Method for Early Error Detection in a Drive System, a System for Early Error Detection, Wind Generator Comprising the System and Use of the System

Abstract

A system for early error detection in a wind generator drive system includes a first rotation sensor that is coupled to an input shaft of a drive gear or transmission stage to capture an input angle of rotation. A second rotation sensor is coupled to an output shaft of the drive gear or transmission stage to capture an output angle, which is performed in response to the input angle. A control unit is configured to simultaneously capture a first and a second time dependent signal, which are indicative of the input angle and the output angle, respectively. The control unit is configured to determine a time dependent angle difference from the first and the second signals under consideration of a transmission ratio of the drive gear or transmission stage, and analyzes this difference to perform early error detection in the drive system.

Claims

1. A system for early error detection in a drive system of a wind generator comprising: a) a first rotation sensor, which is coupled to an input shaft of a the drive gear or transmission stage, to sense an input angle of rotation, b) a second rotation sensor, which is coupled to an output shaft of the drive gear or transmission stage, to sense an output angle of rotation, wherein the output angle of rotation is an output of the drive gear or transmission stage, which is performed in response to the input angle of rotation, c) a control unit, which is configured to simultaneously capture a first time dependent signal for the input angle of rotation from the first rotation sensor and a second time dependent signal for the output angle of rotation from the second rotation sensor, wherein the control unit is further configured to determine a time dependent angle difference from the first and the second time dependent signals under consideration of a transmission ratio of the drive gear or transmission stage, and wherein the control unit is further configured to analyze this time dependent angle difference to perform an early error detection in the drive system.

2. The system according to claim 1, wherein the drive system is one of the following: a pitch drive system, a nacelle drive system, azimuth or yaw drive, and a main drive system.

3. The system according to claim 1, wherein the first rotation sensor is coupled to a driving shaft of a drive motor, which drives the input shaft of the drive gear, and the second rotation sensor is an angle sensor that determines an angle of a component which is driven by the drive system.

4. The system according to claim 1, wherein the control unit is further configured to perform a spectral analysis, in particular an order tracking analysis, of an amplitude of the time dependent angle difference, wherein the order tracking analysis uses the input angle of rotation as a basis.

5. The system according to claim 4, wherein the control unit is configured to perform an order tracking analysis, which results in an envelope curve spectrum, and wherein the control unit is further configured to match at least one predetermined feature, which is assigned to an error relative to a bearing failure or a shaft breakage, with a feature in the envelope curve spectrum.

6. The system according to claim 4, wherein the control unit is further configured to perform an order tracking analysis, which results in an amplitude spectrum, and wherein the control unit is configured to match at least one predetermined feature with a feature in the amplitude spectrum, the predetermined feature being assigned to an error relative to at least one of the following: a gearing damage, an unbalance of gears, a misalignment of gears, a roller bearing damage, a shaft damage.

7. The system according to claim 4, wherein upon successful match of at least one predetermined feature with a feature in a spectrum, an error message relative to the error, which is assigned to the matched feature, is output.

8. A wind generator, in particular an offshore wind generator comprising: a drive system; and a system for early error detection including a first rotation sensor, which is coupled to an input shaft of a drive gear or transmission stage, to sense an input angle of rotation, a second rotation sensor, which is coupled to an output shaft of the drive gear or transmission stage, to sense an output angle of rotation, wherein the output angle of rotation is an output of the drive gear or transmission stage, which is performed in response to the input angle of rotation, a control unit, which is configured to simultaneously capture a first time dependent signal for the input angle of rotation from the first rotation sensor and a second time dependent signal for the output angle of rotation from the second rotation sensor, wherein the control unit is further configured to determine a time dependent angle difference from the first and the second time dependent signals under consideration of a transmission ratio of the drive gear or transmission stage, and wherein the control unit is further configured to analyze this time dependent angle difference to perform an early error detection in the drive system.

9. A method for using an early error detection system comprising a wind generator, in particular in an offshore wind generator, comprising: using a first rotation sensor, which is coupled to an input shaft of a drive gear or transmission stage, to sense an input angle of rotation, using a second rotation sensor, which is coupled to an output shaft of the drive gear or transmission stage, to sense an output angle of rotation, wherein the output angle of rotation is an output of the drive gear or transmission stage, which is performed in response to the input angle of rotation, using a control unit, which is configured to simultaneously capture a first time dependent signal for the input angle of rotation from the first rotation sensor and a second time dependent signal for the output angle of rotation from the second rotation sensor, wherein the control unit is further configured to determine a time dependent angle difference from the first and the second time dependent signals under consideration of a transmission ratio of the drive gear or transmission stage, and wherein the control unit is further configured to analyze this time dependent angle difference to perform an early error detection in the drive system.

10. A method for early error detection in a drive system of a wind generator including the steps of: a) capturing a first time dependent signal, which is indicative of an input angle of rotation of an input shaft of a drive gear or transmission stage, b) simultaneously capturing a second time dependent signal, which is indicative of an output angle of rotation of an output shaft of the drive gear or transmission stage, c) determining a time dependent angle difference from the first and the second time dependent signals under consideration of a transmission ratio of the drive gear or transmission stage and d) analyzing the time dependent angle difference to perform an early error detection in the drive system.

11. The method of early error detection according to claim 10, wherein the input angle of rotation is an angle of rotation of a rotor of a drive motor, which drives the input shaft of the drive gear, and the output angle of rotation is an angle of a component, which is driven by the drive system.

12. The method of early error detection according to claim 10, wherein the step of analyzing the time dependent angle difference includes performing a spectral analysis of an amplitude of the time dependent angle difference, in particular an order tracking analysis of an amplitude of the time dependent angle difference, wherein the this order tracking analysis takes the input angle of rotation as a basis.

13. The method of early error detection according to claim 12, wherein the order tracking analysis results in an envelope curve spectrum, and wherein at least one predetermined feature, which is assigned to an error relative to a bearing failure or a shaft breakage, is matched with a feature in the envelope curve spectrum.

14. The method of early error detection according to claim 12, wherein the order tracking analysis results in an amplitude spectrum, and wherein at least one predetermined feature, which is assigned to an error relative to a gearing damage, unbalance and/or a misalignment of gears, is matched with a feature in the amplitude spectrum.

15. The method of early error detection according to claim 12, wherein upon successful match of at least one predetermined features with a feature in a spectrum, an error message relative to an error, which is assigned to the matched feature, is output.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Further aspects and features of the invention ensue from the following description of preferred embodiments of the invention with reference to the accompanying drawings, wherein

[0030] FIG. 1 is a simplified offshore wind generator, according to an embodiment of the invention,

[0031] FIG. 2 schematically illustrates a system for early error detection in a drive system, according to another embodiment of the invention,

[0032] FIG. 3 is a flow-chart illustrating a method for early error detection in a drive system, according to still another embodiment of the invention, and

[0033] FIG. 4 is an example of a spectrum, which shows the result of an order tracking analysis.

DETAILED DESCRIPTION

[0034] FIG. 1 is a simplified perspective view of a wind generator 2. By way of an example, the wind generator 2 is an offshore wind generator. It comprises a rotor hub 4 carrying the rotor blades 6. A supporting structure 8, for example a tower, carries a nacelle (not visible) and is based on a suitable underwater foundation in the sea 10. Each rotor blade 6 can be rotated by a pitch angle ?. The pitch action is performed by a pitch drive system, which is typically mounted in the rotor hub 4. The nacelle can be moved by an azimuth drive. Other drive systems, which are not shown, are also present. The present invention applies to any drive system having a drive motor and a drive gear or transmission stage.

[0035] In FIG. 2, there is a simplified schematic drawing, which illustrates a system 12 for early error detection in a drive system, which can be a pitch drive system in this embodiment but can also be any other drive system of a wind turbine, in particular a nacelle drive (azimuth drive, yaw drive) system or a main drive system. If the drive system of a wind generator 2 includes a plurality of drives, at least some drives can be configured according to the embodiment of FIG. 2. The drive comprises a drive motor 14, for example an electric motor, having a drive shaft 16, which is coupled to an input shaft 18 of a drive gear 20 (can also be referred to as a transmission stage). The drive gear 20 can be a step-down planetary gear, for example for a pitch drive. The inverted gear transmission ratio of stage 20 is generally referred to as iDR.

[0036] In case of a pitch drive system, the pitch drive gear 20 comprises an output shaft 22 carrying a drive bevel 24. The drive bevel 24 is configured to engage an internal gear at a blade root of the rotor blade 6 of the wind generator 2. This is to rotate the rotor blade 6 by a pitch angle ? (FIG. 1).

[0037] The system 12 for early error detection in the drive system comprises a first rotation sensor 26 for sensing an input angle of rotation ?.sub.IN(t). The input angle ?.sub.IN(t) represents an input to the drive gear 20 (or transmission stage 20). By way of an example only, the first rotation sensor 26 is coupled to the input shaft 18 of the drive gear 20. In an alternative embodiment, the first rotation sensor 26*, which is shown in dashed lines, is coupled to the driving shaft 16 of the drive motor 14. The first rotation sensor 26, 26* communicates a signal, which is indicative of the input angle ?.sub.IN(t) via a first data link 28 to a control unit 30. Furthermore, the system 12 for early error detection comprises a second rotation sensor 32, which is coupled to the output shaft 22 of drive gear 20. The second rotation sensor 32 acquires an output angle ?.sub.OUT(t), which is communicated to the control unit 30 via the second data link 34. The data links 28, 34 can be configured according to frequently known data communication technology. It can be a wired or a wireless link.

[0038] The system for early error detection 12 is configured in that the signals for the input angle ?.sub.IN(t) and the output angle ?.sub.OUT(t) are acquired simultaneously. In other words, the values refer to a common time scale. Furthermore, the output angle ?.sub.OUT(t) represents an output of the drive gear 20, which is performed in response to the input angle ?.sub.IN(t).

[0039] In particular, the first rotation sensor 26 and the second rotation sensor 32 are high precision sensors. This applies to the resolution on a time scale and to the angular resolution.

[0040] Both input and output signals ?.sub.IN(t), ?.sub.OUT(t), which are captured by the control unit 30, are time dependent values. The control unit 30 is configured to calculate a time dependent angle difference ??(t) from the two time dependent signals. By way of an example only, the angle difference ??(t) can be calculated by subtracting the output angle from the input angle ?.sub.IN(t). However, the output angle ?.sub.OUT(t) should be corrected by the inverted transmission ratio iDR of the transmission stage 20. This generally provides that the so obtained difference ??(t) is:

??(t)=?.sub.IN(t)?iDR*?.sub.OUT(t)

[0041] In the ideal case, ??(t) is then supposed to be zero. Deviations from zero can be small or larger which already indicates a behavior of the transmission stage. Any other mathematical operation, which reflects the difference between the input and the output angles can, however, also be applied.

[0042] The control unit 30 is configured to perform a spectral analysis of the amplitude of the time dependent angle difference ??(t). In particular, an order tracking analysis can be performed on the amplitude of the time dependent angle difference ??(t). This order tracking analysis applies the input angle ?.sub.IN as a basis. An example for a spectrum of an order tracking analysis is shown in the simplified diagram of FIG. 4.

[0043] The order tracking analysis comprises an envelope curve spectrum 42, which is drawn in a dashed line. Furthermore, the plot includes an amplitude spectrum 44, which is drawn as a plurality of single points.

[0044] Various experiments revealed that the amplitude spectrum 44 can be analyzed for characteristic features, for example peaks exceeding certain thresholds, regular distanced peaks, certain patterns, etc. These features are indicative of certain gear errors. The allocation between the features and the errors can be stored in a database 31 in the control unit 31.

[0045] In addition to this, the experiments revealed that features, which can be identified in the amplitude spectrum 44, mainly indicate a gearing damage, unbalance and/or misalignment of gears in the drive gear 20.

[0046] Also the envelope curve 42 was analyzed with respect to particular features. When certain features can be identified in the amplitude spectrum 42, the various practical experiments revealed that these mainly indicate a bearing failure or a shaft breakage in the drive gear 20.

[0047] Within the context of this analysis, the high resolution of the sensors 26, 32 is rather crucial. This applies to the angular resolution as well as to the time resolution. Consequently, small variations between the input angle ?.sub.IN(t) and the output angle ?.sub.OUT(t) can be detected. Advantageously, this enables the system 12 to perform early error detection prior to serious secondary damages, which typically result from small initial damages.

[0048] In FIG. 3, there is a flow chart illustrating a method for early error detection in a drive system of a wind generator 2, according to an embodiment of the invention.

[0049] The condition monitoring starts (step S1) with the acquisition of a first time dependent signal, which is indicative of the input angle of rotation ?.sub.IN(t) of the input shaft 18 of the drive gear 20. Simultaneously, a second time dependent signal is captured (step S2). This is indicative of an output angle of rotation ?.sub.OUT(t) of the output shaft 22 of the drive gear 20. A time dependent angle difference ??(t) is subsequently determined, for example by subtracting the output angle ?.sub.OUT(t) from the input angle ?.sub.IN(t), while the output angle ?.sub.OUT(t) is multiplied with the transmission ratio iDR in accordance with the above equation (step S3). A spectral analysis is performed. For example, an order spectrum is generated. The order spectrum can be determined with respect to the number of rotations of a motor, i.e. the spectrum is indicated as a function of multiples of the rotation frequency. The order spectrum can also be determined as function of multiples of a fixed rotation angle. In the present example, the amplitude of the oscillations in the time dependent angle difference Amp(??(t)) is plotted as a function of the input angle ?.sub.IN (step S4).

[0050] An example for an order spectrum showing the amplitude of the angle difference Amp(??) as a function of the input angle ?.sub.IN, is shown in FIG. 4. Both variables are plotted in arbitrary units. The order spectrum includes an amplitude spectrum 44 and an envelope curve spectrum 42.

[0051] By way of an example only, there is a bearing failure at the input shaft 18 of the drive gear 20. This can be derived from the envelope curve spectrum 42, which shows maxima at regular intervals. The distance between these maxima on the abscissa corresponds with the input angle ?.sub.IN of the input shaft 18. For example, an input angle ?.sub.IN having the arbitrary number 1 indicates a single revolution of the input shaft 18. The peaks in the envelope spectrum 44 occur for every revolution of the input shaft 18, i.e. at approximately ?.sub.IN=1.5-2.5-3.5 etc.

[0052] The amplitude spectrum 44 and the envelope curve spectrum 42 are analyzed with respect to characteristic features therein. These features can, for example, include peaks exceeding certain thresholds, peaks occurring at regular intervals, characteristic curve spectra, characteristic curve shapes, etc. The control unit 30 matches the predetermined features in the database 31 with the spectra. Various experiments revealed that the envelope curve spectrum 42, if it includes certain characteristic features, gives a strong hint towards a bearing failure or shaft breakage. In other words, if certain characteristic features can be identified in the envelope curve spectrum 42, this indicates that there is a bearing failure or a shaft breakage in the drive gear 20. Similarly, the amplitude spectrum 44 is analyzed with respect to certain features. These can be identified with, for example, gearing damage, unbalance and/or misalignment of gears in the drive gear 20, as they occur.

[0053] In the flow chart of FIG. 3, the amplitude spectrum (step S51) and the envelope curve spectrum (step S52) are analyzed simultaneously. However, this can be performed subsequently without substantial deviations from the principles, which are explained with reference to FIG. 3. When a characteristic feature is identified (step S61) in the amplitude order spectrum, an error signal is output, which is indicative of a bearing failure or a shaft breakage (step S71). When a characteristic feature is identified (step S62) in the envelope curve spectrum, an error signal is output, which is indicative of a gear tooth damage, unbalance or misalignment of gears in the drive gear 20 (step S72).

[0054] When no characteristic features can be identified, neither in the amplitude spectrum nor in the envelope curve spectrum (steps S61 and S62), the question is whether the condition monitoring should be continued (step S8). When the condition monitoring continues, the method follows a branch YES and returns to step S2. If the condition monitoring should be terminated, the method of early error detection ends in step S9.

[0055] Advantageously, the condition monitoring of drives according to aspects of the invention can be performed during normal operation of the wind generator 2. No artificial test action is required. Consequently, the system 12 does advantageously not interfere with standard operation. Furthermore, errors in the drive system can be detected at a very early stage, i.e. prior to occurrence of serious secondary damages in the system. This will likely shorten the service downtimes of the wind generator 2. The system 12 for early error detection is particularly advantageous for offshore wind generators.

[0056] In an advantageous embodiment, the drive system is a pitch drive system. The motor is a pitch drive motor and the drive gear is pitch drive gear. The driven component is then a rotor blade.

[0057] Although the invention has been described hereinabove with reference to specific embodiments, it is not limited to these embodiments and no doubt further alternatives will occur to the skilled person that lie within the scope of the invention as claimed.