Patent Description:
<CIT> discloses a condition monitoring system (CMS) for monitoring an abnormality of an apparatus provided for a wind power generation facility. The condition monitoring system uses data that satisfies a predetermined operating condition to generate a threshold value used for abnormality diagnosis of the apparatus, and uses the generated threshold value to perform abnormality diagnosis for the apparatus (see PTL <NUM>).

<CIT> describes a condition monitoring system that diagnoses an abnormality of an apparatus provided in a wind turbine which includes a monitoring apparatus including a sensor provided for the apparatus, a monitoring-side control apparatus that sets a threshold value to be used by the monitoring apparatus for diagnosing the abnormality of the apparatus, and diagnoses the abnormality of the apparatus based on the threshold value, and a monitoring terminal that monitors a condition of the apparatus. The condition monitoring system can diagnose an abnormality of the apparatus provided in the wind turbine.

In <CIT> an abnormal sign diagnosis system for a wind turbine generator system comprising a wind power generator facility and a management device is shown. The management device includes a present diagnosis mode part for diagnosing an abnormal sign of a main shaft bearing at the time of state of grease of the main shaft bearing of the wind power generator facility, and an estimation diagnosis mode part for diagnosing an abnormal estimation at the main shaft bearing at a future time in reference to a vibration initial value after taking a value of vibration of the main shaft bearing as an initial value, accumulation revolution speed of the main shaft of the wind power generator facility to be estimated from a time in which a predetermined time elapses from a starting in operation of the wind power generator facility and the vibration initial value at that time to estimate the main shaft bearing replacement time.

The condition monitoring system described in PTL <NUM> does not use data which does not satisfy the operating condition in generating the threshold value, and the system is not fully exploited to monitor the condition of the apparatus (such as for abnormality diagnosis). However, for example, wind power generation and other similar facilities are affected by natural environments, and accordingly, there are also many periods of time for which operating conditions (such as the rotational speed of the main shaft and the amount of power generated by the power generator) are unsatisfied. Therefore, there is a possibility that the above condition monitoring system may not monitor a condition for many periods of time, resulting in delayed condition monitoring (or abnormality diagnosis).

The present invention has been made to address such an issue, and an object of the present invention is to provide a condition monitoring system for a wind power generation facility capable of effectively utilizing measurement data collected under various operating conditions to monitor a condition of an apparatus, and a wind power generation system comprising the condition monitoring system.

The aspect of the object of the present invention referring to providing a condition monitoring system for a wind power generation facility is solved by a condition monitoring system for a wind power generation according to claim <NUM>. Further-developments are subject matter of the dependent claims.

The present condition monitoring system allows measurement data measured by the measurement device to be associated with cumulative load data that may represent a point in time when the measurement data is measured, and to be also associated with load data obtained at the point in time when the measurement data is measured, to generate a data set of the load data, the cumulative load data, and the measurement data, and the condition monitoring system allows analysis of condition monitoring with an operating load also considered. That is, measurement data is not selected or excluded depending on the facility's operating condition (or operating load), and any collected data (or data set) can be used to monitor a condition of the facility. Thus, the condition monitoring system can effectively use measurement data collected under various operating conditions to monitor the condition of the apparatus.

Further, the above condition monitoring system uses a cumulative load, rather than a data measurement time, and can exclude data obtained for a period of time for which the facility is stopped. As a result, when data interpolation, function fitting, and the like are performed, discontinuity of data can be eliminated to increase accuracy.

The aspect of the object of the present invention referring to providing a wind power generation system is solved by a wind power generation system according to claim <NUM>.

The present invention can thus provide a condition monitoring system capable of effectively utilizing measurement data collected under various operating conditions to monitor a condition of an apparatus, and a wind power generation system comprising the condition monitoring system.

Hereinafter reference will be made to the drawings to describe the present invention in an embodiment. In the figures, identical or corresponding components are identically denoted and will not be described repeatedly.

<FIG> is a diagram generally showing a configuration of a condition monitoring system according to the present embodiment. Referring to <FIG>, the condition monitoring system includes a measurement device <NUM>, a processing server <NUM>, and a monitoring terminal <NUM>.

Measurement device <NUM> is provided to a wind power generation facility <NUM> and calculates an effective value, a peak value, a crest factor, an effective value after envelope processing, a peak value after envelope processing, etc. from sensed values received from a variety of sensors described hereinafter, and transmits them to processing server <NUM> via the Internet <NUM>. While in this example measurement device <NUM> and processing server <NUM> perform communications through a wire, they may do so wirelessly.

Processing server <NUM> includes a CPU (central processing unit), a ROM (read only memory), a RAM (random access memory), and a communication device for communicating with measurement device <NUM> of wind power generation facility <NUM> via Internet <NUM> (all not shown). The CPU loads a program stored in the ROM into the RAM or the like and executes the program. The program stored in the ROM is a program describing a procedure of a process performed by server <NUM>. The process performed by processing server <NUM> will be described in detail hereinafter.

Monitoring terminal <NUM> is connected to processing server <NUM> for example by an in-house LAN (Local Area Network). Monitoring terminal <NUM> is provided to display a condition of each apparatus of wind power generation facility <NUM>, browse data analyzed in processing server <NUM>, input and change various settings in processing server <NUM>, and the like.

<FIG> is a diagram schematically showing a configuration of wind power generation facility <NUM>. Referring to <FIG>, wind power generation facility <NUM> includes a main shaft <NUM>, a blade <NUM>, a gearbox <NUM>, a power generator <NUM>, a main shaft bearing <NUM>, a nacelle <NUM>, and a tower <NUM>. Wind power generation facility <NUM> further includes sensors 70A to <NUM> and a measurement device <NUM>. Gearbox <NUM>, power generator <NUM>, main shaft bearing <NUM>, sensors 70A to <NUM>, and measurement device <NUM> are housed in nacelle <NUM>, and nacelle <NUM> is supported by tower <NUM>.

Main shaft <NUM> is inserted into nacelle <NUM>, connected to the input shaft of gearbox <NUM>, and is rotatably supported by main shaft bearing <NUM>. And main shaft <NUM> transmits rotational torque that is generated by blade <NUM> receiving wind power to the input shaft of gearbox <NUM>. Blade <NUM> is provided at an end of main shaft <NUM>, converts wind power into rotational torque, and transmits it to main shaft <NUM>.

Main shaft bearing <NUM> is disposed in nacelle <NUM> in a fixed manner and supports main shaft <NUM> rotatably. Main shaft bearing <NUM> is a rolling bearing, and for example, it is a self-centering roller bearing, a conical roller bearing, a cylindrical roller bearing, a ball bearing, etc. Note that these bearings may be of a single row or double rows.

Sensors 70A-<NUM> are disposed in nacelle <NUM> at each apparatus in a fixed manner. Specifically, sensor 70A is disposed on main shaft bearing <NUM> in a fixed manner and monitors a condition of main shaft bearing <NUM>. Sensors 70B-70D are disposed on gearbox <NUM> in a fixed manner, and monitor a condition of gearbox <NUM>. Sensors 70E and 70F are disposed on power generator <NUM> in a fixed manner, and monitor a condition of power generator <NUM>. Sensor <NUM> is disposed on main shaft bearing <NUM> in a fixed manner, and monitors misalignment, and abnormal vibration of nacelle <NUM>. Sensor <NUM> is disposed on main shaft bearing <NUM> in a fixed manner, and monitors unbalance, and abnormal vibration of the nacelle.

Gearbox <NUM> is provided between main shaft <NUM> and power generator <NUM> to increase the rotational speed of main shaft <NUM> and output the increased rotational speed to power generator <NUM>. As an example, gearbox <NUM> is composed of a gear speed-up mechanism including a planetary gear, a countershaft, a high speed shaft, etc. Note that although not shown in the figure, gearbox <NUM> is also provided therein with a plurality of bearings to support a plurality of shafts rotatably. Power generator <NUM> is connected to the output shaft of gearbox <NUM>, and generates electric power by the rotational torque received from gearbox <NUM>. Power generator <NUM> is an induction generator, for example. Note that power generator <NUM> is also provided therein with a bearing to support a rotor rotatably.

Measurement device <NUM> receives measurement data of each apparatus's vibration, acoustic emission (AE), temperature, operating sound and other measurement data sensed by sensors 70A-<NUM>. Measurement device <NUM> periodically transmits a variety of types of measurement data to processing server <NUM> via Internet <NUM>.

The measurement data may be converted into parameters that can better indicate conditions of apparatuses. For example, each measurement data may be converted into an effective value, a peak value, a crest factor, an effective value after envelope processing, a peak value after envelope processing, or the like, and measurement device <NUM> may transmit the measurement data converted into any one of the above values to processing server <NUM> via Internet <NUM>. As an example, sensor 70A is a vibration sensor that senses vibration of main shaft bearing <NUM>, and measurement device <NUM> calculates an effective value of vibration (hereinafter referred to as a "degree of vibration") of main shaft bearing <NUM> from data measured by sensor 70A, and transmits the degree of vibration to processing server <NUM>.

Measurement device <NUM> may periodically store the measurement data to a storage device located in measurement device <NUM> and send the stored measurement data to processing server <NUM> via Internet <NUM> in response to a request received from processing server <NUM>.

Wind power generation facility <NUM> is affected by natural environments, and its operating load (such as the rotational speed of the main shaft and the amount of power generated by the power generator) varies. Conventionally, as in the condition monitoring system described in PTL <NUM>, data satisfying a predetermined operating condition has been used to monitor a condition of an apparatus (such as to diagnose abnormality). In other words, measurement data which does not satisfy the operating condition is not used for condition monitoring and a cost of measuring data is wasted, and there is also a possibility that condition monitoring (or abnormality diagnosis) may be delayed.

Accordingly, the condition monitoring system according to the present embodiment allows measurement data measured by measurement device <NUM> to be associated with cumulative load data that may represent a point in time when the measurement data is measured, and to be also associated with load data obtained at the point in time when the measurement data is measured, to generate a data set of the load data, the cumulative load data, and the measurement data. Such a data set is created whenever data is collected, and a plurality of data sets thus generated is subjected to data interpolation to generate interpolated three-dimensional data with the cumulative load data, the load data, and the measurement data represented along a first axis, a second axis, and a third axis, respectively.

Thus using the interpolated three-dimensional data also considering load data obtained at a point in time when measurement is conducted enables analysis of condition monitoring also considering an operating load of wind power generation facility <NUM>. That is, measurement data is not selected or excluded depending on an operating condition (or an operating load) of wind power generation facility <NUM>, and basically, any measured data (excluding abnormality data, noise and the like) can be used to monitor a condition of wind power generation facility <NUM>.

Thus, although details will be described hereinafter, for example, interpolated three-dimensional data can be used to estimate a relationship between the operating load and the measurement data for a current point in time, and the estimated relationship can be used to estimate measurement data for any operating load at the current point in time (i.e., to estimate a current value). Further, interpolated three-dimensional data can be used to predict a relationship between the operating load and the measurement data for any future point in time, and the predicted relationship can be used to estimate measurement data for any operating load at the future point in time (i.e., to estimate a predicted value). Furthermore, it is also possible to estimate when the measurement data exceeds a threshold value for any operating load (i.e., to estimate a cumulative load). These will be described hereinafter in detail.

Further, the condition monitoring system according to the present embodiment uses a cumulative load, rather than a data measurement time, and can exclude data obtained for a period of time for which wind power generation facility <NUM> is stopped. As a result, when data interpolation, function fitting, and the like are performed, discontinuity of data can be eliminated to increase accuracy.

Each above process is performed by processing server <NUM>. Hereinafter, the process performed by processing server <NUM> will be described in detail. In the following description, load data is a rotational speed (in rpm) of main shaft <NUM> (or blade <NUM>), cumulative load data is a cumulative number of rotations (in times) of main shaft <NUM> (or blade <NUM>), and measurement data is a degree of vibration of main shaft bearing <NUM>.

<FIG> is a block diagram functionally representing a configuration of processing server <NUM>. Referring to <FIG>, processing server <NUM> includes a data collection unit <NUM>, a data storage unit <NUM>, a data calculation unit <NUM>, and an estimation unit <NUM>.

Data collection unit <NUM> periodically collects data of a degree of vibration of main shaft bearing <NUM> (i.e., measurement data) from measurement device <NUM> (<FIG>) via Internet <NUM>. Further, as data collection unit <NUM> receives the data of the degree of vibration, data collection unit <NUM> also collects data of a rotational speed of main shaft <NUM> (i.e., load data) synchronous with the degree of vibration.

Data collection unit <NUM> stores the data of the degree of vibration received from measurement device <NUM> to data storage unit <NUM> in time series together with the data of the rotational speed. Data collection unit <NUM> may collect the data periodically in an automated manner as described above, or manually by an operator of monitoring terminal <NUM>. When the data is collected manually by the operator, the data is temporarily stored in measurement device <NUM> of wind power generation facility <NUM>, and in response to a request from the operator, the data stored in measurement device <NUM> is collectively transmitted to processing server <NUM> and stored to data storage unit <NUM>.

Data storage unit <NUM> synchronizes the data of the degree of vibration and that of the rotational speed as collected by data collection unit <NUM> and thus stores them in time series. Furthermore, data storage unit <NUM> stores a data set generated by data calculation unit <NUM>, as will be described hereinafter, and interpolated three-dimensional data. Data storage unit <NUM> is composed for example of a large-capacity storage device such as a hard disk drive (HDD) or a solid state drive (SSD).

Data calculation unit <NUM> processes the data of the degree of vibration and the rotational speed that are stored in data storage unit <NUM> to generate a data set of the rotational speed of main shaft <NUM> (or load data), a cumulative number of rotations (or cumulative load data) of main shaft <NUM>, and the degree of vibration (or measurement data) of main shaft bearing <NUM>. This data set is generated for all collected data. Data calculation unit <NUM> then uses a plurality of such data sets to generate interpolated three-dimensional data with the cumulative number of rotations, the rotational speed and the degree of vibration represented along a first axis, a second axis, and a third axis, respectively. Hereinafter, the process by data calculation unit <NUM> will be described in more detail.

<FIG> is a flowchart of an example of a procedure of the process performed in data calculation unit <NUM>. Referring to <FIG>, data calculation unit <NUM> obtains data of the degree of vibration and that of the rotational speed that are stored in data storage unit <NUM> in chronological order (step S10).

Subsequently, whenever data calculation unit <NUM> obtains such data successively, data calculation unit <NUM> calculates a cumulative number of rotations from the data of the rotational speed. The data of the rotational speed is data collected periodically as prescribed, and hence regularly, and can be accumulated to calculate a cumulative number of rotations. Data calculation unit <NUM> associates the calculated cumulative number of rotations with the data of the rotational speed and that of the degree of vibration that are obtained to generate a data set of the rotational speed, the cumulative number of rotations, and the degree of vibration. Whenever data calculation unit <NUM> obtains data of a degree of vibration and data of a rotational speed from data storage unit <NUM> successively, data calculation unit <NUM> processes the data as described above to generate a data set described above (step S20).

<FIG> plots on a three-dimensional graph each data set generated in step S20 of <FIG>. Referring to <FIG>, a first axis (the X axis) represents the cumulative number of rotations, a second axis (the Y axis) represents the rotational speed, and a third axis (the Z axis) represents the degree of vibration. Each point on the three-dimensional graph represents a value of a data set.

As the first axis represents the cumulative number of rotations, there is no discontinuity appearing if the first axis represents time (that is, there is no period of time that continues for which the rotational speed and the degree of vibration each have a value of approximately <NUM> while rotation is stopped), and accuracy of data interpolation and function fitting, which will be described hereinafter, can be increased.

Referring again to <FIG>, data calculation unit <NUM> performs an interpolation process for each data shown in <FIG> to generate interpolated three-dimensional data with the cumulative number of rotations, the rotational speed, and the degree of vibration represented along the first axis, the second axis, and the third axis, respectively (step S30).

<FIG> represents interpolated three-dimensional data generated from each data shown in <FIG>. Referring to <FIG>, as well as <FIG>, the first axis (the X axis) represents the cumulative number of rotations, the second axis (the Y axis) represents the rotational speed, and the third axis (the Z axis) represents the degree of vibration. The method per se employed to interpolate the <FIG> scattered data to generate the interpolated three-dimensional data as shown can be a variety of known methods, and for example, polynomial approximation can be employed to interpolate the data.

When additional data is collected by data collection unit <NUM>, data calculation unit <NUM> updates the interpolated three-dimensional data. In order to reduce a processing load, the interpolated three-dimensional data may not be updated whenever additional data is collected, and it may be updated less frequently, as appropriate.

Referring again to <FIG>, data calculation unit <NUM> operates in response to a request received from the operator of monitoring terminal <NUM> to perform an output process to output a variety of types of data to a screen of monitoring terminal <NUM> (step S40). By this output process, for example, a diagram in which each data set is plotted, a three-dimensional graph (see <FIG>) or interpolated three-dimensional data in which data is interpolated (see <FIG>), and the like can be output to the screen of monitoring terminal <NUM>. Further, based on the interpolated three-dimensional data generated in step S30, the profile of the degree of vibration in any cross section (a YZ plane with a fixed cumulative number of rotations or an XZ plane with a fixed rotational speed) can be output.

<FIG> represents a profile representing a relationship between the rotational speed and the degree of vibration for some cumulative number of rotations. <FIG> represents a profile representing a relationship between the cumulative number of rotations and the degree of vibration for some rotational speed. Thus, by designating a cumulative number of rotations or a rotational speed, a profile of a degree of vibration for any cross section can be output to the screen of monitoring terminal <NUM>.

Referring to <FIG> again, estimation unit <NUM> is configured to be capable of using the interpolated three-dimensional data generated in data calculation unit <NUM> to perform a current-value estimation process for estimating a degree of vibration (or measurement data) for any rotational speed (or operating load) at the current point in time (or for the current cumulative number of rotations). Further, estimation unit <NUM> is configured to be capable of using the above interpolated three-dimensional data to perform a predicted-value estimation process for predicting a degree of vibration for any rotational speed at any future point in time. Hereinafter, the process performed by estimation unit <NUM> will be described more specifically.

<FIG> is a flowchart of an example of a procedure of a process performed in estimation unit <NUM>. Referring to <FIG>, estimation unit <NUM> determines whether to perform the current-value estimation to estimate a degree of vibration for any rotational speed at the current point in time (step S210). For example, the unit determines to perform the current-value estimation when a request is received from monitoring terminal <NUM> to do so. For NO in step S210, the process proceeds to step S240.

For YES in step S210, estimation unit <NUM> performs the current-value estimation process (step S220). Hereinafter, the current-value estimation process will be described in detail.

<FIG> is a diagram for describing an idea of the current-value estimation. Referring to <FIG>, the horizontal axis represents rotational speed, and the vertical axis represents degree of vibration. A line k1 shows a profile which is extracted from generated interpolated three-dimensional data and which represents the relationship between the rotational speed and the degree of vibration for any past cumulative number of rotations t1. A line k2 shows a profile which is extracted from the interpolated three-dimensional data and which represents the relationship between the rotational speed and the degree of vibration for any past cumulative number of rotations t2.

A dotted line k3 represents an estimated profile representing the relationship between the rotational speed and the degree of vibration for the current cumulative number of rotations tn (or the current point in time). Dotted line k3 is estimated as follows. Initially, a functional form for dotted line k3 is determined based on lines k1 and k2. That is, a functional form for the profile at the current point in time is determined with reference to the shape of a past profile. The function may be a polynomial or employ an exponential function. The functional form is determined by the operator of monitoring terminal <NUM>. The number of past profiles used in determining the functional form is not limited to two profiles (of lines k1 and k2), and may be one or three or more profiles.

And recently obtained data (in this example, Pc1 to Pc3) are used to perform fitting of dotted line k3. Dotted line k3 thus obtained represents a profile representing the relationship between the rotational speed and the degree of vibration for the current cumulative number of rotations tn (or the current point in time), and for example allows a degree of vibration (a point P1) for any rotational speed to be estimated at the current point in time.

<FIG> is a flowchart of an example of a procedure of the current-value estimation process performed in step S220 of <FIG>. Referring to <FIG> together with <FIG>, estimation unit <NUM> sets any reference cumulative number of rotations (step S310). The reference cumulative number of rotations is, for example, any past cumulative numbers of rotations t1 and t2 described with reference to <FIG>, and may be set by the operator of monitoring terminal <NUM> or may be automatically set by estimation unit <NUM> as desired.

Subsequently, estimation unit <NUM> obtains the data (the rotational speed and degree of vibration) for the reference cumulative number of rotations from the interpolated three-dimensional data calculated by data calculation unit <NUM>, and causes monitoring terminal <NUM> to display the data (step S315).

Then, a functional form is set based on the data displayed in step S315 (step S320). The functional form is set by the operator of monitoring terminal <NUM>. Once the functional form has been set, estimation unit <NUM> uses the data obtained and displayed in step S315 to fit the function set in step S320 (step S325). Fitting the function can be done for example through least squares.

Thereafter, estimation unit <NUM> causes monitoring terminal <NUM> to display the fitted function together with the data used to fit the function (step S330). Estimation unit <NUM> then determines whether to apply the functional form set in step S320 (step S335). The functional form is actually determined by the operator of monitoring terminal <NUM>, and estimation unit <NUM> determines that the functional form set in step S320 is applied when monitoring terminal <NUM> receives an input to determine that the functional form is applied.

If the function is insufficiently fitted and no functional form is determined (NO in step S335), the process returns to step S310, and steps S310 to S330 are performed.

When a functional form is determined in step S335 (YES in step S335), estimation unit <NUM> sets the number of recent reference data or a recent range (e.g., a range of cumulative numbers of rotations for which the recent reference data is obtained) (step S340). This sets a condition for extracting reference data (in <FIG>, Pc1 to Pc3) used for fitting dotted line k3 shown in <FIG>. Estimation unit <NUM> then obtains recent data (for example, Pc1 to Pc3 in <FIG>) from data storage unit <NUM> in accordance with the condition set in step S340 for extraction (step S345).

Subsequently, estimation unit <NUM> uses the obtained reference data to fit the function determined in step S335 (step S350). In this case as well, for example, fitting the function can be done for example through least squares. Then, estimation unit <NUM> causes monitoring terminal <NUM> to display the fitted function together with the reference data used for fitting the function (step S355).

Subsequently, estimation unit <NUM> obtains a rotational speed as a target for estimation (step S360). The rotational speed as a target for estimation corresponds to the rotational speed of point P1 that is set by the operator of monitoring terminal <NUM> and for which estimating a degree of vibration is desired, as shown in <FIG>. Estimation unit <NUM> uses the fitted function to estimate a degree of vibration for the rotational speed as the target for estimation (i.e., perform the current-value estimation) (step S365).

Referring to <FIG> again, when the current-value estimation process is performed in step S220, estimation unit <NUM> outputs to monitoring terminal <NUM> an estimation result obtained through the current-value estimation process, that is, a profile of a function representing a relationship between the rotational speed and the degree of vibration for the current point in time (or the current cumulative number of rotations), as well as the rotational speed set as the target for estimation and an estimated value of a degree of vibration for the rotational speed set as the target for estimation (step S230).

Subsequently, estimation unit <NUM> determines whether to estimate a degree of vibration for any rotational speed at any future point in time (i.e., to perform predicted-value estimation) (step S240). For example, the unit determines to perform the predicted-value estimation when a request is received from monitoring terminal <NUM> to do so. For NO in step S240, the process ends.

For YES in the step S240, estimation unit <NUM> performs the predicted-value estimation process (step S250). Hereinafter, the predicted-value estimation process will be described in detail.

<FIG> is a diagram for describing an idea of the predicted-value estimation. Referring to <FIG>, the horizontal axis represents the rotational speed and the vertical axis represents the degree of vibration. Lines k1 to k3 are the same as those shown in <FIG>. That is, line k1 shows a profile which is extracted from interpolated three-dimensional data and which represents a relationship between the rotational speed and the degree of vibration for any past cumulative number of rotations t1, and line k2 shows a profile which is extracted from the interpolated three-dimensional data and which represents a relationship between the rotational speed and the degree of vibration for any past cumulative number of rotations t2. A line k3 represents an estimated profile representing a relationship between the rotational speed and the degree of vibration for the current cumulative number of rotations tn (or the current point in time).

A dotted line k4 represents an estimated profile representing a relationship between the rotational speed and the degree of vibration for any future cumulative number of rotations (tn + Δt). Dotted line k4 is estimated as follows. Initially, any reference rotational speed is set, and a profile representing the relationship between the cumulative number of rotations and the degree of vibration for the reference rotational speed is obtained from the interpolated three-dimensional data. The obtained profile (or function) is used to predict a degree of vibration for a future cumulative number of rotations (tn + Δt) at the reference rotational speed. Such a degree of vibration for the future cumulative number of rotations (tn + Δt) is predicted for a plurality of reference rotational speeds (Pa1 to Pa4 in <FIG>).

Then, the predicted degrees of vibration (Pa1 to Pa4) for the future cumulative number of rotations (tn + Δt) are used to fit dotted line k4. A functional form for dotted line k4 is set with reference to lines k1 to k3. Dotted line k4 thus obtained represents a profile representing a relationship between the rotational speed and the degree of vibration for the future cumulative number of rotations (tn + Δt), and for example allows a degree of vibration (a point P2) for any rotational speed to be estimated for the future cumulative number of rotations (tn + Δt).

<FIG> is a flowchart of an example of a procedure of the predicted-value estimation process performed in step S250 of <FIG>. Referring to <FIG> together with <FIG>, estimation unit <NUM> sets any reference rotational speed (step S410). The reference rotational speed is, for example, a rotational speed for point Pa1 as has been described with reference to <FIG>, and may be set by the operator of monitoring terminal <NUM> or may be automatically set by estimation unit <NUM> as desired.

Subsequently, estimation unit <NUM> obtains the data (the cumulative number of rotations and degree of vibration) for the reference rotational speed from the interpolated three-dimensional data calculated by data calculation unit <NUM>, and causes monitoring terminal <NUM> to display the data (step S415).

Then, a functional form is set based on the data displayed in step S415 (step S420). The functional form is set by the operator of monitoring terminal <NUM>. Once the functional form has been set, estimation unit <NUM> uses the data obtained and displayed in step S415 to fit the function set in step S420 (step S425). Fitting the function can be done for example through least squares.

Thereafter, estimation unit <NUM> causes monitoring terminal <NUM> to display the fitted function together with the data used to fit the function (step S430). Subsequently, estimation unit <NUM> sets a cumulative number of rotations for prediction (tn + Δt) (step S435). The cumulative number of rotations for prediction is set by the operator of monitoring terminal <NUM> and sets a future point in time for which providing a prediction is desired (i.e., a future cumulative number of rotations).

Then, estimation unit <NUM> uses the function fitted in step S425 to calculate data indicating a degree of vibration for the cumulative number of rotations for prediction (tn + Δt) for predicted-value estimation, and causes monitoring terminal <NUM> to display the calculated data together with the function (step S440). The data for predicted-value estimation, as calculated herein, is, for example, point Pa1 shown in <FIG>.

Subsequently, estimation unit <NUM> determines whether any data for predicted-value estimation has been determined (step S445). It is necessary to generate data for predicted-value estimation for a plurality of points with the reference rotational speed varied, and a desired number of points is not obtained, it is determined that no data for predicted-value estimation is determined (NO in step S445). In this case, the process returns to step S410, and further data for predicted-value estimation is generated with the reference rotational speed varied.

When it is determined in step S445 that data for predicted-value estimation has been determined (YES in step S445), a functional form is set based on a generated plurality of data for predicted-value estimation (e.g., Pa1 to Pa4 in <FIG>) (step S450). The functional form is set by the operator of monitoring terminal <NUM>. Once the functional form has been set, estimation unit <NUM> uses the plurality of data for predicted-value estimation to fit a function for the cumulative number of rotations for prediction that is set in step S435 (step S455). In this case as well, for example, fitting the function can be done for example through least squares.

Then, estimation unit <NUM> causes monitoring terminal <NUM> to display the fitted function together with the data used to fit the function for predicted-value estimation (step S460). Subsequently, estimation unit <NUM> obtains a rotational speed as a target for estimation (step S465). The rotational speed as the target for estimation corresponds to the rotational speed for point P2 that is set by the operator of monitoring terminal <NUM> and for which estimating a degree of vibration for the cumulative number of rotations for prediction (tn + Δt) is desired, as shown in <FIG>. Estimation unit <NUM> uses the fitted function to estimate a degree of vibration for the rotational speed as the target for estimation (i.e., perform the predicted-value estimation) (step S470).

Thus, according to the present embodiment, measurement data is not selected or excluded depending on an operating condition (or load) of wind power generation facility <NUM>, and any collected data (or data set) can be used to monitor a condition of wind power generation facility <NUM>. Thus, measurement data collected under various operating conditions can effectively be used to monitor conditions of a variety of types of apparatuses.

Further, according to the present embodiment, a cumulative load (or a number of rotations), rather than a data measurement time, can be used, and data for a period of time for which wind power generation facility <NUM> is stopped can be excluded. As a result, when data interpolation, function fitting, and the like are performed, discontinuity of data can be eliminated to increase accuracy.

Further, according to the present embodiment, displaying interpolated three-dimensional data on a three-dimensional graph allows a dangerous condition of wind power generation facility <NUM> to be confirmed together with an operating load of wind power generation facility <NUM>.

Further, in the present embodiment, generated interpolated three-dimensional data is used to estimate a relationship between an operating load (or a rotational speed) and measurement data (or a degree of vibration) for a current point in time (or a current cumulative number of rotations). Therefore, according to the present embodiment, the estimated relationship can be used to estimate measurement data for any operating load at the current point in time (i.e., to perform current-value estimation).

Further, in the present embodiment, generated interpolated three-dimensional data is used to predict a relationship between an operating load (a rotational speed) and measurement data (a degree of vibration) for any future point in time (or any future cumulative number of rotations). Therefore, according to the present embodiment, the predicted relationship can be used to estimate measurement data for any operating load at the future point in time (i.e., to perform predicted-value estimation).

In the above-described predicted-value estimation, a reference rotational speed may be set, and a future point in time (or a cumulative number of rotations) for which a degree of vibration exceeds a threshold value for that reference rotational speed may be predicted.

<FIG> is a flowchart of an example of a procedure of a process for predicting a future point in time (or a cumulative number of rotations) for which a degree of vibration exceeds a threshold value. A series of steps indicated in this flowchart is also performed in estimation unit <NUM>.

Referring to <FIG>, estimation unit <NUM> sets a threshold value for the degree of vibration (step S510). The threshold value can be appropriately determined or changed by the operator of monitoring terminal <NUM>, and is used for example to diagnose main shaft bearing <NUM> for abnormality. Further, estimation unit <NUM> sets a reference rotational speed (step S515). The reference rotational speed is also set by the operator of monitoring terminal <NUM>, and a cumulative number of rotations when the degree of vibration exceeds the threshold value is predicted for the reference rotational speed.

Steps S520 to S535 are identical to the <FIG> steps S415 to S430, respectively. That is, estimation unit <NUM> obtains the data (the cumulative number of rotations and degree of vibration) for the reference rotational speed from interpolated three-dimensional data, and causes monitoring terminal <NUM> to display the data (step S520). Subsequently, a functional form is set (step S525), and the data obtained and displayed in step S520 is used to fit of the function set in step S525. Thereafter, estimation unit <NUM> causes monitoring terminal <NUM> to display the fitted function together with the data used to fit the function (step S535).

Estimation unit <NUM> uses the fitted function to predict a cumulative number of rotations for which the degree of vibration set in step S510 is attained (step S540). Then, estimation unit <NUM> causes monitoring terminal <NUM> to display the predicted cumulative number of rotations together with the threshold value for the degree of vibration (step S545).

Such a series of steps allows interpolated three-dimensional data generated from collected data to be used to predict when the degree of vibration exceeds the threshold value in the future, (i.e., to predict a cumulative number of rotations).

It should be understood that the embodiments disclosed herein are illustrative and not restrictive in any respect. The scope of the present invention is defined by the terms of the claims, rather than the embodiments described above.

Claim 1:
A condition monitoring system for a wind power generation facility (<NUM>) comprising:
a measurement device (<NUM>) that is configured to measure a condition of an apparatus provided for a facility (<NUM>); and
a processor (<NUM>) that is configured to associate measurement data indicating the condition measured by the measurement device (<NUM>) with load data representing an operating load of the facility (<NUM>) acting at a time when the measurement data is measured and cumulative load data representing a cumulative operating load accumulated up to the time when the measurement data is measured, to generate a data set of the load data, the cumulative load data, and the measurement data for the time when the measurement data is measured,
characterized in that the processor (<NUM>)
is configured to collect the measurement data and the load data periodically or aperiodically; and
is further configured to subject a plurality of data sets each generated based on the collected measurement data and the load data and the cumulative load data calculated from the load data to data interpolation to generate interpolated three-dimensional data with the cumulative load data, the load data, and the measurement data represented along a first axis, a second axis, and a third axis, respectively, wherein the processor (<NUM>) further:
is configured to use the interpolated three-dimensional data to calculate a relationship between the cumulative load data and the measurement data with the load data set to a predetermined value; and
is configured to use a result of the calculation to predict a magnitude of the cumulative load data for which the measurement data exceeds a threshold value.