprises one or more of the operating conditions remaining substantially constant after initial variation due to system compliance during the predetermined pitch event in a first direction and one or more operating conditions being substantially symmetrical for an identical pitch event in an opposite direction.
9. The method of claim 1, further comprising preventing a rotor of the wind turbine from rotating during the predetermined pitch event.
10. The method of claim 1, further comprising monitoring a wind speed at the wind turbine and actively yawing the nacelle of the wind turbine away from the incoming wind direction only if the wind speed exceeds a set wind speed threshold.
11. A system for reducing loads of a wind turbine, the system comprising: at least one sensor configured for monitoring a rotor blade of the wind turbine; a controller communicatively coupled to the at least one sensor, the controller comprising at least one processor configured to perform one or more operations, the one or more operations comprising: determining an operational state of the wind turbine; commanding a predetermined pitch event; monitoring at least one operating condition of a pitch drive mechanism of a rotor blade of the wind turbine during the predetermined pitch event; and, if the operational state corresponds to a predetermined operational state and the at least one operating condition follows a pitch fault pattern during the predetermined pitch event, yawing a nacelle of the wind turbine away from an incoming wind direction.
12. The system of claim 11, wherein monitoring the at least one operating condition of the pitch drive mechanism of the rotor blade further comprises monitoring at least one operating condition of a pitch actuator of the pitch drive mechanism.
13. The system of claim 12, wherein the pitch actuator comprises at least one of a rotary actuator or a linear actuator, the at least one operating condition comprising at least one of voltage, current, torque, force, pressure, or flow rate of the pitch drive mechanism.
14. The system of claim 13, wherein the predetermined pitch event comprises at least one of acceleration to a first speed, dwelling at a predetermined speed for a predetermined time period, and/or deceleration to a second speed.
15. The system of claim 14, wherein an acceleration rate of the acceleration requires full motor current of the pitch drive motor or actuator force of the pitch hydraulic device.
16. The system of claim 11, wherein the predetermined operational state of the wind turbine comprises at least one of an idling state, a parked state, turbine shutdown, or a maintenance state.
17. The system of claim 11, wherein the pitch fault pattern comprises one or more of the operating conditions remaining substantially constant after initial variation due to system compliance during the predetermined pitch event in a first direction and one or more operating conditions being substantially symmetrical for an identical pitch event in an opposite direction.
18. The method of claim 11, wherein the one or more operations further comprise preventing a rotor of the wind turbine from rotating during the predetermined pitch event.
19. A method for reducing loads of a wind turbine, the method comprising: commanding, via a controller, a predetermined pitch event; monitoring, via the controller, at least one operating condition of a pitch drive mechanism of a rotor blade of the wind turbine during the predetermined pitch event; and, if the at least one operating condition varies from a standard operating pattern by a predetermined percentage during the predetermined pitch event, yawing a nacelle of the wind turbine away from an incoming wind direction.
20. The method of claim 19, wherein the standard operating pattern comprises a first operating condition of the pitch drive mechanism being proportional to a commanded speed of the pitch drive mechanism and a second operating condition reaching a maximum value during acceleration and plateauing at a lower value during constant speed, the first operating condition comprising voltage, the second operating condition comprising at least one of current, force, or pressure.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
DETAILED DESCRIPTION
[0026] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0027] Referring now to the drawings,
[0028] Referring now to
[0029] It should be appreciated that the main shaft 40 may generally be supported within the nacelle 16 by a support frame or bedplate 46 positioned atop the wind turbine tower 12. For example, the main shaft 40 may be supported by the bedplate 46 via a pair of pillow blocks mounted to the bedplate 46.
[0030] As shown in
[0031] In addition, as shown in
[0032] Further, as shown, a wind sensor 58 may be provided on the wind turbine 10. The wind sensor 58, which may for example be a wind vane, and anemometer, and LIDAR sensor, or another suitable sensor, may measure wind speed and direction. As such, the sensors 57, 58 may further be in communication with the controller 26, and may provide related information to the controller 26. For example, yawing of the wind turbine 10 may occur due to sensing of changes in the wind direction 28, in order to maintain alignment of the wind turbine 10 with the wind direction 28. In addition, yawing of the wind turbine 10 may occur due to sensing a stuck blade, which is described in more detail herein.
[0033] Further, the turbine controller 26 may also be communicatively coupled to various components of the wind turbine 10 for generally controlling the wind turbine 10 and/or such components. For example, the turbine controller 26 may be communicatively coupled to the yaw drive mechanism(s) 38 of the wind turbine 10 for controlling and/or altering the yaw direction of the nacelle 16 relative to the direction 28 (
[0034] Still referring to
[0035] As such, the turbine controller 26 may be communicatively coupled to each pitch adjustment mechanism 32 of the wind turbine 10 (one of which is shown) through a pitch controller 30 for controlling and/or altering the pitch angle of the rotor blades 22 (i.e., an angle that determines a perspective of the rotor blades 22 with respect to the direction 28 of the wind). For instance, the turbine controller 26 and/or the pitch controller 30 may be configured to transmit a control signal/command to each pitch adjustment mechanism 32 such that the pitch adjustment mechanism(s) 32 adjusts the pitch angle of the rotor blades 22 as described herein. The turbine controller 26 may control the pitch angle of the rotor blades 22, either individually or simultaneously, by transmitting suitable control signals/commands to a pitch controller of the wind turbine 10, which may be configured to control the operation of a plurality of pitch drives or pitch adjustment mechanisms 32 of the wind turbine, or by directly controlling the operation of the plurality of pitch drives or pitch adjustment mechanisms.
[0036] In addition, as shown, the pitch drive mechanism(s) 32 described herein may also include an encoder 59 communicatively coupled to the pitch controller 30 and/or the turbine controller 26. In one embodiment, the encoder 59 may be an incremental encoder that provides encoder signals for input to the controllers 26, 30 via one or more I/O interfaces (not shown). Accordingly, the pitch encoder 59 may be in communication with the turbine controller 26 to produce speed signals representative of the pitch angular speed of the rotor blade 22.
[0037] Referring now to
[0038] As used herein, the term processor refers not only to integrated circuits referred to in the art as being included in a computer, but also refers to a controller, a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits. Additionally, the memory device(s) 62 may generally comprise memory element(s) including, but not limited to, computer readable medium (e.g., random access memory (RAM)), computer readable non-volatile medium (e.g., a flash memory), a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), a digital versatile disc (DVD) and/or other suitable memory elements. Such memory device(s) 62 may generally be configured to store suitable computer-readable instructions that, when implemented by the processor(s) 60, configure the controller 26 to perform various functions including, but not limited to, transmitting suitable control signals to implement corrective action(s) in response to a distance signal exceeding a predetermined threshold as described herein, as well as various other suitable computer-implemented functions.
[0039] As discussed above, a wind turbine 10, such as the nacelle 16 thereof, may rotate about the yaw axis 36 as required. In particular, rotation about the yaw axis 36 may occur due to changes in the wind direction 28, such that the rotor 18 is aligned with the wind direction 28. For example, when the wind turbine 10 is in an idling state, the controller 26 actively tracks the wind direction to provide better alignment to the wind and minimize start-up delays when the wind speed increases or decreases back into the operating range. However, in a situation where the wind turbine 10 is in an idling or parked stated and one or more of the rotor blades 22 becomes stuck, there are limited benefits to tracking the wind because repair will be required before restarting the wind turbine 10. Thus, in such situations, the turbine controller 26 is configured to implement a control strategy to reduce the drag force on the faulted rotor blade so as to reduce loads thereon and/or to prevent rotor imbalance.
[0040] More specifically, as shown in
[0041] As shown at 102, the method 100 includes determining an operational state of the wind turbine 10. In such embodiments, the operational state of the wind turbine 10 may be an idling state, a parked state, and/or a maintenance state or combinations thereof. As used herein, the idling state of the wind turbine 10 generally refers to the operational state where, due to lack of wind or some other operational conditions (e.g. faults), the rotatable hub 20 of the wind turbine 10 is allowed to rotate (i.e. idle) at low rotational speeds, e.g. around 0.2 rpm, rather than being stopped completely. In contrast, a parked state of the wind turbine 10 generally refers to the operational state where the rotatable hub 20 is stopped and prevented from rotating. In addition, a maintenance state of the wind turbine 10 generally refers to operational state where the wind turbine 10 is undergoing a maintenance procedure and is shut down. Therefore, in certain embodiments, the maintenance state and the parked state may be synonymous.
[0042] Referring back to
[0043] As shown at 106, the method 100 includes monitoring at least one operating condition of the pitch drive mechanism 32 of the rotor blade 22 of the wind turbine 10 during the predetermined pitch event. For example, in one embodiment, the controller 26 (or the pitch controller 30) may be configured to monitor at least one operating condition of a pitch actuator 33 of the pitch drive mechanism 32. More specifically, in such embodiments, the pitch actuator 33 may include the pitch drive motor described herein, a pitch hydraulic device, or any other suitable actuating device. Thus, operating condition(s) described herein may include, for example, voltage, current, torque, force, pressure, flow rate, or any other suitable parameter of the pitch actuator of the pitch drive mechanism 32.
[0044] Still referring to
[0045] In particular embodiments, for example, the pitch fault pattern may correspond to a first operating condition of the pitch drive mechanism 32 plateauing at the start of the predetermined pitch event and a second operating condition reaching a maximum value for the entire predetermined pitch event in a positive direction and a negative direction. In such embodiments, the first operating condition may be voltage, whereas the second operating condition may be current, force, or pressure (i.e. depending on the type of pitch actuator).
[0046] For example, as shown in
[0047] Referring back to
[0048] In additional embodiments, the method 100 may include preventing the rotor 18 from rotating during the predetermined pitch event. For example, during normal operation of the wind turbine 10, the load will naturally vary during rotor rotation. For this reason, the system and method of the present disclosure may consider the rotor location during the commanded pitch event and/or may stop the rotor 18 from rotating to prevent the asymmetrical load from changing during the commanded pitch event. For example, in one embodiment, the controller 26 may limit the commanded pitch event to be short enough in duration such that the load change due to the rotor rotation may be minimal.
[0049] Referring now to
[0050] It should also be understood that if the wind turbine 10 continues to operate normally, the controller 26 is configured to continuously monitor the incoming wind direction 28 and yaw the nacelle 16 into the incoming wind direction 28 to provide improved alignment to the wind with minimal start-up delays when the wind speed increases or decreases back into the operating range.
[0051] Referring now to
[0052] As shown at 202, the method 200 includes commanding a predetermined pitch event, such as any of the pitch events described herein. As shown at 204, the method 200 includes monitoring at least one operating condition of the pitch drive mechanism 32 of the rotor blade 22 of the wind turbine 10 during the predetermined pitch event. For example, as mentioned, the controller 26 (or the pitch controller 30) may be configured to monitor an operating condition(s) of a pitch actuator 33 of the pitch drive mechanism 32, such as voltage, current, torque, force, pressure, flow rate, or any other suitable parameter thereof.
[0053] Still referring to
[0054] Referring particularly to
[0055] As shown at 208, if the operating condition(s) varies from the standard operating pattern during the predetermined pitch event by a predetermined percentage or amount, the method 100 further includes yawing the nacelle 16 of the wind turbine 10 away from the incoming wind direction 28.
[0056] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.