The present disclosure relates in general to wind turbine, and more particularly to methods for preventing wind turbine rotor blade tower strikes.
Wind power is considered one of the cleanest, most environmentally friendly energy sources presently available, and wind turbines have gained increased attention in this regard. A modern wind turbine typically includes a tower, a generator, a gearbox, a nacelle, and one or more rotor blades. The rotor blades capture kinetic energy of wind using known airfoil principles. The rotor blades transmit the kinetic energy in the form of rotational energy so as to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.
During operation of the wind turbine, the rotor blades can become worn, damaged, or deflected. For example, tip separation, delamination, or deflection may change the shape of the rotor blade. In addition, the tower may become damaged. Such tip separation, delamination, deflection, and/or tower damage generally increases the risk of a rotor blade tower strike. Repair of blade tower strikes can be very expensive due to the costs associated with repair and/or replacement of the rotor blades and/or the tower as well as downtime of the wind turbine.
Thus, design modifications of the wind turbine, such as nacelle upward tilt, blade coning, and blade pre-bend have been implemented on modern wind turbines to mitigate such blade tower strikes. However, it is still important to understand the design margin for blade tower clearance on a functioning wind turbine.
As such, the present disclosure is continuously seeking new and improved methods for preventing wind turbine rotor blade tower strikes. Accordingly, the present disclosure is directed to methods for continuously measuring blade tip deflection via an array of sensors so as to prevent rotor blade tower strikes.
Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In one aspect, the present disclosure is directed to a method for preventing a tower strike of a tower of a wind turbine by a rotor blade thereof. The method includes mounting a plurality of sensors circumferentially around the tower at a height generally aligning with a blade tip of the rotor blade in a rotor plane as the blade tip passes through a six o'clock position. Further, the method includes generating, via one or more of the plurality of sensors, at least one distance signal representative of a distance between the blade tip of the rotor blade and the tower as the rotor blade passes by one or more of the sensors. Thus, the method also includes implementing, via a wind turbine controller, a corrective action if the distance signal exceeds a predetermined threshold.
In one embodiment, the method includes generating, via one or more of the plurality of sensors, a plurality of distance signals representing the distance between the blade tip of the rotor blade and the tower as the rotor blade passes by the sensors and filtering the plurality of distance signals. In another embodiment, if the rotor blade passes equally between two of the plurality of sensors, the method may include simultaneously generating, via the two sensors, a plurality of distance signals representing the distance between the blade tip of the rotor blade and the tower.
In another embodiment, the step of implementing the corrective action may include implementing a thrust reduction action. More specifically, in certain embodiments, the step of implementing the thrust reduction action may include increasing a pitch angle of the rotor blade, increasing a torque demand of a generator of the wind turbine, reducing a rotor speed of the wind turbine, yawing a nacelle of the wind turbine, and/or modifying a tip-speed-ratio (TSR) of the rotor blade. In additional embodiments, the step of implementing the corrective action may further include modifying a turbine speed set point and at least one of a power set point or a torque set point of the wind turbine after implementing the thrust reduction action.
In several embodiments, the method may also include checking one or more operating conditions of the wind turbine before implementing the thrust reduction action.
In additional embodiments, the method may include determining a yaw position of a rotor of the wind turbine, storing the yaw position in a memory device of the wind turbine controller, and adjusting the corrective action based on the yaw position.
In another embodiment, the sensor(s) may include any suitable sensor including but not limited to a laser sensor, a video sensor, a radio sensor, a proximity sensor, an ultrasonic sensor, or similar. In addition, the method may further include mounting the plurality of sensors circumferentially around the tower via at least one of one or more magnets, one or more fasteners, an adhesive, a track, or combinations thereof. Further, in certain embodiments, the method may include evenly spacing the plurality of sensors circumferentially around the tower.
In yet another embodiment, the method may include communicatively coupling each of the plurality of sensors to the controller via a power cable or wireless communication.
In another aspect, the present disclosure is directed to a wind turbine. The wind turbine includes a tower extending from a support surface, a nacelle mounted atop the tower, a rotor mounted to the nacelle and having a rotatable hub and at least one rotor blade extending therefrom, a plurality of sensors, and a wind turbine controller. Further, the sensors are circumferentially mounted around the tower at a height generally aligning with a blade tip of the rotor blade in a rotor plane as the blade tip passes through a six o'clock position. Further, the sensors may be arranged in any suitable number of rows. In addition, one or more of the sensors is configured to generate a plurality of distance signals representative of a distance between the blade tip of the rotor blade and the tower as the rotor blade passes by one or more of the sensors. Thus, the wind turbine controller is configured to implement a corrective action if the distance signal exceeds a predetermined threshold. It should also be understood that the wind turbine may further include any of the additional features and/or embodiments as described herein.
In yet another aspect, the present disclosure is directed to a method for preventing a rotor blade tower strike of a tower of a wind turbine. The method includes mounting a plurality of sensors circumferentially around the tower at a height generally aligning with a blade tip of the rotor blade in a rotor plane as the blade tip passes through a six o'clock position. Further, the method includes mounting one or more additional sensors on a nacelle of the wind turbine. The method also includes generating, via one or more of the plurality of sensors, at least one distance signal representative of a distance between the rotor blade and the tower. Moreover, the method includes implementing, via a wind turbine controller, a corrective action if the distance signal exceeds a predetermined threshold. It should also be understood that the method may further include any of the additional steps and/or features as described herein.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
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:
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.
Referring now to the drawings,
The wind turbine 10 may also include a wind turbine controller 26 centralized within the nacelle 16. However, in other embodiments, the controller 26 may be located within any other component of the wind turbine 10 or at a location outside the wind turbine 10. Further, the controller 26 may be communicatively coupled to any number of the components of the wind turbine 10 in order to control the components. As such, the controller 26 may include a computer or other suitable processing unit. Thus, in several embodiments, the controller 26 may include suitable computer-readable instructions that, when implemented, configure the controller 26 to perform various different functions, such as receiving, transmitting and/or executing wind turbine control signals.
Referring now to
Each rotor blade 22 may also include a pitch adjustment mechanism 32 configured to rotate each rotor blade 22 about its pitch axis 28, depending on the wind speed and/or wind direction. As such, pitching the blades 22 directly affects the power output of the generator 24. More specifically, each pitch adjustment mechanism 32 may include a pitch drive motor 40 (e.g., any suitable electric, hydraulic, or pneumatic motor), a pitch drive gearbox 42, and a pitch drive pinion 44. In such embodiments, the pitch drive motor 40 may be coupled to the pitch drive gearbox 42 so that the pitch drive motor 40 imparts mechanical force to the pitch drive gearbox 42. Similarly, the pitch drive gearbox 42 may be coupled to the pitch drive pinion 44 for rotation therewith. The pitch drive pinion 44 may, in turn, be in rotational engagement with a pitch bearing 46 coupled between the hub 20 and a corresponding rotor blade 22 such that rotation of the pitch drive pinion 44 causes rotation of the pitch bearing 46. Thus, in such embodiments, rotation of the pitch drive motor 40 drives the pitch drive gearbox 42 and the pitch drive pinion 44, thereby rotating the pitch bearing 46 and the rotor blade 22 about the pitch axis 28. Similarly, the wind turbine 10 may include one or more yaw drive mechanisms 66 communicatively coupled to the controller 26, with each yaw drive mechanism(s) 66 being configured to change the angle of the nacelle 16 relative to the wind (e.g., by engaging a yaw bearing 68 of the wind turbine 10).
Referring now to
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) 60 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) 60 may generally be configured to store suitable computer-readable instructions that, when implemented by the processor(s) 58, 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.
The sensors 52 described herein may include any suitable sensor now known or later developed in the art that is capable of measuring a distance. For example, in certain embodiments, the sensor(s) 52 may include a laser sensor, a video sensor, a radio sensor, a proximity sensor, an ultrasonic sensor, an optical sensor, or similar. More specifically, in certain embodiments, the sensors 52 may include laser distance sensors that can withstand water, dust, and other environmental conditions experienced at a wind turbine site.
Referring now to
In addition, as shown, the sensors 52 may be mounted in a single row (
Further, as shown in
Referring now to
Referring back to
In further embodiments, the method 100 may include determining at least one wind condition of the wind turbine 10 and adjusting the distance signals based on the at least one wind condition. For example, in certain embodiments, the wind condition may include wind direction, wind speed, or any other wind and/or weather parameter. Thus, in such embodiments, the controller 26 may be configured to plot the distance signals against an average wind speed. As expected, the rotor blade 22 typically passes closest to the tower 12 around rated wind speeds. Accordingly, such wind and/or weather conditions can be considered by the controller 26 when evaluating the likelihood of a rotor blade tower strike.
In additional embodiments, the method 100 may include generating a plurality of distance signals via the sensors 52 that are representative of the distance 72 between the blade tip 23 of the rotor blade 22 and the tower 12 as the rotor blade 22 passes by the sensor(s) 52 and filtering the plurality of distance signals. For example, as shown in
Accordingly, as shown at 90, the blade deflection data set can be used to implement a corrective action so as to prevent a rotor blade tower strike. Referring back to
If the predetermined threshold is exceeded, the controller 26 is configured to implement one or more corrective actions so as to prevent a rotor blade tower strike. For example, in certain embodiments, the corrective action(s) may include implementing a thrust reduction action 93. More specifically, in such embodiments, the thrust reduction action(s) may include increasing a pitch angle 95 of the rotor blade 22, increasing a torque demand 96 of a generator 24 of the wind turbine 10, reducing a rotor speed 97 of the wind turbine 10, yawing the nacelle 16 of the wind turbine 10, and/or modifying a tip-speed-ratio (TSR) 94 of the rotor blade 22. Accordingly, as shown at 99, the controller 26 is configured to provide appropriate operational set points for wind turbine 10 so as to maintain a desired clearance between the tower 12 and the rotor blades 22. For example, in several embodiments, the step of implementing the corrective action may include modifying a turbine speed set point and at least one of a power set point or a torque set point of the wind turbine after implementing the thrust reduction action. More specifically, in certain embodiments, the controller 26 may modify the turbine speed set point and the torque set point of the wind turbine 10 so as to avoid rotor blade tower strikes. In alternative embodiments, the controller 26 may modify the turbine speed set point and a power set point 98 of the wind turbine 10 so as to avoid rotor blade tower strikes.
Exemplary embodiments of systems and methods for a wind turbine are described above in detail. The systems and methods are not limited to the specific embodiments described herein, but rather, components of the systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein, and are not limited to practice with only the wind turbine systems as described herein.
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.