Wind Turbines and Other Rotating Structures with Instrumented Load-Sensor Bolts or Instrumented Load-Sensor Blades

• US 20110158806A1
• Filed: 04/15/2010
• Published: 06/30/2011
• Est. Priority Date: 04/15/2009
• Status: Abandoned Application

• Current Assignee: Lord Corporation (Parker-Hannifin Corporation)
• Original Assignee: Lord Corporation (Parker-Hannifin Corporation)
• Inventors: Maass, David, Leamon, Thomas M., Galbreath, Jacob H., Arms, Steven W., Townsend, Christopher P., Churchill, David L.
• Application Number:
  US12/761,259
• Publication Number:
  US 20110158806A1
• Time in Patent Office: Days
• US Class Current: 416/31
• CPC Class Codes: F03D 1/0658 Arrangements for fixing wind-engaging parts to a hub
• CPC Class Codes: F03D 7/0224 Adjusting blade pitch
• CPC Class Codes: F03D 7/043 characterised by the type of control logic
• CPC Class Codes: F05B 2260/301 Retaining bolts or nuts
• CPC Class Codes: F05B 2260/80 Diagnostics
• CPC Class Codes: F05B 2270/1095 by limiting mechanical stresses
• CPC Class Codes: F05B 2270/328 Blade pitch angle
• CPC Class Codes: F05B 2270/332 Maximum loads or fatigue criteria
• CPC Class Codes: F05B 2270/802 Calibration thereof
• CPC Class Codes: F05B 2270/807 Accelerometers
• CPC Class Codes: F05B 2270/808 Strain gauges; Load cells
• CPC Class Codes: Y02E 10/72 Wind turbines with rotation axis in wind direction

Abstract

A turbine includes a turbine blade, a plurality of sensors, a wireless sensor module, a data aggregator, and a blade pitch control unit. The plurality of sensors are distributed in a plurality of locations on the turbine blade suitable for determining a moment of the turbine blade. The sensor module is configured to transmit data to the data aggregator to determine the moment. The data aggregator is configured to provide an output to the blade pitch control unit. The blade pitch control unit is configured to adjust pitch of the turbine blade based on the moment.

Claims

1. A turbine, comprising a turbine blade, a plurality of sensors and a wireless sensor module, a data aggregator, and a blade pitch control unit, wherein said plurality of sensors are distributed in a plurality of locations on said turbine blade suitable for determining a moment of said turbine blade, wherein said sensor module is configured to transmit data to said data aggregator to determine said moment, wherein said data aggregator is configured to provide an output to said blade pitch control unit, wherein said blade pitch control unit is configured to adjust pitch of said turbine blade based on said moment.

2. A turbine as recited in claim 1, wherein each said sensor module further includes an electronic circuit, wherein said sensor is connected to said electronic circuit, wherein said electronic circuit includes a processor.

3. A turbine as recited in claim 2, wherein said sensor electronic circuit includes a wireless communications device and wherein said data aggregator includes a wireless receiver.

4. A turbine as recited in claim 3, wherein said wireless communications device includes an RF transceiver.

5. A turbine as recited in claim 3, wherein said data aggregator is on a non rotating portion of said turbine, further comprising a hub, wherein said blade is connected to said hub, wherein said wireless sensor module is mounted in said hub.

6. A turbine as recited in claim 3, wherein said data aggregator is on a non rotating portion of said turbine, further comprising a plurality of said wireless sensor modules, wherein one of said plurality of wireless sensor module is mounted in each said location.

7. A turbine as recited in claim 6, wherein sampling of said plurality of sensors by said wireless sensor modules is time synchronized.

8. A turbine as recited in claim 1, wherein said blade moment includes at least one from the group consisting of flapping moment and edgewise moment.

9. A turbine as recited in claim 1, wherein said sensor includes a strain gauge.

10. A turbine as recited in claim 9, further comprising a plurality of smart fasteners, wherein each said smart fastener connects said turbine blade to said hub, wherein each said smart fastener includes one said sensor module.

11. A turbine as recited in claim 10, wherein each said smart fastener includes a plurality of strain gauges.

12. A turbine as recited in claim 11 wherein each said smart fastener includes a bolt, wherein said sensor module further includes an electronic circuit, wherein said plurality of sensors is connected to said electronic circuit, wherein said electronic circuit includes a processor and a wireless transmitter.

13. A turbine as recited in claim 12, wherein said sensors are positioned in said bolt to provide a measurement for use in determining said blade moment.

14. A turbine as recited in claim 13, wherein said strain gauge is oriented to measure strain along an axis of said bolt.

15. A turbine as recited in claim 12, wherein said bolt includes a pin portion and a housing portion, wherein said pin portion extends from said housing portion, wherein said strain gauge is mounted in said pin portion and wherein said electronic circuit is mounted in said housing portion.

16. A turbine as recited in claim 9, wherein said strain gauge includes a DVRT.

17. A turbine as recited in claim 1, wherein each said sensor module further includes an electronic circuit, wherein said sensor is connected to said electronic circuit, wherein said electronic circuit includes a processor, a memory, a clock, and a two-way wireless communications device, wherein said memory includes a program that provides same-time sampling by all of said sensor modules.

18. A turbine as recited in claim 17, further comprising a source of a beacon, wherein said memory includes a program for setting said clock to said beacon and initiating sample timing to provide for said same-time sampling.

19. A turbine as recited in claim 17, wherein said memory is connected for recording data, wherein said same-time sampling is at a rate exceeding 50,000 samples per second and uses less than 6 mj of energy for recording a byte of data.

20. A turbine as recited in claim 17, wherein said memory includes an FRAM.

21. A turbine as recited in claim 1, wherein said electronic circuit further comprises a source of power.

22. A turbine as recited in claim 21, wherein said source of power includes a battery.

23. A turbine as recited in claim 21, wherein said source of power includes an energy harvesting circuit.

24. A turbine as recited in claim 23, wherein said energy harvesting circuit includes a curvilinear linkage.

25. A turbine as recited in claim 23, wherein said energy harvesting circuit includes a flexure element having a mechanical disadvantage.

26. A turbine as recited in claim 25, wherein said flexure element has a diamond shape.

27. A turbine as recited in claim 1, wherein said data aggregator includes an aggregator processor and an aggregator memory, wherein said aggregator memory includes a program for using synchronous time stamped data from said plurality of said smart fasteners to determine a parameter of said blade.

28. A turbine as recited in claim 1, wherein said turbine further comprises a gear box, a second sensor, and a second electronic circuit, wherein said second sensor and said second electronic circuit are mounted on said gear box, wherein said second electronic circuit includes a processor, a memory, a clock, and a wireless communications device for communicating time stamped gear box data to said data aggregator.

29. A turbine as recited in claim 1, further comprising a device for communicating data derived from said sensor module external to said turbine.

30. A turbine as recited in claim 29, further comprising an internet server, wherein said device for communicating data externally communicates with said internet server.

31. A turbine as recited in claim 1, wherein said turbine blade is part of one from the group consisting of a helicopter and a wind turbine.

32. A system, comprising a plurality of wireless data collecting devices sampling simultaneously, wherein each of said plurality of wireless data collecting devices includes a real time clock and a receiver, further comprising a base station, wherein said base station includes a transmitter for transmitting a beacon for maintaining said real time clocks synchronous with each other, wherein said receiver is for receiving said beacon, wherein each of said plurality of wireless data collecting devices includes a processor and a memory, wherein said memory includes a program for sampling data on a schedule determined by time from said clock, wherein said schedule is the same for each of said plurality of wireless data collecting devices.

33. A system as recited in claim 32, wherein said beacon is for resetting and aligning said real time clock in each said wireless data collecting device with said beacon.

34. A system as recited in claim 33, wherein said beacon is broadcast on a schedule, wherein said receivers at each wireless data collecting device turn on in time to receive said beacon and then turn off.

35. A system as recited in claim 34, wherein receiver duty cycle is less than 1%.

36. A system as recited in claim 33, wherein each of said plurality of wireless data collecting devices includes an energy harvesting device.

37. A turbine as recited in claim 33, wherein each of said plurality of wireless data collecting devices is mounted on one from the group consisting of a structure, a bridge, helicopter and a wind turbine.

38. A wireless data collection and storage device, comprising a housing including a sensor, a processor, a clock, a high speed low power non-volatile data storage device, and a transceiver, wherein said a high speed low power non-volatile data storage device uses less than 6 nJ per byte of data stored in non-volatile memory when storing at a rate exceeding 50,000 samples per second.

39. A wireless data collection and storage device as recited in claim 38, wherein said a high speed low power non-volatile data storage device includes an FRAM.

40. A wireless data collection and storage device as recited in claim 38, wherein said a high speed low power non-volatile data storage device is included as a circular buffer.

41. A wireless data collection and storage device as recited in claim 38, wherein said sensor includes a strain sensor.

42. An energy harvesting system, comprising an energy harvesting device having a flexure element having a mechanical disadvantage, wherein said flexure element is precompressed and bonded exclusively at one end.

43. An energy harvesting system as recited in claim 42, further comprising a sensor, wherein said energy harvesting device is connected for powering said sensor.

44. An energy harvesting system, comprising a mechanical device, a magnet, and a coil, wherein said mechanical device includes linked flexure elements that provide curvilinear relative motion between said magnet and said coil.

45. An energy harvesting system as recited in claim 44 further comprising a pair of said magnets, wherein each member of said pair has same poles, wherein said same poles are held facing each other in said pair.

46. An energy harvesting system, comprising a pair of magnets, wherein each member of said pair has same poles, wherein said same poles are held facing each other in said pair.

47. An energy harvesting system for harvesting energy from a vibrating surface, comprising a resonant flexure element and an accelerometer, wherein said accelerometer is mounted to receive vibration energy from the vibrating surface and wherein said accelerometer is isolated from said resonant flexure element.

48. A wind turbine, comprising a wind turbine blade, a smart fastener, and a hub, wherein said smart fastener connects said wind turbine blade to said hub, wherein said smart fastener includes a sensor and an electronic circuit, wherein said sensor is positioned for sensing load on said smart fastener, and wherein said electronic circuit is connected to said sensor for receiving data detected by said sensor.

49. A method of sampling data, comprising:

providing a plurality of wireless nodes, wherein each said wireless node includes a receiver and a real time clock;

broadcasting a common beacon;

using said common beacon in each of said wireless nodes to synchronize said real time clocks; and

performing an action simultaneously in all said wireless nodes, wherein timing in each said wireless node is determined by said synchronized real time clock.

50. A method as recited in claim 49, further comprising providing a sensor in each said wireless node, wherein said action includes making a measurement with said sensor.