The present disclosure relates in general to wind turbines, and more particularly to systems and methods for preventing catastrophic damage in a drivetrain of a wind turbine.
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 nacelle mounted atop the tower, a rotor mounted to the nacelle having one or more rotor blades, and a drivetrain assembly within the nacelle. The drivetrain assembly typically includes various drivetrain components, such as a generator and a gearbox. The nacelle includes a rotor assembly coupled to the gearbox and to the generator. In many wind turbines, the generator and the gearbox are mounted to a bedplate within the nacelle via one or more torque arms. As such, the one or more 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 the gearbox, or if the 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.
Some wind turbines may include a low-speed resolution speed sensor and a high-resolution speed sensor, such as an encoder, on the generator for assessing rotor speed. The high-resolution speed sensor provides a high fidelity measurement of speed used to control the wind turbine. More specifically, a turbine controller may compare signals from the low-speed resolution speed sensor and the high-resolution speed sensor and determine a difference therebetween. If the difference is above a certain threshold for a certain amount of time, the controller will detect an issue (e.g. a damaged or broken drivetrain component) and initiate a shutdown procedure. Such a comparison may also indicate an issue between the sensors themselves. The control tightens the allowable deviation and time allowances with respect to power or some other machine parameter to increase or decrease the sensitivity of the comparison. The ability to timely detect a mismatch between the two sensors is limited by accuracy of the low precision sensor and the sampling rate or update rate of this sensor.
However, in the event that the drivetrain system or one of its components fails, the time to detect the failure and react may exceed the sensitivity of the comparison, thereby preventing the controller from detecting the failure for longer than desirable.
In view of the aforementioned issues, the art is continuously seeking new and improved systems and methods for preventing catastrophic damage in a wind turbine by detecting damage in the drivetrain sooner.
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 catastrophic damage in a drivetrain of a wind turbine. The drivetrain includes, at least, a rotor and a generator. The method includes receiving, via a controller, a speed measurement of the generator of the drivetrain. The method also includes determining an electrical torque of the generator. The method further includes estimating, via the controller, a mechanical torque of the rotor as a function of at least one of the electrical torque and the speed measurement. Further, the method includes comparing, via the controller, the estimated mechanical torque to an implausible torque threshold, wherein torque values above the implausible torque threshold are indicative of a failure of the drivetrain of the wind turbine. Moreover, the method includes implementing, via the controller, a control action for the wind turbine when the estimated mechanical torque exceeds the implausible torque threshold.
In one embodiment, the speed measurement of the generator may be measured via a high resolution speed sensor.
In another embodiment, determining the electrical torque of the generator may include at least one measuring the electrical torque of the generator via one or more sensors or estimating the electrical torque of the generator.
For example, in one embodiment, estimating the electrical torque of the generator may include measuring a power output of the generator and determining the electrical torque of the generator as a function of the power output and the speed of the generator.
In further embodiments, estimating the mechanical torque of the rotor as a function of at least one of the electrical torque and the speed measurement may include determining a speed error of the speed measurement of the generator and estimating, via a proportional controller, the mechanical torque as a function of the speed error.
In such embodiments, determining the speed error of the speed measurement of the generator may include determining a difference between the speed measurement of the generator and an estimate of a speed of the generator. As such, the speed error may correspond to a change in speed or acceleration required for the generator to accelerate or decelerate inertia of the drivetrain to maintain the speed measurement of the generator.
In additional embodiments, the method may further include comparing the speed error to an implausible speed threshold, wherein speeds greater that the implausible speed threshold are indicative of a failure of the drivetrain of the wind turbine.
In several embodiments, the method may also include determining a torque error as a difference between the electrical torque and the estimated mechanical torque and estimating the speed of the generator as a function of the torque error.
In particular embodiments, the method may include estimating the mechanical torque of the rotor as a function of the electrical torque, the speed measurement of the generator, and a friction coefficient of the generator.
In another embodiment, the control action for the wind turbine may include shutting down the wind turbine.
In another aspect, the present disclosure is directed to a drivetrain assembly of a wind turbine. The drivetrain assembly includes a main shaft for coupling to a rotor of the wind turbine, a gearbox coupled to the main shaft, a generator coupled to the gearbox, and a controller for controlling operation of the wind turbine. The controller includes at least one processor configured to perform a plurality of operations, the including but not limited to receiving a speed measurement of the generator of the drivetrain, determining an electrical torque of a generator of the drivetrain of the wind turbine, estimating a mechanical torque of the rotor as a function of at least one of the electrical torque and the speed measurement of the generator, comparing the estimated mechanical torque to an implausible torque threshold, wherein torque values above the implausible torque threshold are indicative of a failure of the drivetrain of the wind turbine, and implementing a control action for the wind turbine when the estimated mechanical torque exceeds the implausible torque threshold.
In yet another aspect, the present disclosure is directed to a method for preventing catastrophic damage in a drivetrain of a wind turbine. The method includes determining an electrical torque of a generator of the drivetrain. The method also includes receiving, from one or more sensors, a speed measurement of the generator. Further, the method includes determining, via a controller, a mechanical torque of a rotor of the wind turbine or an acceleration of the generator required to accelerate or decelerate inertia of the drivetrain to maintain the speed measurement. Moreover, when the mechanical torque and/or the acceleration exceed an implausible threshold, the method includes implementing a control action for the wind turbine.
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 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,
Referring now to
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.
As shown in
As shown in
Further, as shown, the turbine controller 26 may also be communicatively coupled to each pitch adjustment mechanism 32 of the wind turbine 10 through a separate or integral pitch controller 30 (
In addition, as shown in
It should also be appreciated that, as used herein, the term “monitor” and variations thereof indicates that the various sensors of the wind turbine 10 may be configured to provide a direct measurement of the parameters being monitored and/or an indirect measurement of such parameters. Thus, the sensors described herein may, for example, be used to generate signals relating to the parameter being monitored, which can then be utilized by the controller 26 to determine the condition.
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) 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(s) 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.
Referring now to
As shown at (102), the method 100 includes receiving a speed measurement of the generator 24 of the drivetrain, e.g. via the controller 26. In one embodiment, the speed measurement may be measured via a high resolution speed sensor, such as the generator sensor 58.
As shown at (104), the method 100 includes determining an electrical torque of the generator 24 of the drivetrain of the wind turbine 10. For example, in one embodiment, the electrical torque of the generator 24 may be determined by measuring the electrical torque of the generator 24 via one or more sensors.
Additionally or alternatively, the electrical torque of the generator 24 may be determined by estimating the electrical torque (e.g. TELEC) of the generator 24. For example, in one embodiment, the controller 26 may estimate the electrical torque of the generator 24 by measuring a power output of the generator 24 and determining the electrical torque of the generator 24 as a function of the power output and the speed of the generator 24. More specifically, the controller 26 may use the known relationship of torque (T), power (P), and speed (ω) as shown in Equation (1) below to determine the electrical torque.
T=P/ω Equation (1)
Referring still to
In addition, the estimation of the mechanical torque TMECH can be better understood with reference to
In addition, as shown, the controller 26 may utilize a proportional controller 152 to estimate the mechanical torque TMECH as a function of the speed error ωERROR. It should be understood that the proportional controller 152 described herein may include a proportional (P) controller, a proportional integral (PI) controller, a proportional derivative (PD) controller, a proportional integral derivative (PID) controller, or similar. As such, the speed error ωERROR may correspond to a change in speed or acceleration required for the generator 24 to accelerate or decelerate inertia of the drivetrain to maintain the speed measurement of the generator 24.
The estimated mechanical torque TMECH can then be used, along with the electrical torque TELEC to determine a torque error (e.g. TERROR). More specifically, as shown, the torque error TERROR may be calculated as a difference between the electrical torque TELEC and the estimated mechanical torque TMECH. Thus, as shown, the controller 26 may also include a computer-implemented model 154 for estimating the speed ωGest of the generator 24 as a function of the torque error TERROR. For example, in certain embodiments, the model 154 may operate according to the relationship provided in Equation (2) below:
Ja=TMECH−TELEC−μfωGest Equation (2)
where TMECH−TELEC is equal to TERROR,
J is the inertia of the wind turbine 10, and
a is the acceleration of the generator 24.
Thus, as shown in
(1/μf)(TERROR)/(1+sT) Equation (3)
where T is a time constant represented by J/μf.
Referring back to
In additional embodiments, the method 100 may also include comparing the speed error ωERROR to an implausible speed threshold. In such embodiments, speed values greater that the implausible speed threshold may also be indicative of a failure of the drivetrain of the wind turbine. In one embodiment, for example, speed values greater that the implausible speed threshold may result in excessive loading of the wind turbine 10 greater than an allowed extreme loading of the wind turbine 10. Thus, as used herein, “an implausible speed threshold” generally refers to an unattainable speed or change in speed value that cannot be realistically achieved, therefore, the only logical conclusion is that one or more drivetrains components is damaged or has failed. In other words, as an example, if a load is being applied on the generator 24 and a mechanical fuse or coupling breaks or fails, then the generator speed will quickly change. Therefore, the abrupt change in speed of the generator 24 is indicative of component failure.
Referring still to
Referring now to
As shown at (202), the method 200 includes determining an electrical torque of the generator 24 of the drivetrain. As shown at (204), the method 200 includes receiving, from one or more sensors (such as generator sensor(s) 58), a speed measurement of the generator 24. As shown at (206), the method 200 includes determining, via the controller 26, a mechanical torque of the rotor 18 of the wind turbine 10 or an acceleration of the generator 24 required to accelerate or decelerate inertia of the drivetrain to maintain the speed measurement. As shown at (208), the method 200 includes determining whether the mechanical torque and/or the acceleration exceed an implausible threshold. If so, as shown at (210), the method 200 includes implementing a control action for the wind turbine 10, such as shutting down the wind turbine 10.
Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments. Similarly, the various method steps and features described, as well as other known equivalents for each such methods and feature, can be mixed and matched by one of ordinary skill in this art to construct additional systems and techniques in accordance with principles of this disclosure. Of course, it is to be understood that not necessarily all such objects or advantages described above may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested 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.
Number | Name | Date | Kind |
---|---|---|---|
2195766 | Courcoulas | Apr 1940 | A |
7476985 | Llorente Gonzalez | Jan 2009 | B2 |
9062653 | Brath | Jun 2015 | B2 |
9688284 | Pongracz | Jun 2017 | B2 |
9729096 | Edwards | Aug 2017 | B2 |
9745958 | Agarwal | Aug 2017 | B2 |
9797377 | Bhaskar | Oct 2017 | B2 |
9866160 | Tan | Jan 2018 | B2 |
9920743 | Agarwal | Mar 2018 | B2 |
10359473 | Qiao | Jul 2019 | B2 |
10428792 | Illing | Oct 2019 | B2 |
10781792 | Vaddi | Sep 2020 | B2 |
11078934 | Caldwell | Aug 2021 | B2 |
20030185665 | Hansen | Oct 2003 | A1 |
20090263245 | Shi | Oct 2009 | A1 |
20110084485 | Miranda | Apr 2011 | A1 |
20120074698 | Hearns | Mar 2012 | A1 |
20120104754 | Rudolf | May 2012 | A1 |
20120241279 | Graham | Sep 2012 | A1 |
20130049733 | Neti | Feb 2013 | A1 |
20130214535 | Brath | Aug 2013 | A1 |
20140346985 | Magne | Nov 2014 | A1 |
20150081192 | Pongracz | Mar 2015 | A1 |
20150244296 | Edwards | Aug 2015 | A1 |
20160010620 | Han | Jan 2016 | A1 |
20160017865 | Illing | Jan 2016 | A1 |
20160033580 | Qiao | Feb 2016 | A1 |
20170158348 | Teubner | Jun 2017 | A1 |
20170276238 | Lochocki, Jr. | Sep 2017 | A1 |
20170284359 | Burkle | Oct 2017 | A1 |
20180245609 | Caldwell | Aug 2018 | A1 |
20190058425 | De Rijcke | Feb 2019 | A1 |
20190063508 | Harrington | Feb 2019 | A1 |
20190263508 | Crane | Aug 2019 | A1 |
20190332958 | Subhankar | Oct 2019 | A1 |
20200325874 | Cardinal | Oct 2020 | A1 |
20210246881 | Priore, III | Aug 2021 | A1 |
Number | Date | Country |
---|---|---|
100593641 | Mar 2010 | CN |
108386324 | Aug 2018 | CN |
105673322 | Sep 2018 | CN |
108757340 | Nov 2018 | CN |
WO2018001434 | Jan 2018 | WO |
Entry |
---|
European Search Report, dated Aug. 19, 2020, for EP Application No. 20168033.7. |
Number | Date | Country | |
---|---|---|---|
20200325874 A1 | Oct 2020 | US |