Identification of wind turbine main-shaft torsional loads from high-frequency SCADA (supervisory control and data acquisition) measurements using an inverse-problem approach

To assess the structural health and remaining useful life of wind turbines within wind farms, the site-specific structural response and modal parameters of the primary structures are required. In this regard, a novel inverse-problem-based methodology is proposed here to identify the dynamic quantities of the drivetrain main shaft, i.e. torsional displacement and coupled stiffness. As a model-based approach, an inverse problem of a mathematical model concerning the coupled-shaft torsional dynamics with high-frequency SCADA (supervisory control and data acquisition) measurements as input is solved. It involves Tikhonov regularisation to minimise the measurement noise and irregularities on the shaft torsional displacement obtained from measured rotor and generator speed. Subsequently, the regularised torsional displacement along with necessary SCADA measurements is used as an input to the mathematical model, and a model-based system identification method called the collage method is employed to estimate the coupled torsional stiffness. It is also demonstrated that the estimated shaft torsional displacement and coupled stiffness can be used to identify the site-specific main-shaft torsional loads. It is shown that the torsional loads estimated by the proposed methodology is in good agreement with the aeroelastic simulations of the Vestas V52 wind turbine. Upon successful verification, the proposed methodology is applied to the V52 turbine to identify the site-specific main-shaft torsional loads and damage-equivalent load. Since the proposed methodology does not require a design basis or additional measurement sensors, it can be directly applied to wind turbines within a wind farm that possess high-frequency SCADA measurements.

A compensation scheme applied on wind turbine blade pitch control for the reduction of non-torque main shaft loads

It has been well established that non-torque main shaft loads influence the internal drive train loads. This paper proposes a scheme that compensates for non-torque loads in the blade pitch controller. The compensation scheme is implemented on a dynamic model developed in FAST/Simulink. Three wind conditions of 8, 11.4 and 20 m/s are examined. The dynamic analysis of the bending moment in the low-speed shaft showed a reduction in bending moment by 3 % for the rated wind speed (11.4 m/s) and 1.8 % for the above-rated wind speed (20 m/s), highlighting the effectiveness of the proposed scheme. However, a reduction in bending moment also slightly decreased the shaft’s speed by 2.3 % and 0.5 %, respectively. Similarly, the turbine power was decreased by 9 % and 1 %, respectively. In comparison, further gain scheduling within the compensation scheme reduces the power loss to as low as 0.3 %. The 2 to 3 % reduction in the low-speed shaft bending moment can significantly influence the drive train loads and easily outweigh any loss resulting in the shaft rotational speed and turbine power. Thus, this paper shows that using bending moment error as feedback within the compensation scheme positively affects the low-speed shaft’s bending moment with the eventual potential of reducing drivetrain loads.

Experimental Validation of Subsystem Models for a Novel Variable Displacement Hydraulic Motor

A novel, variable displacement, low-speed high-torque hydraulic motor is being developed that is expected to be highly efficient across a broad operating range. To ensure the final hardware achieves the expected performance, the models used in the development of the motor must be experimentally validated and revised. The focus of this work is on mechanical energy loss models that were used to guide the design of a single-cylinder motor prototype and then experimental tests used for validation. Losses were modeled and organized into five primary groups: main shaft bearings, main shaft seal, case windage, valve actuation, and linkage losses. The single-cylinder prototype was fabricated, and test parameters were defined. Two test rigs were designed and built to capture losses of the motor experimentally; one was used to collect low torque, zero/low-pressure differential results, and the other used to collect high torque, high-pressure differential results. A staged assembly procedure was developed to capture the independent contributions of each loss. By reviewing the quality of correlation between test observations and model predictions and revising the model when necessary, the models were validated. The correlation was improved by reviewing and modifying model inputs. This allows future solutions to be more accurately predicted in the design phase to drive the design of better machines. The validated model package was able to predict the motor performance within an acceptable range of error.

Stability Analysis of Surrounding Rock of Large Section Ultradeep Shaft Wall

In order to study the stability of deep surrounding rock during the excavation of new main shaft in Xincheng gold mine, a construction method suitable for large section ultradeep shaft is proposed. A series of analyses were carried out in this study, including the in situ stress test, stress response of surrounding rock disturbance, deformation and failure characteristics, and numerical simulation. Based on the above analysis, the stability control method of surrounding rock in the process of deep excavation of the new main shaft is proposed. The results show that (1) the maximum principal stress of deep surrounding rock of new main shaft is horizontal stress, and the surrounding rock of the shaft has strong rock burst tendency after excavation; (2) the influence range of the deep shaft excavation disturbance is 6.4 times the shaft radius, in which the temporary support should be strengthened to avoid the influence of excavation disturbance on the stability of shaft wall rock; (3) the failure shape of surrounding rock of the deep shaft excavation was “ear” failure, and the failure depth was not more than 2.5 m; (4) after replacing the original “one-excavation and one-masonry” construction with “three-excavation and one-masonry” construction, the temporary support span of the main shaft was adjusted to 12 m, which can make the subsequent concrete shaft wall in the state of “no pressure bearing or slow low pressure bearing,” and the lining compressive safety coefficient was increased to 1.98, which meets the safety requirements.

ОПОРА ДЛЯ ПОГЛОШЕНИЯ КОЛЕБАНИЙ ГЛАВНОГО ВАЛА ЩВЕЙНОЙ МАШИНЫ

В этой статье представлена информация о снижение вибрации и шума главного вала и за счёт этого повешение надёжности, производительности швейной машины. Поставленная задача решается путем амортизации колебаний и шума главного вала швейный машин, совершенствованием конструкции подшипниковых опор. This article presents information about reducing vibration and noise of the main shaft and thereby increasing the reliability and productivity of the sewing machine. The task is solved by damping the vibrations and noise of the main shaft of sewing machines, improving the design of bearing supports.

Rotation Accuracy Analysis of Aerostatic Spindle Considering Shaft’s Roundness and Cylindricity

The rotation accuracy of the aerostatic spindle can easily be affected by shaft shape errors due to the small gas film clearance. Thus, the main shaft shape errors with the largest scale—that is, the roundness and cylindricity errors—are studied in this paper, and a dynamic mathematical model is established with the consideration of the roundness, cylindricity errors, and spindle speed. In order to construct the shaft model, the discrete coefficient index of the shaft radius based on roundness measurement data are proposed. Then, the simulation calculations are conducted based on the measured cylindricity data and the constructed shaft model. The calculation results are compared with the spindle rotation accuracy measured using the spindle error analyzer. The results show that the shaft with a low discrete coefficient is subjected to less unbalanced force and smaller rotation errors, as obtained by the experiment.

Study on the Unbalanced Curl Seal Failure of the Magnetorheological Fluid Sealing Device of the Hydraulic Turbine Main Shaft under Different Speed Abrupt Conditions

The fluid flow in the runner of a hydraulic turbine has serious uncertainties. The sealing failure of the magnetorheological (MR) fluid sealing device of the main shaft of the hydroturbine, caused by a sudden change in speed, has always been a difficult topic to research. This study first derives the MR fluid seal pressure and unbalanced curl equations of the hydroturbine main shaft, and then analyzes the seal pressure and friction heat under different rotational speed mutation conditions through experiments. After verification, the temperature field and magnetic field distribution of the MR fluid sealing device of the main shaft of the hydraulic turbine are obtained via numerical calculation. The results show that the external magnetic field affects the magnetic moment of the magnetic particles in the MR fluid, resulting in a significant change in frictional heat, thereby reducing the saturation of magnetic induction intensity of the MR fluid. This results in a decrease in the sealing ability of the device. The size and abrupt amplitude of the main shaft of the hydraulic turbine, and friction heat is positively correlated reducing the sealing ability of the device and causing sealing failure. Based on our results, we recommend adding the necessary cooling to the device to reduce the frictional heat, thereby increasing the seal life of the device.