Grant: Idea to Innovation

Wind energy has been the fastest growing energy source over the last decade. In spite of the increased popularity of wind energy, wind turbines (WTs) are still experiencing costly repair, productivity loss and catastrophic breakdowns due to undetected component faults. Gearboxes and bearings are among the most failure-prone WT components because of their harsh, volatile working conditions. This along with their restricted access and remote locations calls for an on-line monitoring system. However, an effective monitoring system is not yet available. We have developed a cost effective and easy to implement technique (patent pending) to detect gearbox and bearing faults. This technique is based on the Teager energy operator (TEO). It can effectively extract incipient gearbox and bearing fault signatures. This technique is reliable, versatile, and much less susceptible to condition changes. A prototype has been developed and tested against two commercial monitors. The tests clearly demonstrated the technical superiority of our technology. The goal of the proposed project is to test our technology for WT applications and to begin technology transfer to Canadian industry. The objectives are to: (1) conduct systematic lab tests using a WT test rig and field data from a WT subject to various condition changes, (2) identify optimal sensor/detector configurations, and develop an optimized TEO algorithm for wind turbines, and (3) design a prototype suitable for testing in a real WT in collaboration with an industrial partner. This technology, once fully tested and transferred to Canadian industry, will help reduce WT maintenance cost, downtime and avoid catastrophic failures by timely and responsive diagnosis of gearbox and bearing conditions. This will have a profound impact on Canadian economy and global environment.