Methods and systems for detecting sensor fault modes

Patent metadata

Field	Value
Publication number	US-10344740-B2
Application number	US-201615269839-A
Country	US
Kind code	B2
Filing date	Sep 19, 2016
Priority date	Nov 2, 2011
Publication date	Jul 9, 2019
Grant date	Jul 9, 2019

Abstract

A method of detecting a fault mode of a sensor is provided. The sensor may be, for example, a bending moment sensor and may sense a bending moment of a blade on a wind turbine generator (WTG). The method includes comparing data output by a first sensor with reference data indicating what is expected to be output by the first sensor to produce a first comparison result and comparing data output by the first sensor with data output by a second sensor to produce a second comparison result. A determination of whether the first sensor has entered a fault mode is made based at least in part on the first and second comparison results.

First claim

The invention claimed is:

1. A method for detecting a fault mode of a first sensor, the method comprising:
comparing, with sensor circuitry, data output by the first sensor with reference data indicating what is expected to be output by the first sensor to produce a first comparison result, wherein the reference data includes at least one of: pre-determined data output of the first sensor during operation in a controlled environment, and model data output from a model, wherein the model includes at least one relationship determining the model data output as a function of observed operating conditions and knowledge of properties of the first sensor;
comparing, with the sensor circuitry, the data output by the first sensor with a second data output by a second sensor to produce a second comparison result;
determining, with the sensor circuitry, whether the first sensor has entered a fault mode based at least in part on the first and the second comparison results; and
upon the sensor circuitry determining that the first sensor has entered the fault mode, the sensor circuitry issues an indication of the fault mode to a controller of a wind turbine generator (WTG) that configures the controller to issue pitch commands to adjust a blade pitch of the wind turbine generator, wherein the pitch commands are based on the controller performing at least one of: ignoring an output of the first sensor and reducing a reliance on the first sensor.

2. The method of claim 1 , wherein the first sensor is configured for use in measuring a first characteristic of a structure and the second sensor is configured for use in measuring a second characteristic of the structure.

3. The method of claim 2 , wherein:
the structure is the wind turbine generator including blades,
the first characteristic of the structure is a bending moment experienced by a first blade of the wind turbine generator, and
the second characteristic of the structure is one of: a bending moment experienced by a second blade of the wind turbine generator, a rotation speed of a generator of the wind turbine generator, an acceleration of a nacelle of the wind turbine generator, an acceleration of the first blade of the wind turbine generator, a thrust force of wind on the WTG, a rotation speed of a rotor of the wind turbine generator, and a pitch angle of at least one of the blades of the wind turbine generator.

4. The method of claim 1 , wherein the first sensor is configured to measure a characteristic of a structure and the second sensor is configured to measure a characteristic of the environment in which the structure is located.

5. The method of claim 4 , wherein:
the structure is the wind turbine generator including blades,
the characteristic of the structure is a bending moment experienced by a blade of the wind turbine generator, and
the characteristic of the environment is one of: a wind speed, a wind direction, a density of air surrounding the wind turbine generator, and a temperature of air surrounding the wind turbine generator.

6. The method of claim 1 , further comprising:
sending an indication of the detected fault mode to a controller of the first sensor when determining that the first sensor entered the fault mode; and
compensating, at the controller of the first sensor, for the detected fault mode.

7. The method of claim 1 , wherein the reference data includes the pre-determined data output of the first sensor during operation in the controlled environment.

8. The method of claim 7 , wherein the reference data further includes the model data output from the model.

9. The method of claim 1 , wherein the reference data includes the model data output from the model.

10. The method of claim 1 , wherein the pitch commands are based on the controller reducing, without entirely eliminating, the reliance on the first sensor.

11. A method of operating a wind turbine generator (WTG) comprising a first sensor, the method comprising:
operating the first sensor using sensor circuitry included in the WTG, wherein the sensor circuitry receives data from the first sensor representing a bending moment experienced by a blade of the WTG;
comparing the data from the first sensor with data from a second sensor to produce a comparison result;
determining whether the first sensor has entered a fault mode based at least in part on the comparison result;
communicating a sensor validity indication from the sensor circuitry to a WTG controller based on whether the first sensor has entered the fault mode; and
communicating, from the WTG controller, commands to control operation of one or more actuators of the WTG based at least on (i) the bending moment experienced by the blade and (ii) the sensor validity indication.

12. The method of claim 11 , wherein the first sensor includes:
a fiber bragg grating (FBG) placed on a surface of the blade,
wherein the sensor circuitry is optically coupled to the FBG via an optical fiber, wherein the sensor circuitry includes:
a light source configured to emit a light signal; and
a light receiver configured to receive a reflection of the light signal from the FBG and to convert the reflected light signal into the data representing the bending moment experienced by the blade.

13. The method of claim 11 , wherein the one or more actuators of the WTG comprise one of the following:
a pitch actuator configured to control a blade pitch of the WTG;
a yaw motor configured to control a yaw of the WTG; and
one or more components configured to control one or more of a torque, speed, and a power of the WTG.

14. An apparatus, comprising:
low level fault detection circuitry configured to compare data output by a first sensor with reference data to detect a first fault mode of the first sensor, wherein the reference data includes at least one of: pre-determined data output of the first sensor during operation in a controlled environment, and model data output from a model, wherein the model includes at least one relationship determining the model data output as a function of observed operating conditions and knowledge of properties of the first sensor;
high level fault detection circuitry configured to compare data output by the first sensor with data output by a second sensor to detect a second fault mode of the first sensor; and
a controller arranged to adjust a blade pitch of a wind turbine generator by issuing pitch commands to adjust a blade pitch of the wind turbine generator, wherein upon the controller receiving an indication of at least one of the first and the second fault modes from the low and the high level fault detection circuitry, the controller is configured to perform at least one of: ignoring an output of the first sensor and reducing a reliance on the first sensor.

15. The apparatus of claim 14 , wherein the reference data includes the pre-determined data output of the first sensor during operation in the controlled environment.

16. The apparatus of claim 15 , wherein the reference data further includes the model data output from the model.

17. The apparatus of claim 14 , wherein the reference data includes the model data output from the model.

18. The apparatus of claim 14 , wherein the controller is configured to reduce, without entirely eliminating, the reliance on the first sensor.

Assignees

• Vestas Wind Sys As

Inventors

• Caponetti Fabio
• Brath Per
• Hammerum Keld
• Nielsen Johnny

Classifications

• F03D17/00

  Monitoring or testing of wind motors, e.g. diagnostics (testing during commissioning of wind motors F03D13/30) · CPC title

• F03G7/00 Primary

  Mechanical-power-producing mechanisms, not otherwise provided for or using energy sources not otherwise provided for · CPC title

• F03D7/042 Primary

  by means of an electrical or electronic controller · CPC title

• F03D7/0224

  Adjusting blade pitch · CPC title

• G05B15/02

  electric · CPC title