Patent Application
20110158805
The present invention relates to a pitch control system for operating the blade pitch of the rotor blades of a wind turbine generator. In particular, the present invention relates to testing operational signals of a blade pitch system in order to detect pitch system faults.
One of the fundamental operating components of wind turbine generators is the pitch system for adjusting the pitch of the rotor blades during operation. An important element in the pitch system is the pitch bearing.
Pitch system are subject to faults during use, such faults can relate to bearing faults or faults in other pitch system components.
Bearing damage can e.g. result from corrosion, friction in the pitch system mechanics, lack of grease, fatigue of damaged pitch bearings, etc. Damaged bearings increase the risk of blade pitch blocking which can be crucial for the loads on the turbine. Moreover, the delivery time of bearings is typically very long, damaged bearings can therefore result in long unwanted downtimes.
It may therefore be important to test a pitch system of a wind turbine generator.
The present invention seeks to provide an improved way of evaluating the conditions of a pitch system of a wind turbine generator.
It may be seen as an object of the present invention to address the above-mention aspects in order to improve the fault detection of pitch systems. Preferably, the invention alleviates, mitigates or eliminates one or more problems related to fault detection of pitch systems.
According to a first aspect of the invention there is provided a method of operating a pitch control system for a wind turbine generator comprising two or more rotor blades, the two or more rotor blades comprise a blade pitch system for operating the blade pitch, the method comprises:
The invention relates generally to a wind turbine generator comprising two or more rotor blades, however typically the turbines comprise three rotor blades.
The pitch control system may be a part of the wind turbine generator's general electronic control system, such as a dedicated module of the general electronic control system or other means of providing control of the pitching. In embodiments such module may provide the functionality of pitch system testing or pitch system conditional monitoring to the pitch control system.
The pitching of the rotor blades is controlled by applying a command signal, also referred to as a pitch demand, to the blade pitch system in order to operate the pitch system according to a desired action. The command signal is typically in the form of demanded pitch angle and pitching speed. Subsequent to, or concurrently with, applying the command signal, the pitch control system also receives a response signal indicating the pitch response obtained in response to the command signal and desired pitch system action from the blade pitch system. The pitch response may be a detection of the actual pitch action, e.g. a detection of the actual pitch angle and pitch speed by means of sensors.
The reference may be in any form suitable for comparison to the response signal or derivative of the response signal. The reference may be in the form of a reference value, in the form of a threshold, in the form of a range, in the form of a reference signal, etc.
In an advantageous embodiment, a signal indicative of a pitch system fault is generated if a difference between the response signal and the reference is detected as being larger than a preset criterion. A pitch system fault may cause the behaviour of the pitch system to deviate from the expected or normal behaviour. This may e.g. be reflected as a retarded response, an uneven response, or any other unexpected response of the pitch system to the applied command signals. A pitch system fault may indicate a pitch bearing fault, however other faults of the pitch system may also be reflected in the pitch system fault, such as seal leakage, or other mechanical faults. A pitch system fault may be reflected directly in the response signal, and the detection may be done by use of the response signal as directly received from the blade pitch system. However, the comparison of the response signal to the reference may advantageously be based on, or be done in terms of, a derived functional expression of the response signal. In an embodiment, the derived functional expression may be based on a difference signal between the response signal and the command signal. By using a difference signal a more clear indication of a pitch system fault may be achieved. The difference signal may be a signal indicating a difference in time, i.e. a signal indicating the time the actual pitch is lacking after the demanded pitch. The difference signal may also be a signal indicating an acceleration, i.e. a signal indicating how fast the actual pitch is adapting to the demanded pitch. The difference signal may also be a signal indicating a difference in degrees, i.e. a signal indicating how many degrees the actual pitch is lacking after the demanded pitch. Other types of difference signals may also be used.
The comparison of the response signal to the reference may in general be based on, or be done in terms of, derived functional expressions or derived statistical values of the response signal. Basing the comparison on derived functional expressions or statistical analysis may improve the certainty of the derived conclusions. A number of derived functional expressions and derived statistical values may be used. As a specific example, the response signal may be compared in terms of a comparison of standard deviations of a difference signal.
The difference between the response signal and the reference may be evaluated against a preset criterion. The use of a preset criterion is a convenient way of evaluating signal behaviour. A number of different types of criteria can be used.
By comparing the response signal from the blade pitch system to a reference, detection of pitch system faults, such as pitch bearing blocking, may be detected at an early stage and thereby avoided or at least diminished before a pitch bearing breaks down occurs, and proper action taken timely. For example, if the pitch bearing behaviour of the bearings is not too different from the preset criteria or if the behaviour can be accounted for in the general operational routines, the wind turbine generator may be down-rated rather than stopped. Moreover, appropriate replacement parts can be ordered in time, and maintenance carefully scheduled. Emergency maintenance may thereby be avoided or at least diminished.
In a first type of embodiment, the two or more rotor blades are pitched by a common blade pitch system. In this situation a common command signal is applied to the blade pitch system and a common response signal is received from the blade pitch system. In this type of embodiment, the response signal from the blade pitch system may be compared to a reference. The reference may be known from table values, test results, obtained during running-in operation, or from other means. The reference may either be fixed to a predefined reference, or adaptively updated during use. It may be advantageous to adaptively update the reference if a slow drift of the response signal can be accepted, so that only abrupt or sudden changes may be taken as an indication of a pitch system fault.
In a second type of embodiment, each of the two or more rotor blades are pitched by independent blade pitch systems. In this situation individual command signals are applied to the each of the independent blade pitch systems and individual response signals are received from each of the independent blade pitch systems.
A pitch system may be exposed to various factors which may incur a drift or change over time in the response parameters of the pitch system during the operation. Such factors may relate to temperature gradients, transient loads, such as gusting, and other factors. The individual pitch systems may be exposed to different factors, and the response parameters of the individual pitch systems may behave differently over time for different blade pitch systems. In the second type of embodiment, pitch system faults reflected in the response signals may be detected already when a single pitch system starts to behave in a different manner.
In the second type of embodiment, the reference may be derived from at least one individual response signal. It is thereby rendered possible to test the individual response signals of each of the two or more rotor blades against the collective behaviour of all or some of the involved pitch systems. In general, the reference may be based on a functional expression or statistical analysis of the individual response signals.
In an advantageous embodiment, the reference may be derived from at least one individual response signal, and the at least one individual response signal may be selected based on a statistical analysis of the individual response signals received from each of the independent blade pitch systems.
A subgroup comprising one or more individual response signals may be selected from the group of all the individual response signals. The subgroup may be selected so that the response signals comprised in the subgroup possess a similar behaviour. The reference may be derived from signal values of the response signals of the subgroup. By basing the reference on signal values obtained from similarly behaving response signals, it is ensured that any differences are detected from the actual operation conditions as obtained during operation and not from ideal pre-operation parameters. A preset criterion may set so as to detect such a difference or deviation, e.g. a given percentage, of a response signal from the behaviour of the subgroup.
Members of the subgroup of the pitch responses may thus be selected based on statistical analysis of the response signals. Basing the reference and/or the selection of the members of the subgroup on derived functional expressions or statistical analysis may improve the certainty of the derived conclusions, since the response signals may possess a certain degree of noise. A number of functional expressions and derived statistical values may be used. Examples include, but are not limited to, mean values and standard deviations.
In an advantageous embodiment, an error signal based on the command signal and the response signal is monitored and an alarm signal is generated if the error signal fulfils an alarm criterion. The detection of the alarm signal may generate a request for comparing the response signals, i.e. a request for a test of the pitch response. An alarm criterion may be set up to detect unusual or unwanted operation. Such alarms may be common during wind turbine operation. An alarm, however, does not necessarily reflect a pitch system fault. But a pitch system fault will likely lead to an alarm at some stage, it is therefore advantageous to test the pitch system subsequent to receiving an alarm. Since alarm systems may be common to wind turbine control systems, embodiments of the present invention may advantageously be implemented as an improved functionality to existing alarm systems without major restructuring of the existing systems.
In embodiments, the test of the pitch response may be requested to occur subsequent to receiving an alarm, however a test may also be set to occur at a scheduled time instance or reoccur at preset intervals.
The testing of the response signals may, in embodiments, be conducted while the wind turbine generator is connected to a power grid. This may e.g. be advantageous if the test request is based on an alarm. In other embodiments may the test of the response signals be conducting while the wind turbine generator is disconnected from a power grid. This may be advantageous if the test affects the produced power in an unwanted or non-allowed way. An alarm may also be set so that the test is conducted while the wind turbine generator is disconnected from a power grid.
In advantageous embodiments, the command signal comprises a time-varying test signal, such as a test signal superimposed onto the command signal. The test signal may be in the form of a sine signal (cosine or sinus), in the form of a stepped ramp or in the form of a linear ramp. Simulations have shown that a sine signal or a stepped ramp may improve the detection of pitch system faults. In general, any form of time-variation may be used. A time varying test signal may stress the pitch system and thereby enhance the presence of any deviating or sub-optimal behaviour in the pitch response.
In an advantageous embodiment, the test signal may be in the form of a plurality of signal segments. Imposing a plurality of signal segments, such as a sequence of signal segments, may further improve the detection of a pitch system fault, since a variation in the behaviour of the pitch response between the segments may further indicate a pitch system fault. Typically between 2 and 10 segments, such as 2, 3, 5, 7, 10 may be used. However even more segments may also be used.
In accordance with a second aspect of the present invention, there is provided a pitch control system for a wind turbine generator comprising two or more rotor blades, the two or more rotor blades comprise a blade pitch system for operating the blade pitch, the pitch control system comprises:
The pitch control system may be a control system implementing the method of the first aspect.
In accordance with a third aspect of the present invention, there is provided a wind turbine generator, wherein the blade pitch systems are controlled by, or implements the functionality of, a pitch control system in accordance with the first or second aspect of the invention.
In a third aspect of the present invention, there is provided a computer program product having a set of instructions, when in use on a computer, to cause the computer to perform the method of the first aspect. The computer may be a processing unit implemented into the control system of the second or third aspect of the invention.
In general, the individual aspects of the present invention may each be combined with any of the other aspects. These and other aspects of the invention will be apparent from the following description with reference to the described embodiments.
Embodiments of the invention will be described, by way of example only, with reference to the drawings, in which
In an embodiment the pitching of the rotor blades are monitored, e.g. by means of an error signal. The error signal may be based on the command signal and the response signal from each of the rotor blades. For example, the error signal may be a difference signal between the demanded pitch and the actual pitch. In an embodiment, an alarm signal is generated if the error signal fulfils an alarm criterion. An example of an alarm criterion may be that the actual pitch of a rotor blade is lacking behind the demanded pitch for more than a given preset time. For example a signal indicating that the pitch of blades for a common pitch system, or blade A for an individual pitch system has been 2 degrees behind the demanded pitch for 3 seconds may trigger an alarm signal, other alarm criteria can be envisioned. A number of reasons may cause a lacking of the pitch. One important reason relates to a bearing fault of one of the blades. However, a number of reasons which do not indicate a bearing fault may also cause such effects, and a wind turbine owner may ignore an alarm since it is judged that the probability of a false alarm is higher than the probability of a true alarms. In situations, the alarm signal may completely be neglected by setting the action of the alarm to “automatic restart”. Ignoring a true alarm or not timely taking action on a true alarm may cause serious damage to a pitch bearing which again may cause pitch bearing blocking which will result in unwanted down time of the entire turbine.
The response signal from the blade pitch system of the rotor blades may be tested by comparing the response signals of the rotor blades and indicating a pitch bearing fault if a difference between response signals and reference is detected as being larger than a preset criterion. The comparison of the response signals may also be based on derived values, typically derived statistical values, from the pitch response.
In an embodiment, the test is initiated or triggered by the generation of an alarm signal, in another embodiment the test is performed at preset intervals, in yet another embodiment the test is performed at a scheduled time instance. For example, a test may be performed every 3 months, every time the wind turbine generator is disconnected from a power grid, or at other instances.
In this embodiment, the preset criterion may be in the form of a threshold or threshold range as indicated with the lines 27. As an example, if the mean value is detected to surpass the threshold (range) it may be taken as an indication of a pitch system fault or suspected fault.
In general, the reference and the preset criterion may be based on a functional expression or statistical analysis of the response signal of the group of response signals that behave normally. To this end, this group, i.e. a subgroup of the signals, has to be detected. Detection of a subgroup of response signals may e.g. be achieved by a statistical analysis of all the response signals and then group together all the response signals which behave in a similar manner, a number of mathematical routines exist for this.
When testing the response signals from the blade pitch system of the rotor blades by comparing the response signals and indicating a pitch bearing fault if a difference in the response signals is detected, it may be an advantage to impose a test signal to the command signal. The test signal may be a time-varying signal. A time-varying signal may force the pitch system to quickly adapt to changing conditions which may bring out or accentuate a pitch fault into the response signal. The specific form of the time-varying signal need not be important, however for easier implementation well-known or well behaved time-varying signals may advantageously be used. In embodiments, the pitch demand may comprise a sine signal, a stepped ramp, a linear ramp or even other types of test signals. In the following a pitch demand with a superimposed sine signal is described.
In
The imposed sine signal is reflected in the output power, as an increased output fluctuation (
The test of the pitch response may in an embodiment be conducted while the wind turbine generator is connected to a power grid. However, as seen from
As can be seen the standard deviation 60 from the periods without imposed signal varies somewhat between the tests 1 to 5, whereas the standard deviation 61 from the periods with imposed signal is fairly constant. The determination of standard deviations, or other derived functional expressions or statistical measures, can be used as the reference to evaluate the pitch responses up against preset criteria when determining the presence of a possible or suspected bearing fault. In the Figure the derived signal is shown for a single pitch response, in accordance with embodiments of the present invention, a similar analysis may be made for each individual pitch system and compared in order to detect any deviating behaviour.
A signal handling unit 70 applies a command signal to the blade pitch system 71 and receives the response signal from the blade pitch system of each of the rotor blades. The response signals from the blade pitch system are tested in a test unit or comparison unit 72 by comparing the response signals in accordance with embodiments of the present invention.
In an embodiment, three error signals, e.g. the difference signal between demanded pitch and actual pitch, are monitored and an alarm signal 74 is generated if the error signal fulfils an alarm criterion. In another embodiment, only a single error signals is monitored.
The detection of the alarm signal generates a request for testing the response signals 75. The test request may include an instruction as to when and how the test is to be performed. For example, if the test is performed during operation, certain conditions may have to be fulfilled, e.g. meteorological conditions or specific grid conditions. The test request may also specify that the turbine is disconnected from the grid until a test have been performed, or the test request may specify that the next time the turbine is disconnected from the grid a test is performed. Other possibilities for specific test requests exist.
Different types of tests may be performed. In a first type of test, the error signal obtained from normal operation is monitored. With regard to
In other types of tests, the command signal enforces a sine signal, a stepped ramp or a linear ramp on to the demanded pitching. An error signal, as exemplified in
The outcome of the test may be graded, e.g. in terms of five grades running from A to E (ref. numeral 76) and to each of the grades a specific action may be attached 77.
In the test, the response signals are evaluated against a preset criterion. The grading may reflect the difference between the actual pitch responses (or their derived statistical values) and the preset criterion.
As a grading example the following grading and resulting actions may be used:
If the test result is clearly within the preset criterion, the operation may be graded A and the WTG action may be set to continue normal operation 700.
If the test result is just within the limits of the preset criterion, the operation may be graded B and the test may be repeated 701.
If the test result is outside the preset criterion within an acceptable limit, the operation may be graded C and the test may be repeated 702.
If the test result is somewhat outside the preset criterion but still above a critical limit, the operation may be graded D and the WTG may be set to pause 703.
If the test result is outside the preset criterion with a critical amount, the operation may be graded E and the WTG may be stopped 704.
In
A signal handling unit 80 applies a command signal or pitch demand 83 to the blade pitch system 81 of (each) of the rotor blades and receives the response signal(s) or pitch response(s) 84 from the blade pitch system of the rotor blades. The pitch response(s) are inputted 86 into a test unit or comparing unit 82 for testing/comparing the response signal(s) to a reference. In an embodiment, a signal indicative of a pitch bearing fault is generated 87 if a difference between the response signal(s) and the reference is detected as being larger than a preset criterion.
The invention can be implemented by means of hardware, software, firmware or any combination of these. The invention or some of the features thereof can also be implemented as software running on one or more data processors and/or digital signal processors. The individual elements of an embodiment of the invention may be physically, functionally and logically implemented in any suitable way such as in a single unit, in a plurality of units or as part of separate functional units. The invention may be implemented in a single unit, or be both physically and functionally distributed between different units and processors.
Although the present invention has been described in connection with the specified embodiments, it should not be construed as being in any way limited to the presented examples. The scope of the present invention is to be interpreted in the light of the accompanying claim set. In the context of the claims, the terms “comprising” or “comprises” do not exclude other possible elements or steps. Also, the mentioning of references such as “a” or “an” etc. should not be construed as excluding a plurality. The use of reference signs in the claims with respect to elements indicated in the figures shall also not be construed as limiting the scope of the invention. Furthermore, individual features mentioned in different claims, may possibly be advantageously combined, and the mentioning of these features in different claims does not exclude that a combination of features is not possible and advantageous.
| Number | Date | Country | Kind |
|---|---|---|---|
| PA 2008 01192 | Aug 2008 | DK | national |
| 2009 10138723.7 | Jan 2009 | CN | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/DK09/50216 | 8/26/2009 | WO | 00 | 3/8/2011 |
| Number | Date | Country | |
|---|---|---|---|
| 61190692 | Aug 2008 | US |
