Method and apparatus of monitoring a machine

A monitoring system for a machine is provided. The machine includes at least one movable member including at least one sensor configured to generate at least one speed measurement of the moveable member. The machine also includes at least one processor coupled in electronic data communication to the sensor. The sensor is configured to generate at least one time stamp value for the at least one speed measurement signal. The at least one processor is configured to generate a plurality of time-stamped speed measurement signals of the at least one moveable member. The processor is further configured to determine a prioritization of the plurality of time-stamped speed measurement signals as a function of at least one predetermined temporal value.

BACKGROUND OF THE INTENTION

This invention relates generally to machines and more particularly, to methods and apparatus for monitoring wind turbines.

Generally, a wind turbine generator includes a turbine that has a rotatable hub assembly including multiple blades. The hub assembly is coupled to a rotor and the blades transform mechanical wind energy into a mechanical rotational torque that drives one or more generators via the rotor. The generators are generally, but not always, rotationally coupled to the rotor through a gearbox. The gearbox steps up the inherently low rotational speed of the rotor to enable the generator to efficiently convert the rotational mechanical energy into electrical energy that is supplied to a utility grid. Gearless direct drive wind turbine generators also exist. Generally, the rotor, generator, gearbox and other components are mounted within a housing or nacelle, that is positioned atop a base, such as truss, lattice or tubular tower.

Some known wind turbines include vibration monitoring systems that record, transmit, and analyze data that includes, but is not limited to, component speed and vibration data. Generally, component speed and vibration data form an inter-relationship that facilitates analysis of a component at a particular time. Therefore, recording component speed and vibration data, while mitigating a time differential between the two, facilitates component analysis. However, at least some known vibration monitoring systems are not configured to record, transmit, and/or process component speed and vibration data simultaneously and as such, may need to utilize component speed and vibration data recorded at differing times.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a monitoring system for a machine is provided. The machine includes at least one movable member including at least one sensor configured to generate at least one speed measurement signal of the moveable member. The machine also includes at least one processor coupled in electronic data communication to the sensor. The sensor is configured to generate at least one time-stamp value for the at least one speed measurement signal. The at least one processor is configured to generate a plurality of time-stamped speed measurement signals of the at least one moveable member. The processor is further configured to determine a prioritization of the plurality of time-stamped speed measurement signals as a function of the at least one predetermined temporal value.

In a further aspect, a method of monitoring a machine is provided. The machine includes at least one moveable member, and a monitoring system including at least one sensor and at least one processor coupled in electronic data communication with the at least one sensor. The method includes receiving a plurality of speed measurement signals within the processor from the at least one sensor, assigning a time-stamp value to each of the plurality of speed measurement signals via the processor to generate a plurality of time-stamped speed measurement signals, determining a prioritization of the plurality of time-stamped speed measurement signals within the processor, and transmitting at least one prioritized time-stamped speed measurement signal.

In a further aspect, a wind turbine generator is provided. The wind turbine generator includes at least one rotatable member, and a monitoring system. The monitoring system includes at least one sensor configured to generate at least one speed measurement of the moveable member. The at least one processor is coupled in electronic data communication to the sensor. The sensor is configured to generate a time stamp value for the at least one speed measurement signal such that the at least one processor is configured to generate a plurality of time-stamped speed measurement signals of the at least one moveable member. The processor is further configured to determine a prioritization of the plurality of time-stamped speed measurement signals.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1is a schematic illustration of an exemplary wind turbine generator100. In the exemplary embodiment, wind turbine generator100is a horizontal axis wind turbine. In the exemplary embodiment, wind turbine generator100is a 1.5 megawatt (MW) series wind turbine generator100commercially available from General Electric, Schenectady, N.Y. Alternatively, wind turbine100may be a vertical axis wind turbine. Wind turbine100has a tower102extending from a supporting surface104, a nacelle106mounted on tower102, and a rotor108coupled to nacelle106. Rotor108has a rotatable hub110and a plurality of rotor blades112coupled to hub110.

In the exemplary embodiment, rotor108has three rotor blades112. In an alternative embodiment, rotor108may have more or less than three rotor blades112. In the exemplary embodiment, tower102is fabricated from tubular steel and has a cavity (not shown inFIG. 1) extending between supporting surface104and nacelle106. In an alternate embodiment, tower102is a lattice tower. A height of tower102is selected based upon factors and conditions known in the art.

Blades112are positioned about rotor hub110to facilitate rotating rotor108to transfer kinetic energy from the wind into usable mechanical energy, and subsequently, electrical energy. Blades112are mated to hub110by coupling a blade root portion120to hub110at a plurality of load transfer regions122. Load transfer regions122have a hub load transfer region and a blade load transfer region (both not shown inFIG. 1). Loads induced in blades112are transferred to hub110via load transfer regions122.

In the exemplary embodiment, blades112have a length between 50 meters (m) (164 feet (ft)) and 100 m (328 ft). Alternatively, blades112may have a length greater than 100 m (328 ft) or less than 50 m (164 ft). As the wind strikes blades112, rotor108is rotated about rotation axis114. As blades112are rotated and subjected to centrifugal forces, blades112are also subjected to various bending moments and other operational stresses. As such, blades112may deflect and/or rotate from a neutral, or non-deflected, position to a deflected position and associated stresses, or loads, may be induced in blades112. Moreover, a pitch angle of blades112, i.e., the angle that determines blades112perspective with respect to the direction of the wind, may be changed by a pitch adjustment mechanism (not shown inFIG. 1) to facilitate increasing or decreasing blade112speed by adjusting the surface area of blades112exposed to the wind force vectors. Pitch axes118for blades112are illustrated. In the exemplary embodiment, the pitches of blades112are controlled individually. Alternatively, blades112pitch may be controlled as a group.

In some configurations, one or more microcontrollers in a control system (not shown inFIG. 1) are used for overall system monitoring and control including pitch and rotor speed regulation, yaw drive and yaw brake application, and fault monitoring. Alternatively, distributed or centralized control architectures are used in alternate embodiments of wind turbine100.

FIG. 2is a fragmentary perspective view, partly in section, of an exemplary nacelle106that may be used with wind turbine generator100(shown inFIG. 1). Various components of wind turbine100are housed in nacelle106atop tower102. Pitch drive mechanisms130(only one illustrated inFIG. 2) modulate the pitch of blades112along pitch axis118(both shown inFIG. 1).

Generally, rotor108is rotatably coupled to an electric generator132positioned within nacelle106via rotor shaft134(sometimes referred to as low-speed shaft134), a gearbox136, a high-speed shaft138, and a coupling140. Rotation of shaft134rotates gearbox136that subsequently rotates shaft138. Shaft138rotates generator132via coupling140and shaft138rotation facilitates production of electrical power within generator132. Gearbox136and generator132are supported by support members142and144, respectively.

A yaw adjustment mechanism146is also positioned in nacelle106and may be used to rotate nacelle106and rotor108about axis116(shown inFIG. 1) to facilitate controlling the perspective of wind turbine100with respect to the direction of the wind. Control mechanism146is coupled to nacelle106, and a meteorological mast148includes a wind vane and anemometer (neither shown inFIG. 2). Mast148is positioned on nacelle106and provides information to the turbine control system that may include wind direction and/or wind speed. A portion of the turbine control system resides within a control panel150.

A main bearing152is positioned within and is supported by nacelle106. Bearing152facilitates radial support and alignment of shaft134. Shaft134is rotatably coupled to gearbox136via a coupling154.

FIG. 3is a schematic view of an exemplary vibration monitoring system300that may be used with wind turbine100(shown inFIG. 1). In the exemplary embodiment, gearbox136includes three gear assemblies and utilizes a dual path geometry to drive high-speed shaft138as discussed further below. Alternatively, gearbox136has any configuration that facilitates operation of wind turbine100as described herein. Further, alternatively, wind turbine100has a direct-drive configuration, i.e., main rotor shaft134is coupled directly to generator132via coupling140and system300is configured to monitor other components of wind turbine100. Generally, rotation of shaft134rotates gearbox136that subsequently rotates shaft138. More specifically, in the exemplary embodiment, gearbox136includes an input gear assembly302, an intermediate gear assembly304, and an output gear assembly306. Each gear assembly302,304, and306includes at least two gears. Specifically, input gear assembly302includes an input gear310and an input step-up gear312, intermediate gear assembly304includes an intermediate gear314and an intermediate step-up gear316, and output gear assembly306includes an output gear318and an output step-up gear320. In the exemplary embodiment, an outer diameter and plurality of teeth of each input gear310,314, and318is greater than an outer diameter and number of teeth of each respective step-up gear312,316, and320. Each input gear310,314, and318is configured to rotate and engage a portion of step-up gear312,316, and320. Specifically, as each input gear310,314, and318rotates, so does each associated step-up gear312,316, and320, respectively.

Gearbox136also includes various shafts. Specifically, gearbox136includes shaft134. Rotation of shaft134drives input gear310that subsequently rotates input step-up gear312. A first output shaft332rotatably couples input step-up gear312to intermediate gear314such that rotation of input step-up gear312rotates first output shaft332subsequently rotating intermediate gear314. Shaft332receives at least some radial support from at least one bearing333. Intermediate gear314subsequently rotates intermediate step-up gear316. Similarly, a second output shaft334rotatably couples intermediate step-up gear316to output gear318such that rotation of intermediate step-up gear316rotates second output shaft334subsequently rotating output gear318. Shaft334receives at least some radial support from at least one bearing335. Output gear318subsequently rotates output step-up gear320. A third output shaft336rotatably couples output step-up gear320to shaft138such that rotation of output step-up gear320rotates third output shaft336subsequently rotating shaft138facilitating generator132production of electrical power. Shaft336receives at least some radial support from at least one bearing337. Third output shaft336is coupled to high-speed shaft138via coupling140, as described above.

Gears310,314, and318engage respective gears312,316, and320via the plurality of teeth formed on a radially outermost portion of gears310,312,314,316,318, and320. Additionally, gears310,314, and318have a larger circumferential measurement than gears312,316, and320. Therefore, gears310,314, and318have a first rate of rotation that drives associated gears312,316, and320, respectively, with a second rate of rotation. In the exemplary embodiment, the second rate of rotation is greater than the first rate of rotation. Hence, in the exemplary embodiment, when a rate of rotation of gear310is approximately 20 revolutions per minute (rpm), the rate of rotation of gear320is approximately 1400 rpm. Thus, a total gearbox step-up ratio of 70:1 is achieved.

Additionally, nacelle106includes various bearings coupled to each shaft that facilitate radial support and alignment of their respective shaft. Each shaft includes at least one set of two bearings (not shown). Additionally, nacelle106includes a generator inboard bearing350and a generator outboard bearing352. In the exemplary embodiment, bearings350and352are rotatably coupled to shaft138.

Generally, system300includes a plurality of accelerometers. In the exemplary embodiment, nacelle106includes at least six accelerometers including a main bearing accelerometer360, a first output shaft accelerometer362, a second output shaft accelerometer364, a third output shaft accelerometer366, a generator inboard bearing accelerometer368, and a generator outboard bearing accelerometer370. System300also includes at least two Keyphasor speed sensors, a low-speed Keyphasor sensor372and a high-speed Keyphasor sensor374. Accelerometer360is positioned adjacent to main bearing152. Accelerometers362,364, and366are positioned adjacent to bearings333,335, and337, respectively. Accelerometers368and370are positioned adjacent to bearings350, and352, respectively. Accelerometers360,362,364,366,368, and370measure radial acceleration. “Keyphasor” is a registered trademark of Bently Nevada, Minden, Nev.

Keyphasors372and374generate electric pulses related to a point on rotating shafts134and138, respectively. Keyphasors372and374each generate a signal via a transducer (not shown) observing a once-per-revolution event. Keyphasors372and374are positioned on or near shafts134and138, respectively. Of the six accelerometers360,362,364,366,368, and370, two accelerometers360and362are associated with Keyphasor372, and four accelerometers364,366,368, and370are associated with Keyphasor374.

Additionally, accelerometers360,362,364,366,368, and370, and Keyphasors372and374include sensors configured to collect and transmit data from each accelerometer360,362,364,366,368, and370to a Decision Support Module (DSM)380for a wind power generator. In the exemplary embodiment, DSM380is commercially available from General Electric Corporation Bently-Nevada, Minden, Nev. Alternatively, DSM380is any suitable apparatus that facilitates operation of system300as described herein. Additionally, DSM380is electronically coupled to a processor382.

Processor382processes data received from accelerometers360,362,364,366,368, and370and Keyphasors372and374via DSM380. Processor382includes at least one processor and a memory (neither shown). As used herein, the term computer is not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a processor, a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein. In the exemplary embodiment, memory may include, but is not limited to, a computer-readable medium, such as a random access memory (RAM). Alternatively, a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a digital versatile disc (DVD) may also be used.

FIG. 4is a block diagram view of an exemplary machine speed and average revolutions per minute (rpm) logic module400that may be used with system300. Typically, system300includes one logic module400for each of accelerometers364,366,368, and370. Therefore, logic module400receives an input from an accelerometer402that includes at least one of accelerometers364,366,368, and370. Waveform data406is collected via accelerometer402and is assigned a time stamp via a speed measurement signal time stamp function block404. Function block404outputs a speed measurement time stamp signal B that is transmitted within system300. Waveform data406is transmitted to a waveform data record408wherein a start rpm speed measurement signal410is transmitted within system300. Within waveform data record408, an average rpm calculated speed signal A is determined by summation of a pre-defined number of signals410and division of the summation by the pre-defined number of signals410. Signal A is transmitted from waveform data record408to register412for further use within system300.

Logic module400also includes a generator speed measurement signal time stamp function block414that receives a generator speed measurement signal C from a source (not shown) external to DSM380and assigns a generator speed measurement signal time stamp H. For example, a supervisory control and data acquisition system (SCADA) (not shown) coupled in electronic data communication with DSM380. Signal C and signal H are transmitted for further use within system300. Logic module400also includes a delta time function block416that receives signal B and signal H. Signal B and signal H are compared and a time stamp differential signal417is generated. Signal417is transmitted to an absolute value function block418wherein the absolute value of signal417is determined and transmitted for later use in logic module400.

Logic module400also includes a high-speed shaft Keyphasor speed measurement signal time stamp function block420that receives a high-speed shaft generator speed measurement signal D from Keyphasor374, and assigns a generator speed measurement signal time stamp K. Signal D and signal K are transmitted for further use within system300. Logic module400also includes a delta time function block421that receives signal D and signal K. Similarly, signal D and signal K are compared and a time stamp differential signal419is generated. Signal419is transmitted to an absolute value function block422wherein the absolute value of signal419is determined and transmitted for later use in logic module400.

Function block418transmits a signal425to a less than function block423. Similarly, function block422transmits a signal427to function block423. Function block423determines the smaller of signals425and427, and transmits a selection signal459to a switch function block424. Function block424selects either signal C or signal D based on signal429. For example, if signal425represents a smaller time differential than signal427, signal C is selected by function block424. Moreover, signal425and signal427are transmitted to a minimum value selection function block426for further use within logic module400.

Predetermined temporal values are configured within system300. For example, a maximum time differential is configured within a maximum time delta function block428, such that a time stamp is applied to the maximum time differential and a signal is transmitted to a unit conversion function block430. The maximum time differential is an operand that is manually configured by an operator. The maximum time differential value configured within function block428is typically selected to facilitate the diagnostic features of system300as is discussed further below. Function block430converts the signal to units of seconds and transmits the converted signal to an auto-switch function block434to be further used in logic module400. Function block434receives the signal from function block430and receives a number constant from a number constant register432. Register432maintains an operator-defined time value. Function block434transmits the operator-defined temporal value maintained within register432in the event that the maximum time differential is not configured within function block428as discussed above.

Logic module400also includes a less than function block436that receives an output signal437from function block426and an output signal439from function block434. Function block436determines the smaller of signals437and439, and transmits a selection signal443to a switch function block454. In the exemplary embodiment, number constant register451maintains a predetermined temporal value of zero. In the event that signal437exceeds signal439, a signal445transmits to a switch function block454to block a signal456transmitted from function block424. Subsequently, in the exemplary embodiment, a value of zero propagates to switch function block454. In the event that signal437is less than signal439, signal456is transmitted through switch function block454. Switch function block454receives signal456, which includes either signal C or signal D or the value zero from register451. Switch function block454then transmits a signal458.

Logic module400also includes an auto-switch460that receives signals410and458, and transmits a signal462to a machine speed register470for further use within system300.

In operation, logic module400, generally, transmits signal410via auto-switch460to register470. The value in machine speed register470is used within system300to process and analyze waveform data406. Therefore, the preferred value within register470is signal410(i.e., start rpm speed measurement signal410). In the event that signal410is unavailable, a substitute signal458is transmitted into register470. Substitute signal458includes at least one of signal C, signal D, or the value zero. The use of value zero within register470precludes analysis and processing of waveform data406even though continued data collection for subsequent activities that include, but are not limited to, manual review and analysis, is permitted. Therefore, signals C and D are preferred over the value of zero to facilitate processing and analyzing waveform data406.

FIG. 5is a block diagram view of an exemplary first output shaft speed logic module500that may be used with system300. Logic module500receives the first output shaft accelerometer362signal. Waveform data signal502is collected via accelerometer362and is assigned a time stamp via a first output speed measurement signal time stamp function block504. Function block504outputs a speed measurement time stamp signal E that is transmitted within system300. Waveform data signal502is transmitted to a waveform data record506wherein a start rpm speed measurement signal F is transmitted within system300. System300also includes a main bearing logic module (not shown) that is substantially similar to logic module500.

In operation, logic module500transmits signal502to waveform data record506. Module500also transmits signal E elsewhere within system300. The value in record506is used within system300to process and analyze signal502. Therefore, the preferred value within record506is signal F (i.e., start rpm speed measurement signal F).

FIG. 6is a block diagram view of an exemplary first output shaft speed prioritization logic module600that may be used with system300. System300also includes a main bearing logic module (not shown) that is substantially similar to logic module600.

Logic module600includes a third output shaft speed measurement signal time stamp function block602. A third output shaft speed measurement signal (not shown) is transmitted to function block602from a register470(shown inFIG. 4) associated with a logic module400that is further associated with accelerometer336(shown inFIG. 3). Function block602assigns a third output shaft speed measurement signal time stamp B from accelerometer366. Signal B is transmitted to a delta time function block604that receives signal B and signal E (shown inFIG. 5). Signal B and signal E are compared and a time stamp differential signal605is generated. Signal605is transmitted to an absolute value function block606wherein the absolute value of signal605is determined and transmitted for later use in logic module600.

Logic module600includes a third output shaft speed measurement signal time stamp function block608. A second output shaft speed measurement signal (not shown) is transmitted to function block608from a register470associated with a logic module400that is further associated with accelerometer364(shown inFIG. 3). Function block608assigns a second output shaft speed measurement signal time stamp G from accelerometer364. Signal G is transmitted to a delta time function block610that receives signal G and signal E. Signal G and signal E are compared and a time stamp differential signal611is generated. Signal611is transmitted to an absolute value function block612wherein the absolute value of signal611is determined and transmitted for later use in logic module600.

Logic module600includes a generator inboard bearing speed measurement signal time stamp function block614. A generator inboard bearing speed measurement signal (not shown) is transmitted to function block614from a register470associated with a logic module400that is further associated with accelerometer368(shown inFIG. 3). Function block614assigns a generator inboard bearing speed measurement signal time stamp L from accelerometer368. Signal L is transmitted to a delta time function block616that receives signal L and signal E. Signal L and signal E are compared and a time stamp differential signal617is generated. Signal617is transmitted to an absolute value function block618wherein the absolute value of signal617is determined and transmitted for later use in logic module600.

Logic module600includes a generator outboard bearing speed measurement signal time stamp function block620. A generator outboard bearing speed measurement signal (not shown) is transmitted to function block620from a register470associated with a logic module400that is further associated with accelerometer370(shown inFIG. 3). Function block620assigns a generator outboard bearing speed measurement signal time stamp M from accelerometer370. Signal M is transmitted to a delta time function block622that receives signal M and signal E. Signal M and signal E are compared and a time stamp differential signal623is generated. Signal623is transmitted to an absolute value function block624wherein the absolute value of signal623is determined and transmitted for later use in logic module600.

Logic module600also includes function block504(shown inFIG. 5) that transmits signal E (shown inFIG. 5). Signal E is transmitted to a delta time function block628that receives signal E and signal H (shown inFIG. 4). Signal E and signal H are compared and a time stamp differential signal629is generated. Signal629is transmitted to an absolute value function block630wherein the absolute value of signal629is determined and transmitted for later use in logic module600.

Similarly, signal E is transmitted to a delta time function block632that receives signal E and signal K (shown inFIG. 4). Signal E and signal K are compared and a time stamp differential signal633is generated. Signal633is transmitted to an absolute value function block634wherein the absolute value of signal633is determined and transmitted for later use in logic module600.

Function blocks606,612,618,624,630, and634each transmit a signal from each respective function block to a sample buffer636. Buffer636includes a plurality of registers (not shown) that contain time stamp data transmitted from function blocks606,612,618,624,630, and634, and generates a numerical value of 1, 2, 3, 4, 5, and 6, respectively. Buffer636transmits a plurality of time stamp signals637from the plurality of registers to a minimum value selection function block638. Function block638selects the smallest time stamp value maintained in the plurality of registers, and transmits a sample buffer time stamp register number signal I with a numerical value of 1, 2, 3, 4, 5, or 6, and a sample buffer time stamp value signal639for further use within logic module600.

Logic module600includes at least one predetermined temporal value. For example, a maximum time differential is configured within a maximum time delta function block640, such that a time stamp is applied to the maximum time differential and a signal is transmitted to a unit conversion function block642. The maximum time differential is an operand that is manually configured by an operator. The maximum time differential value configured within function block640is typically selected to facilitate the diagnostic features of system300as is discussed further below. Function block642converts the signal to units of seconds and transmits the converted signal to an auto-switch function block646to be further used in logic module600. Function block646receives the signal from function block642and receives a number constant from a number constant register644. Register644maintains an operator-defined temporal value. Function block646transmits the operator-defined temporal value maintained within register644in the event that the maximum time differential is not configured within function block640as discussed above.

Logic module600also includes a multiplication function block650that receives a signal from function block646and a number from a number constant register648. Logic module600also includes a between function block652that receives signal639and the outputs of function blocks646and650. In the exemplary embodiment, register648contains a value of negative one such that function block650generates and transmits a negative value of the output of auto-switch function block646to function block652. Therefore, function block652is configured to only transmit sample buffer time stamp value signals within a range of plus and minus the value within register644. Such transmission is indicative of sample buffer636containing at least one valid sample. Moreover, when sample buffer636contains at least one valid sample that is transmitted by function block652, a discrete yes-signal J is transmitted from function block652for further use within system300. Furthermore, when sample buffer636does not contain at least one valid sample that is transmitted by function block652, a discrete no-signal J is transmitted from function block652for further use within system300.

Logic module600also includes an auto-switch function block654that receives signal C from function block414(shown inFIG. 4), and a value from a number constant register656. Register656contains a value pre-defined by an operator. Function block654selects and transmits a generator speed signal P that is either the operator defined value or signal C for later use in logic module600.

Logic module600also includes an auto-switch function block658that receives signal D from function block420(shown inFIG. 4), and a value from a number constant register660. Register660contains a value pre-defined by an operator. Function block658selects and transmits a high-speed shaft Keyphasor speed signal N that is either the operator defined value or signal D for later use in logic module600.

Logic module600includes an equals logic function block664that receives signal I and a value from a number constant register662. In the exemplary embodiment, the value in register662is the numeral 6. Function block664also transmits a discrete output signal that equals a yes-signal when signal I and the value of register662are equal, i.e., both equal 6. Alternatively, if signal I and the number from register662are not equal, i.e., signal I does not equal 6, function block664outputs a no-signal. Logic module600also includes an and-logic function block666that receives the yes-signals and the no-signals from function block664, and signal J. Function block666also transmits a discrete output that includes either a yes-signal or a no-signal. A yes-signal is generated by function block666in the event that it receives a yes-signal from function block664and a yes-signal J from function block652. A no-signal is generated by function block666in the event that it receives a no-signal from function block664or a no-signal J from function block652. Logic module600also includes a switch function block670that receives the output of function block666. Function block670receives signal N and a number value from a number constant register668. Function block670transmits either signal N or the value of the output of register668. When the output of function block666is a yes-signal, signal N is transmitted through function block670for further use within logic module600. When the output of function block666is a no-signal, the value contained within register668is transmitted through function block670for further use within logic module600. In the exemplary embodiment, a value of zero is placed in register668.

Logic module600includes an equals logic function block674that receives signal I and a value from a number constant register672. In the exemplary embodiment, the value in register672is the numeral 5. Function block674is transmits a discrete output signal that equals a yes-signal when signal I and the value of register672are equal, i.e., both equal 5. Alternatively, if signal I and the number from register672are not equal, i.e., signal I does not equal 5, function block674output is a no-signal. Logic module600also includes an and-logic-function block676that receives the yes-signals and the no-signals from function block674, and signal J. Function block676also transmits a discrete output that includes either a yes-signal or a no-signal. A yes-signal is generated by function block676in the event that it receives a yes-signal from function block674and a yes-signal J from function block652. A no-signal is generated by function block676in the event that it receives a no-signal from function block674or a no-signal J from function block652. Logic module600also includes a switch function block678that receives the output of function block676. Function block678also receives signal P and the output of function block670. Function block678transmits either signal P or the output of function block670. When the output of function block676is a yes-signal, signal P is transmitted through function block678for further use within logic module600. When the output of function block670is a no-signal, the output of function block670is transmitted through function block678for further use within logic module600.

Logic module600includes an equals logic function block682that receives signal I and a value from a number constant register680. In the exemplary embodiment, the value in register680is the numeral 4. Function block682transmits a discrete output signal that equals a yes-signal when signal I and the value of register680are equal, i.e., both equal 4. Alternatively, if signal I and the number from register662are not equal, i.e., signal I does not equal 4, function block682output is a no-signal. Logic module600also includes an and-logic-function block684that receives the yes-signals and the no-signals from function block682, and signal J. Function block684also transmits a discrete output that includes either a yes-signal or a no-signal. A yes-signal is generated by function block684in the event that it receives a yes-signal from function block682and a yes signal J from function block652. A no-signal is generated by function block684in the event that it receives a no-signal from function block682or a no-signal J from function block652.

Logic module600also includes a switch function block688that receives the output of function block684. Function block688also receives a generator outboard bearing average rpm calculated speed signal686, Function block688transmits either signal686or the output signal of function block678. When the output of function block684is a yes-signal, signal686is transmitted through function block688for further use within logic module600. When the output of function block684is a no-signal, the output of function block678is transmitted through function block688for further use within logic module600.

Logic module600includes an equals logic function block692that receives signal I and a value from a number constant register690. In the exemplary embodiment, the value in register690is the numeral 3. Function block692transmits a discrete output signal that equals a yes-signal when signal I and the value of register690are equal, i.e., both equal 3. Alternatively, if signal I and the number from register690are not equal, i.e., signal I does not equal 3, function block692output is a no-signal. Logic module600also includes an and-logic-function block694that receives the yes-signals and the no-signals from function block692, and signal J. Function block694also transmits a discrete output that includes either a yes-signal or a no-signal. A yes-signal is generated by function block694in the event that it receives a yes-signal from function block692and a yes-signal J from function block652. A no-signal is generated by function block694in the event that it receives a no-signal from function block692or a no-signal J from function block652. Logic module600also includes a switch function block698that receives the output of function block694. Function block698also receives a generator inboard bearing average rpm calculated speed signal696. Function block698transmits either signal696or the output signal of function block688. When the output of function block694is a yes-signal, signal696is transmitted through function block698for further use within logic module600. When the output of function block694is a no-signal, the output of function block688is transmitted through function block698for further use within logic module600.

Logic module600includes an equals logic function block702that receives signal I and a value from a number constant register700. In the exemplary embodiment, the value in register700is the numeral 2. Function block702transmits a discrete output signal that equals a yes-signal when signal I and the value of register700are equal, i.e., both equal 2. Alternatively, if signal I and the number from register700are not equal, i.e., signal I does not equal 2, function block702output is a no-signal. Logic module600also includes an and-logic-function block704that receives the yes-signals and the no-signals from function block702, and signal J. Function block704also transmits a discrete output that includes either a yes-signal or a no-signal. A yes-signal is generated by function block704in the event that it receives a yes-signal from function block702and a yes-signal J from function block652. A no-signal is generated by function block704in the event that it receives a no-signal from function block702or a no-signal J from function block652. Logic module600also includes a switch function block708that receives the output of function block704. Function block708also receives a second output shaft average rpm calculated speed signal706. Function block708transmits either signal706or the output signal of function block698. When the output of function block704is a yes-signal, signal706is transmitted through function block708for further use within logic module600. When the output of function block704is a no-signal, the output of function block698is transmitted through function block708for further use within logic module600.

Logic module600includes an equals logic function block712that receives signal I and a value from a number constant register710. In the exemplary embodiment, the value in register710is the numeral 1. Function block712transmits a discrete output signal that equals a yes-signal when signal I and the value of register710are equal, i.e., both equal 1. Alternatively, if signal I and the number from register710are not equal, i.e., signal I does not equal 1, function block712output is a no-signal. Logic module600also includes an and-logic-function block714that receives the yes-signals and the no-signals from function block712, and signal J. Function block714also transmits a discrete output that includes either a yes-signal or a no-signal. A yes-signal is generated by function block714in the event that it receives a yes-signal from function block712and a yes-signal J from function block652. A no-signal is generated by function block714in the event that it receives a no-signal from function block712or a no-signal J from function block652. Logic module600also includes a switch function block718that receives the output of function block714. Function block718also receives a third output shaft average rpm calculated speed signal716. Function block718transmits either signal716or the output signal of function block708. When the output of function block714is a yes-signal, signal716is transmitted through function block718for further use within logic module600. When the output of function block704is a no-signal, the output of function block708is transmitted through function block718for further use within logic module600.

Logic module600also includes a not-equals logic function block722that receives the output of function block718and a value from a number constant register720that contains an operator defined value. Logic module600also includes an and-logic function block724that receives a signal from function block722and receives signal J from function block652. In the event that the output of function block718does not equal the value contained in register720, a discrete yes-signal is transmitted from function block722to function block724. In the event that the output of function block718does equal the value contained in register720, a discrete no-signal is transmitted from function block722to function block724. In the exemplary embodiment, the value in register720is zero. In the event that function block724receives a yes-signal from function block722and a yes-signal J from function block652, a discrete yes-signal is transmitted to a switch function block730. In the event that function block724receives a no-signal from function block722or a no-signal J from function block652, a discrete no-signal is transmitted to function block730.

Logic module600also includes a multiplication function block728that receives signal F and a value from a total gearbox ratio constant register726. Function block728is further configured to multiply signal F by a pre-defined value within register726and to transmit an output signal to function block730. Function block730also receives an output signal from function block718. In the event that function block730receives a yes-signal from function block724, the output signal of function block718is transmitted as a machine speed for first output shaft register732. In the event that function block730receives a no-signal from function block724, the output signal of function block728is transmitted as a machine speed to register732.

In operation, function block602, generally, transmits signal B to function block604. Function block504transmits signal E to function block604. Signal B and signal E are compared and time stamp differential signal605is generated. Signal605is the difference between signal B and signal E. Signal605is transmitted to function block606wherein the absolute value of signal605is determined. Absolute value of signal605is then transmitted into a “value 1” register (not shown) within sample buffer636for temporary storage.

Similarly, function block608, generally, transmits signal G to function block610. Function block504transmits signal E to function block610. Signal G and signal E are compared and time stamp differential signal611is generated. Signal611is the difference between signal G and signal E. Signal611is transmitted to function block612wherein the absolute value of signal611is determined. Absolute value of signal611is then transmitted into a “value 2” register (not shown) within sample buffer636for temporary storage.

Similarly, function block614, generally, transmits signal L to function block616. Function block504transmits signal E to function block616. Signal L and signal E are compared and time stamp differential signal617is generated. Signal617is the difference between signal L and signal E. Signal617is transmitted to function block618wherein the absolute value of signal617is determined. Absolute value of signal617is then transmitted into a “value 3” register (not shown) within sample buffer636for temporary storage.

Similarly, function block620, generally, transmits signal M to function block622. Function block504transmits signal E to function block622. Signal M and signal E are compared and time stamp differential signal623is generated. Signal623is the difference between signal M and signal E. Signal623is transmitted to function block624wherein the absolute value of signal623is determined. Absolute value of signal623is then transmitted into a “value 4” register (not shown) within sample buffer636for temporary storage.

Similarly, function block414, generally, transmits signal C to auto switch function block654wherein signal C is compared to a value maintained in register656. Either signal C or the pre-defined value in register656is transmitted as signal P from auto switch function block654to function block678for use described further below. Function block414also generates signal H and transmits signal H to function block628. Signal H and signal E are compared and time stamp differential signal629is generated. Signal629is the difference between signal H and signal E. Signal629is transmitted to function block630wherein the absolute value of signal629is determined. Absolute value of signal629is then transmitted into a “value 5” register (not shown) within sample buffer636for temporary storage.

Similarly, function block420, generally, transmits signal D to auto switch658wherein signal D is compared to a value maintained in register660. Either signal D or the pre-defined value in register660is transmitted as signal N from auto switch658to function block670for use described further below. Function block420also generates signal K and transmits signal K to function block632. Signal K and signal E are compared and time stamp differential signal633is generated. Signal633is the difference between signal K and signal E. Signal633is transmitted to function block634wherein the absolute value of signal633is determined. Absolute value of signal633is then transmitted into a “value 6” register (not shown) within sample buffer636for temporary storage.

Signals B, G, L, M, E, H, and K are generated and transmitted as described above in a random order. Therefore, the registers within sample buffer636corresponding to “value 1”, “value 2”, “value 3”, “value 4”, “value 5”, and “value 6” are populated within respective signals randomly as well. Function block638facilitates transmission of the lowest value of “value 1” through “value 6” (i.e., the most recent time stamp signal). Sample buffer636transmits signal I to function blocks664,674,682,692,702, and712for use as described later.

Function block640, function block642, function646, registers644and648, and function block650cooperate to generate a signal of a pre-determined range of time stamp values that is transmitted to function block652. Function block652receives signal639that is transmitted from function block638, and determines if the value associated with signal639is within the aforementioned pre-determined range. If the value is within the pre-determined range, discrete signal J is transmitted to function blocks666,676,684,694,704,714, and724as described further below.

Signal I is received by function block664wherein signal I is compared to the numeral 6 within register662. The numeral 6 corresponds to the register containing “value 6” within sample buffer636. If signal I does not correspond to the numeral 6, a no-signal is transmitted to function block666. If signal I corresponds to the numeral 6, a yes-signal is transmitted to function block666. If the value of signal639is within the pre-determined range as described above, a discrete signal J that includes a yes-signal is transmitted to function block666.

Otherwise, a discrete signal J that includes a no-signal is transmitted to function block666. In the event that function block666receives at least one discrete no-signal, a no-signal is transmitted to function block670, and a signal with the numerical value of zero, as contained in register668, is transmitted from function block670to function block678. In the event that function block666receives two discrete yes-signals, a yes-signal is transmitted to function block670, and function block670transmits signal N to function block678.

Similarly, signal I is received by function block674wherein signal I is compared to the numeral 5 within register672. The numeral 5 corresponds to the register containing “value 5” within sample buffer636. If signal I does not correspond to the numeral 5, a no-signal is transmitted to function block676. If signal I corresponds to the numeral 5, a yes-signal is transmitted to function block676. If the value of signal639is within the pre-determined range as described above, a discrete signal J that includes a yes-signal is transmitted to function block676. Otherwise, a discrete signal J that includes a no-signal is transmitted to function block676. In the event that function block676receives at least one discrete no-signal, a no-signal is transmitted to function block678, and the signal that is transmitted from function block670(i.e., either zero or signal N) as described above is transmitted through function block678to function block688. In the event that function block676receives two discrete yes-signals, a yes-signal is transmitted to function block678, and function block678transmits signal P to function block688.

Similarly, signal I is received by function block682wherein signal I is compared to the numeral 4 within register680. The numeral 4 corresponds to the register containing “value 4” within sample buffer636. If signal I does not correspond to the numeral 4, a no-signal is transmitted to function block684. If signal I corresponds to the numeral 4, a yes-signal is transmitted to function block684. If the value of signal639is within the predetermined range as described above, a discrete signal J that includes a yes-signal is transmitted to function block684. Otherwise, a discrete signal J that includes a no-signal is transmitted to function block684. In the event that function block684receives at least one discrete no-signal, a no-signal is transmitted to function block688, and the signal that is transmitted from function block678(i.e., either zero, signal N or signal P) as described above is transmitted through function block688to function block698. In the event that function block684receives two discrete yes-signals, a yes-signal is transmitted to function block688, and function block688transmits a signal equivalent to the value of signal686(i.e., generator outboard bearing average rpm calculated speed signal) to function block698. Signal686is equivalent to a signal A transmitted from register412(both shown inFIG. 4) associated with a logic module400that is further associated with high-speed accelerator370. Average rpm signal686is used within module600since low-speed accelerometers360and362typically generate less accurate speed signals as a function of the lower rotational speed of shafts134and332as compared to the higher rotational speed of shafts334,336, and138. Therefore, a signal including an average value of outputs from accelerometer370typically facilitates a more accurate determination of shaft138rotational speed as compared to any calculated shaft138speed signals from accelerometers360and362.

Similarly, signal I is received by function block692wherein signal I is compared to the numeral 3 within register690. The numeral 3 corresponds to the register containing “value 3” within sample buffer636. If signal I does not correspond to the numeral 3, a no-signal is transmitted to function block694. If signal I corresponds to the numeral 3, a yes-signal is transmitted to function block694. If the value of signal639is within the pre-determined range as described above, a discrete signal J that includes a yes-signal is transmitted to function block694. Otherwise, a discrete signal J that includes a no-signal is transmitted to function block694. In the event that function block694receives at least one discrete no-signal, a no-signal is transmitted to function block698, and the signal that is transmitted from function block688(i.e., either zero, signal N, signal P, or generator outboard bearing average rpm calculated speed signal) as described above is transmitted through function block698to function block708. In the event that function block694receives two discrete yes-signals, a yes-signal is transmitted to function block698, and function block698transmits a signal equivalent to the value of signal696(i.e., generator inboard bearing average rpm calculated speed signal) to function block708. Signal696is equivalent to a signal A transmitted from register412associated with a logic module400that is further associated with high-speed accelerator368. Average rpm signal696is used within module600since low-speed accelerometers360and362typically generate less accurate speed signals as a function of the lower rotational speed of shafts134and332as compared to the higher rotational speed of shafts334,336, and138. Therefore, a signal including an average value of outputs from accelerometer368typically facilitates a more accurate determination of shaft138rotational speed as compared to any calculated shaft138speed signals from accelerometers360and362.

Similarly, signal I is received by function block702wherein signal I is compared to the numeral 2 within register700. The numeral 2 corresponds to the register containing “value 2” within sample buffer636. If signal I does not correspond to the numeral 2, a no-signal is transmitted to function block704. If signal I corresponds to the numeral 2, a yes-signal is transmitted to function block704. If the value of signal639is within the predetermined range as described above, a discrete signal J that includes a yes-signal is transmitted to function block704. Otherwise, a discrete signal J that includes a no-signal is transmitted to function block704. In the event that function block704receives at least one discrete no-signal, a no-signal is transmitted to function block708, and the signal that is transmitted from function block698(i.e., either zero, signal N, signal P, generator outboard bearing average rpm calculated speed signal or generator inboard bearing average rpm calculated speed signal) as described above is transmitted through function block708to function block718. In the event that function block704receives two discrete yes-signals, a yes-signal is transmitted to function block708, and function block708transmits a signal equivalent to the value of signal706(i.e., second output shaft average rpm calculated speed signal) to function block718. Signal706is equivalent to a signal A transmitted from register412associated with a logic module400that is further associated with high-speed accelerator364. Average rpm signal706is used within module600since low-speed accelerometers360and362typically generate less accurate speed signals as a function of the lower rotational speed of shafts134and332as compared to the higher rotational speed of shafts334,336, and138. Therefore, a signal including an average value of outputs from accelerometer364typically facilitates a more accurate determination of shaft138rotational speed as compared to any calculated shaft138speed signals from accelerometers360and362.

Similarly, signal I is received by function block712wherein signal I is compared to the numeral 1 within register710. The numeral 1 corresponds to the register containing “value 1” within sample buffer636. If signal I does not correspond to the numeral 1, a no-signal is transmitted to function block714. If signal I corresponds to the numeral 1, a yes-signal is transmitted to function block714. If the value of signal639is within the pre-determined range as described above, a discrete signal J that includes a yes-signal is transmitted to function block714. Otherwise, a discrete signal J that includes a no-signal is transmitted to function block714. In the event that function block714receives at least one discrete no-signal, a no-signal is transmitted to function block718, and the signal that is transmitted from function block708(i.e., either zero, signal N, signal P, generator outboard bearing average rpm calculated speed signal, generator inboard bearing average rpm calculated speed signal or second output shaft average rpm calculated speed signal) as described above is transmitted through function block718to function blocks722and730. In the event that function block714receives two discrete yes-signals, a yes-signal is transmitted to function block718, and function block718transmits a signal equivalent to the value of signal716(i.e., third output shaft average rpm calculated speed signal) to function blocks722and730. Signal716is equivalent to a signal A transmitted from register412associated with a logic module400that is further associated with high-speed accelerator366. Average rpm signal716is used within module600since low-speed accelerometers360and362typically generate less accurate speed signals as a function of the lower rotational speed of shafts134and332as compared to the higher rotational speed of shafts334,336, and138. Therefore, a signal including an average value of outputs from accelerometer366typically facilitates a more accurate determination of shaft138rotational speed as compared to any calculated shaft138speed signals from accelerometers360and362.

Function block722receives the signal transmitted from function block718as described above and function block722determines if the value from function block718is equal or not equal to a pre-determined numerical value contained within register720. In the exemplary embodiment, register720contains the numerical value of zero. If the values are not equal (i.e., the number received from function block718is not the numerical value of zero that originated within register668), a discrete yes-signal is transmitted to function block724. Otherwise, if the values are equal, a discrete no-signal is transmitted to function block724. If all of the time stamp values contained within the six registers within sample buffer636exceed the pre-determined range, the numerical value of zero originating in register668will propagate up to function block722. The numerical value of zero is not used to determine a machine speed for diagnostic purposes. In contrast, function block728multiplies signal F by the numerical value contained within register726to determine an approximate rotational speed of shaft138that is transmitted to function block730. If function block724receives at least one discrete no-signal, the approximate rotational speed of shaft138is transmitted to register732to determine the machine speed for diagnostic purposes.

The method and apparatus for operating a wind turbine generator as described herein facilitate operation of a wind turbine generator. More specifically, the vibration monitoring system as described above facilitates an efficient and effective electric power production scheme. Moreover, the vibration monitoring system facilitates decreasing the errors of accuracy of individual wind turbine generator component vibration measurements, and subsequently, component vibration analyses may be made with increased confidence. Such system therefore facilitates reliability of the associated wind turbine generator.

Exemplary embodiments of vibration monitoring systems as associated with wind turbine generators are described above in detail. The methods, apparatus and systems are not limited to the specific embodiments described herein nor to the specific illustrated vibration monitoring system.