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P. Tavner, “How Are We Going to Make Offshore Wind Farms More Reliable?” presented at the 2011 SUPERGEN Wind
General Assembly, Durham University, United Kingdom, March 20, 2011.
Gear teeth: macropitting (Source: Blade damage: lighting strike (Source: Blade: erosion on the leading edge
North American Windpower) Sandia National Laboratories) (Source: Sandia National Laboratories)
Our work has been focused on fault diagnosis and prognosis for bearings,
blades, rotors/shafts, and generators of various wind turbines, gearboxes
of indirect-drive wind turbines, and power electronic converters
W. Qiao and D. Lu, “A survey on wind turbine condition monitoring and fault diagnosis−Part I: Components and
subsystems,” IEEE Trans. Industrial Electronics, vol. 62, no. 10, pp. 6536-6545, Oct. 2015.
The shaft torque vibration at the fault characteristic frequency will modulate
frequency and amplitude of generator current signals: due to mechanical
couplings between generator and failed wind turbine component(s) as well
as electromagnetic coupling between generator rotor and stator
Current frequency modulation:
f1 (t ) = f1, w (t ) + A1,v (t ) ⋅ sin 2π ⋅ f fault (t ) ⋅ dt + ϕ f (t )
Current amplitude modulation:
I s (t ) = I s , w (t ) + As ,v (t ) ⋅ sin 2π ⋅ f fault (t ) ⋅ dt +ψ f (t )
X. Gong and W. Qiao, “Bearing fault diagnosis for direct-drive wind turbines via current
demodulated signals,” IEEE Trans. Industrial Electronics, vol. 60, no. 8, pp. 3419-3428, Aug. 2013.
Power & Energy Systems Laboratory 9
Challenges in Current-Based Fault Diagnosis & Prognosis
A single fault characteristic frequency in vibration becomes multiple fault
characteristic frequencies in current due to frequency/amplitude
modulations
Excitations at fault characteristic frequencies in current could be masked by
subbands of the dominant components that are irrelevant to fault in the frequency
spectrum of current
Low signal-to-noise ratio (SNR): the total energy of excitations related to a fault is
dispersed into multiple fault characteristic frequencies -7
x 10
4
(i.e., 1P frequency) 2
0 S1 S2 S3 S4 S5 t
Phase (Degree)
300
240
180 C fb
120 = sin(θ )
60 I1
0 S1 S2 S3 S4 S5 t
S (n + 1) − S (n) C (n + 1) − C (n)
S s (ls ) = S (n) + ⋅ [θ s (ls ) − θ (n)] Cs (ls ) = C (n) + ⋅ [ S s (ls ) − S (n)]
θ (n + 1) − θ (n) S (n + 1) − S (n)
X. Gong and W. Qiao, “Current-based mechanical fault detection for direct-drive wind turbine via synchronous sampling
and impulse detection,” IEEE Trans. Industrial Electronics, vol. 62, no. 3, pp. 1693-1720, Mar. 2015.
Broken cage
The test bearing before and after experiment
Healthy
bearing
2.5
1.5
0.5
600 60% 2
1.5
400 40% 1
0.5
200 20% 0
0 20 40 60 80 100 28 30 32 34 36 38 40 42
Time (s)
Frequency (Hz)
Test gear with a crack Estimated shaft speed and load Current frequency spectrum
obtained from the classic FFT
50
50
fs
fs
PSD of resampled stator current
40
30
30
f s-f 3 f s-f 2
f s+f 2 f s+f 3
20 f s-f 1 f s+f 1 20
fs-f 3
f s-f 2
f s+f 2 f s+f 3
10 10
0 0
28 30 32 34 36 38 40 42 28 30 32 34 36 38 40 42
Frequency (Hz) Frequency (Hz)
Current PSD spectrum of healthy gearbox Current PSD spectrum of faulted gearbox
Data
8 channels: 2 stator voltages, 3 stator currents, and 3 rotor currents
Data length: 20 seconds
Sampling rate: 10 kHz
Time interval between two consecutive datasets: 15 minutes
Power & Energy Systems Laboratory 19
Without Synchronous Resampling
PSD spectrum of the
original one-phase stator
current in one data
record of No. 1 turbine
around the fundamental
frequency
A constant fundamental
frequency of 60Hz is
clearly observed in the
spectrum
Only smeared frequency ranges instead of specific characteristic
frequencies related to fault can be observed due to the varying DFIG
shaft rotating frequency
Without using the proposed method, it is hard to extract fault features for
the wind turbines operating in varying speed conditions
F. Cheng, L. Qu, W. Qiao, C. Wei, and L. Hao, “Fault diagnosis of wind turbine gearboxes based on DFIG stator current
envelope analysis,” IEEE Trans. Sustainable Energy, in press.
-30
-40
-50
-60
0 30 60 90 120 150 180 210 240 270 300
Frequency (Hz)
Angular
𝑓 𝑡 cos 0.2𝜋𝑡 𝜋 ⁄3 10
resampling
MFS construction
𝐸𝑛 𝑠 𝐸𝑛 𝑠 ⋅ 𝑤 𝑠 .
J. Wang, Y. Peng, W. Qiao, and J. L. Hudgins, “Bearing fault diagnosis of direct-drive wind turbines using multiscale
filtering spectrum,” IEEE Trans. Industry Applications, vol. 53, no. 3, pp. 3029-3038, May-Jun. 2017.
𝑓 𝑡 cos 0.2𝜋𝑡 𝜋 ⁄3 10
Intermediate results
Energy spectrum
The order 7Or is
interfered by On 3Or 4.5Or MFS MFS
Or
7Or On reveal 7Or
suppress On
Order
Weighting factor
7Or has large weighting Order-domain spectrum
3Or 4.5Or On
value Or
Angular resampling
On have small weighting 7Or submerged in On
values Order
Frequency (Hz)
SRF-unrelated
Fundamental frequency
SRF-unrelated Result of angular resampling
Hilbert
Transform
N
Fault Prognosis xˆk +1 = wk xˆk +1
i i
Yes
i =1
No
Weights
Yes No
degenerated? New zk+1 RUL
available? Prediction
No
wki +1 ∝ wki p( zk +1 | xˆki +1 ), i = 1, 2,, N
Weights − ( zk +1 − xˆki +1 )2
Yes No
degenerated? New zk+1 RUL 1 2 μ0
available? Prediction p( zk +1 | xˆki +1 ) = e
2πμ0
N
p( xk +1 | z1:k +1 ) ≈ wki +1δ ( xk +1 − xˆki +1 )
Normalize Update weights i =1
weights i= 1 2 N
w →w Step 3: Resample
i i
k k +1
xk +1 = O4j
j
1 O 2j
uA j ( xk −i ) = 2b j
, O = ∏ uA j ( xk −i ) O =
2
3
O 4j = O 3j ( c1j x k − 3 + c2j x k − 2 + c3j x k −1 + c4j x k + c5j )
x − mj
O
4−i j
4−i j 2
1 + k −i i
a
j
j j
xˆ ki + m = f k ( xˆ ki + m − 4 , xˆ ki + m − 3 , xˆ ki + m − 2 , xˆ ki + m −1 ) + uk , m = 1, 2, , T p
When the predicted state reaches the threshold at a future time instant,
the predicted RUL is determined as the time between now and that
future time instant.
Power & Energy Systems Laboratory 31
RUL Prediction: Laboratory Run-to-Failure Test
Defect propagation
Incipient
defect
occurred Threshold
Maintenance
performed
The RUL can be effectively predict after Time index Actual time
time index 2100.
1750 3/17/2015 9:49:54 AM
The corresponding time is 3/19/2015
2100 3/21/2015 9:29:40 AM
10:41:06 PM, which is around 12 days
before the alarm should be triggered 2300 3/23/2015 9:49:28 AM
(3/31/2015 4:26:45 PM). 2680 3/31/2015 4:26:45 PM