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Abstract: Condition monitoring has been widely used to detect mechanical and electrical faults of wind turbine in order to avoid
any potential catastrophic failures, reduce operational and maintenance cost, and enhance the reliability and availability of the
equipment. Although several papers about wind turbine condition monitoring can be found in the literatures, adopting a reliable
and cost-effective technique for wind turbines that usually experience severe mechanical stress due to the harsh weather
conditions they are exposed to is still challenging. Although statistical studies show that gearbox failure rate is low, the resulted
downtime and the replacement or repairing cost is substantial. This study introduces an improved technique to monitor the
condition of the wind turbine gearbox based on gearbox vibration and shaft torque signatures analyses. In this context, a test rig
that emulates real wind turbine operation has been developed to analyse the behaviour of wind turbine under various
mechanical fault levels. Shaft torque and mechanical vibration signals are detected using high-resolution sensors and are
analysed using two signal processing techniques: wavelet and order analyses to examine the impact of investigated fault levels
on the wind turbine drive train. Both signal processing techniques are compared based on their sensitivity to detect incipient
fault levels.
IET Sci. Meas. Technol., 2017, Vol. 11 Iss. 4, pp. 431-437 431
© The Institution of Engineering and Technology 2017
fluctuating load, and unstable actions [35]. Order tracking
spectrum is a method to analyse the vibration signal based on
related spectral components rising with the instantaneous rotating
speed. In case of the collected vibration data comprise numerous
spectral components with a significant rotational speed variations
during measurement time, the processed signal will be unclear and
challenging to analyse which may lead to a misinterpretation [36].
Comprehensive discussion and more details including strengths
and limitations of order analysis technique are presented in [37,
Fig. 1 Frequency range includes the details and approximation 38].
coefficients
3 Experimental setup
vibration signature is investigated. In this context, a test rig that
Fig. 2a shows a real photograph of the setup test model that has
emulating real WT operation has been developed. High-resolution
been implemented to carry out the experiments, while Fig. 2b
sensors are used to accurately measure the shaft mechanical torque
shows a schematic diagram of the test rig setup. The developed test
and the gearbox vibration signals. Wavelet and order analysis
rig consists of an induction motor connected to a generator through
signal processing techniques are employed to analyse the measured
gearbox, shaft and coupling system. Numbers of accelerometers of
signals. Both techniques are compared based on their sensitivity to
low (0.1 Hz) and high (1000 Hz) frequency with sensitivity of
detect incipient fault levels.
±10% were installed on the drive train at different locations to
collect the vibration signals. ISOTRON Accelerometer
2 Signal processing techniques (ENDEVECO model 2258A-10), with output sensitivity of 10
In this section, a brief elaboration on wavelet and order analysis is mV/g was mounted on the gearbox towards the low-speed stage of
presented. the shaft. The other (AC133-1D high-performance low-frequency
accelerometer with a sensitivity of 500 mV/g was mounted on the
top side of the gearbox casing. The two-stage helical gearbox
2.1 Wavelet technique
which is the most sensitive and expensive component of the setup
Wavelet technique has been utilised to detect shaft misalignment has tooth ratio of 1: 4.34 and is lubricated with mineral oil SOVG
and bearing troubles by analysing the output power signal of 220. Torque transducer (FUTEK model TRS605) has been fitted
variable speed WTs [31]. Fig. 1 shows the approximation and between the prime mover and the low-speed shaft of the gearbox to
detail coefficients frequency range of a wavelet function that can measure the shaft torque; rated torque is 100 Nm. A comprehensive
be expressed as [30] study on test rig model for WT generator can be found in [21].
j−1
4 Experimental results
Xn = ∑ ai 0, j
φi
0, j
n + ∑ ∑ di jψ i j n
, ,
j i = i0 j 4.1 Torque signature
∫
∞ Fig. 3a shows the torque signal measured by the torque transducer
ai n = x[n]φi n dn (1)
0, j
−∞
0, j during normal operating condition. The torque amplitude is
measured at a rotor speed of 200 rpm when there is no mechanical
∫
∞
stress applied on the drive train.
di, j n = x[n]ψ i, j dn
−∞
Fig. 3b shows the approximation coefficients of the healthy
torque signal using wavelet db14 (Daubechies 14), while Fig. 3c
i /2 i shows the detail coefficients of the torque signal. Fig. 3d shows the
where ψ [n] is the mother wavelet, and φi, j[n] = 2 0 φ(2 0n − j) is a signal in frequency domain using order analysis. The signals of
i
scaling function at a scale s = 2 0 shifted by j. Similarly, Fig. 3 are stored as a healthy reference signature to be compared
i with the future measured signatures in order to detect any variation
ψ i, j[n] = 2i /2ψ(2in − j) is the mother wavelet at a scale s = 2 0
due to possible faults.
shifted by j, ai , j represents the approximation coefficients at a A stressed shaft is implemented by injecting dc current of 85%
0
i of the generator rated current (9.39 A) through the generator stator
scale s = 2 0, and di, j are the detail coefficients at a scale s = 2i.
terminals to emulate real fault conditions on the WT blades such as
A high-order wavelet (Daubechies 14) has been chosen in order icing accumulation, wind shear and gust wind. The injected current
to minimise the overlapping between the frequency bands. DWT is will produce an opposite electromagnetic force that tends to retard
able to localise correctly the frequencies with accurate time the shaft speed which can emulate the above-mentioned real
locations and hence unforeseen transient variations that could take situations.
place within any steady-state regime can be detected by this As can be seen in Fig. 4a, there is a significant increase in the
application [32]. The use of orthogonal wavelets families results in torque amplitude when compared with the case of healthy
no redundancy which means N data points produce N wavelet condition that is shown in Fig. 3a. Most of rolling elements such as
amplitudes [33]. According to [34], the decomposition levels can bearings are designed to operate with a relatively smooth transition
be tested based on the following formula: between loaded and unloaded modes. The rapid and significant
amplitude change shown in the torque signal of Fig. 4a is attributed
Log( f s / f ) to the fact that, the machine is delivering more mechanical power
nd > +1 (2)
Log(2) to overcome the stress on its shaft which result in significant
impact on rolling elements surface durability.
where f s and f are the sampling and supply frequencies, The wavelet approximation coefficient shown in Fig. 4b
respectively. exhibits a significant drop in the amplitude when compared with
the normal operating condition signal shown in Fig. 3b,
2.2 Order analysis consequently the detail coefficients of the wavelet signal has
significantly decreased as can be seen in Fig. 4c. Power spectrum
Fluctuating load conditions and deformity in rotating machines can of the order analysis technique could not be captured for this case
cause constrained vibrations. According to the signal properties of because the high stator injected current caused high stress on the
the machine rotating parts, a vibration signal will be formed. By rotor of the generator and forced the whole drive train to stop when
involving spectra and time histories to the speed of the moving the shaft speed reaches the critical limit.
parts, order analysis has the ability to detect the vibration of
432 IET Sci. Meas. Technol., 2017, Vol. 11 Iss. 4, pp. 431-437
© The Institution of Engineering and Technology 2017
Fig. 2 Real photograph of the setup test model
(a) Test rig setup for WT, (b) Schematic diagram of the test rig setup for WT
Fig. 3 Torque signal under normal operating conditions (healthy conditions with rotor speed 200 rpm)
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© The Institution of Engineering and Technology 2017
Fig. 4 Torque signal under stressed shaft (with rotor speed 200 rpm)
Fig. 5 Vibration signal under normal operating conditions (with rotor speed 200 rpm)
4.2 Vibration signature exhibits a crest value of 80 which is 20 times the amplitude of the
normal signal shown in Fig. 7b.
The vibration signal during normal operating conditions is shown It is also observed that the detail coefficients of the measured
in Fig. 5a which reveals that the vibration signal oscillates between signal are increased from 0.65 for normal operating condition to 12
maximum and minimum limits with some spikes. When analysed for stressed shaft condition as can be seen from Figs. 7c and 8c,
using wavelet technique, a better feature of the healthy vibration respectively. On the other hand, power spectrum for the faulty
signal can be gained and stored for future comparison as can be signal (Fig. 8d) exhibits more harmonics with less amplitude when
shown in the approximate and detail coefficients in Figs. 5b and c. compared with the healthy signature power spectrum (Fig. 7d).
Fig. 5d shows the harmonic contents in the order power spectrum Based on these results, a code to quantify the level of drivetrain
of the vibration signal during healthy operating conditions. stress along with the recommended asset management decision can
When 85% of the full load current is injected to the generator be developed as listed in Table 1. The table is developed based on
stator terminals, while maintaining the shaft speed (200 rpm) and the maximum amplitude of the vibration signal and the
the sensors locations, the vibration signal was recorded as shown in corresponding duration. The recommended asset management
Fig. 6. To show the impact of rotor speed variation on the decisions range from continuing normal operation to taking the WT
measured vibration signature, Fig. 7 shows the vibration signature out of service for serious levels of drivetrain stresses.
for a normal operating condition with a rotor speed of 650 rpm
while Fig. 8 shows the vibration signal with stressed shaft at this
higher speed. Results of Figs. 7 and 8 show that rotor speed has a 5 Comparison analysis
great influence on the measured vibration signature. Higher Studies in [37] show that order analysis can effectively identify and
rotational speed is corresponding to higher vibration amplitude. detect faults within the pinion gear in the gearbox. However, this
Also, it can be observed that the faulty signal shown in Fig. 8b digital signal-based technique requires the collected vibration
434 IET Sci. Meas. Technol., 2017, Vol. 11 Iss. 4, pp. 431-437
© The Institution of Engineering and Technology 2017
Fig. 6 Vibration signal under stressed shaft (with rotor speed 200 rpm)
Fig. 7 Vibration signal under normal operating conditions (with rotor speed 650 rpm)
signal from the machine to be sampled at a fixed angular increment applied to the test including changing in rotor speed which
which means the shaft speed should be kept proportional to the represents the WT blades as affected by the fluctuating loads. The
sampling rate. Without extra specified equipment, such as ratio shaft torque and gearbox vibration signals are measured using high
synthesiser and anti-aliasing tracking filter, the measured signal sensitive sensors for normal operating conditions and for a stressed
will not be accurate. Comprehensive discussions and more details drivetrain shaft which is implemented by injecting a current to the
including strengths and limitations of order analysis technique are generator stator winding to create an opposite torsional torque on
presented in [38, 39]. On the other hand, wavelet analysis the main shaft. The healthy and faulty signals are processed and
technique can identify the coefficients accurately in the low- and analysed using wavelet and order analyses techniques.
high-frequency range which makes it a powerful technique to Experimental results show that wavelet analysis technique has the
monitor and diagnose the health condition of rotating machines. ability to localise the frequencies with accurate time locations, as
Based on the above results, the wavelet technique is found to be well as detecting unforeseen transient variations based on the
superior and more powerful than the order analysis technique that different faulty and healthy scenarios investigated on the developed
may fail to analyse the shaft torque signal under high mechanical test rig. While order analysis shows more harmonics in the
stresses as explained in the case study shown in Fig. 4. analysed faulty signal, it is hard to be diagnosed to detect the root
failure causes. A code to quantify the mechanical stress level on
6 Conclusions the drivetrain is developed based on the measured vibration
signatures and asset management decision is recommended.
Gearbox and generator shaft are vital mechanical components in
WECSs and hence a reliable technique is required to maintain the
reliability of the system. In this paper, a test rig is developed to
emulate real operation of a WT. Different scenarios have been
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Fig. 8 Vibration signal under stressed shaft (with rotor speed 650 rpm)
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