Job Sheet 3 – Electrical Pitch Hub Trainer Components · ... Electrical Pitch Hub Trainer Components ... overcurrent is determined and addressed, ... and activating a self-diagnostic

© Festo Didactic Inc. 88183-20 19

Job Sheet 3 – Electrical Pitch Hub Trainer Components

The Electrical Pitch Hub Training System (Figure 3-1) provides the materials necessary to

to manipulate the components of a wind turbine hub assembly that uses electrical blade pitch

item.

Figure 3-1. Electrical Hub Trainer.

Trainer Components

20 © Festo Didactic Inc. 88183-20

System Parts

Rotor blade: This is one of three blades that are controlled by the software. It allows the trainer

to show a working blade in a scale that represents an actual wind turbine blade pitch control

system (Figure 3-2). If a true rotor blade were present, it would extend from the back of the

trainer as depicted in Figure 3-3. For safety, the representative rotor blade is enclosed behind a

clear plastic panel that cannot be opened.

Figure 3-2. Hub Trainer Blade.

Rear ViewFront View

Figure 3-3. Depiction of Blade Secured to the Electrical Hub Trainer Back.


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Slewing bearing: This component, which can be found in a full-scale wind turbine rotor hub,

secures the rotor blade and allows it to pivot relative to the trainer (Figure 3-4). The slewing

bearing has internal teeth that enable a gear drive system to rotate, or slew, the bearing into the

required position.

Figure 3-4. Slewing Bearing.

Pinion gear: The pinion gear is mated to an electric motor and meshes with the slewing

bearing (Figure 3-5). Powered by the electric motor, the pinion gear transmits the torque

needed to slew the slewing bearing that pitches the rotor blade. The pinion gear is smaller and

has fewer teeth than the slewing bearing; therefore, it rotates faster than the slewing bearing

does during repositioning.

Figure 3-5. Pinion Gear.

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Servomotor:

provides the means to reposition the slewing bearing and related blade (Figure 3-6). It is a

specialized electrical motor that has a built-in encoder that provides motor position feedback

information to the motor drive. A computer or programmable logic controller can interpret these

control signals to precisely position the device the motor is hooked up to.

Figure 3-6. Servomotor.

Gearbox: A small planetary gearbox is attached to the trainer between the servomotor and

the pinion gear (Figure 3-7). It is a reduction gearbox with a ratio of 25 to 1. This converts the

normally high RPM output of the electric motor to a high-torque low RPM output.

Figure 3-7. Planetary Gearbox.


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Limit switches: Two mechanically actuated limit switches (Figure 3-8) are mounted around

bearing assembly, and help the controller determine if position limits are being exceeded while

under automatic control.

Figure 3-8. Limit Switch.

Shuttle: An adjustable shuttle is provided on the blade portion of the slewing bearing (Figure

3-9). The shuttle contacts and activates the appropriate limit switch, depending on its current

position.

Figure 3-9. Adjustable Shuttle.

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Human machine interface (HMI): The HMI is a touch screen that the controller uses to operate

and monitor the electrical pitch hub trainer (Figure 3-10). The HMI uses a supervisory control

and data acquisition system (SCADA) to provide control and data monitoring.

Figure 3-10. Human Machine Interface.

Main power switch: This component is used to turn the training system on and off as needed

(Figure 3-11). It also provides a mechanism to attach a padlock for lockout/tagout procedures.

Figure 3-11. Main Power Switch.


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Emergency-stop switch (ESS): The ESS allows the controller to turn off (remove power from)

all motors on the training system in an emergency situation (Figure 3-12). It can be reset by

rotating the switch knob counterclockwise until it pops out.

Figure 3-12. Emergency-stop Switch.

Start push-button switch: This green push-button switch is used to enable power to the

trainer after the Emergency-stop switch is enabled (Figure 3-13).

Figure 3-13. Reset Push-button Switch.

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Electrical panel: The electrical panel, or cabinet, houses the electrical supply, distribution, and

control functionality for the electrical pitch hub trainer behind a clear, locked door (Figure 3-14).

Figure 3-14. Electrical Cabinet.


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Circuit breaker: The circuit breaker is housed within the electrical panel and contains a

switch that opens (disconnects) the electrical circuit when a certain current (amperage) is

overcurrent is determined and addressed, the circuit can be reset to restore proper operation.

Figure 3-15. Circuit Breaker.

UPS power supply: The UPS backs up the direct AC current fed to the electrical hub trainer by

the wall cord (Figure 3-16).

Figure 3-16. UPS Backup Power Supply.

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UPS relay card: This provides an electrical interface for monitoring the UPS system and

battery status, and activating a self-diagnostic program (Figure 3-17).

Figure 3-17. Relay Card.

Motor starter protector: This is a type of circuit breaker, also called an overload relay, that

protects the electrical pitch hub trainer motor from overcurrent (Figure 3-18). It contains thermal

and magnetic trip mechanisms, as well as an adjustable trip set point.

Figure 3-18. Motor Starter Protector.


Trainer Components

Fuseholder: The fuseholder protects other devices on the trainer by holding fuses that have

overcurrent is determined and addressed, the burned out fuse must be replaced.

Figure 3-19. Fuseholder.

Contactors: Contactors are relays, or remote-controlled switches, that provide high-current

switching capabilities in electrical circuits (Figure 3-20). They also provide on/off control of the

electrical hub motor and emergency systems.

Figure 3-20. Contactors.

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Solid state relays: Solid state relays provide low-current switching capabilities in electrical

circuits, as well as on/off control of circuits and devices that are used in the fault insertion

system of the electrical pitch hub trainer (Figure 3-21).

Figure 3-21. Solid State Relays.


Trainer Components

Servomotor positioning drive: The servomotor positioning drive is an electronic module that

contains the power circuitry and positioning analysis circuitry needed to properly control and

position the servomotor (Figure 3-22). The servo control drive has its own status LED display,

as well as a basic interface.

Figure 3-22. Servomotor Positioning Drive.

Trainer Components


Modular universal controller: This is a control system that is made of a collection of modules,

functions (Figure 3-23). The heart of the controller is a computer processing unit (CPU) module;

however, the unit also contains signal modules for reading measurement instrumentation,

function modules for analog and digital input/output, and communication modules for bus-based

communication.

Figure 3-23. Modular Universal Controller.


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Media converter: The modular universal controller is coupled to a media converter that allows

for both Ethernet and optical communications to the controller (Figure 3-24). For easy access,

a pair of optical interface connectors are located on the outside of the electrical cabinet and are

optically coupled to the media converter inside the cabinet.

Figure 3-24. Media Converter.

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OBJECTIVES

In this job, you will identify and describe the function of the main components of the

electrical pitch hub trainer.

PROCEDURE

Use the information provided in the Information Sheet to respond to these questions.

Which of the following components is coupled to the servomotor and

gearbox, and transmits motor torque that pitches the rotor blade?

a. Slewing bearing

b. Motor drive

c. Transmission

d. Pinion

Which component is represented in the following graphic?

Which component is represented in the following graphic?

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Where is the component shown in the following graphic located on the

electrical pitch hub trainer? (You may refer to the trainer, if necessary.)

Which component backs up the direct AC current fed to the electrical

hub trainer by the wall cord?

Which component provides low-current switching capabilities in

electrical circuits and is used in the fault insertion system of the

electrical pitch hub trainer?

Which easily accessible component allows the controller to remove

power from all motors on the training system in an emergency situation?

Which device provides high-current switching capabilities in the

electrical circuits?


Trainer Components

Name: _________________________________ Date: _____________________

Instructor approval: ___________________________________________________

Which component helps determine whether position limits are exceeded

while under automatic control?

Which electrical component supports optical connectivity?

Documents

Job Sheet 3 – Electrical Pitch Hub Trainer Components · ... Electrical Pitch Hub Trainer Components ... overcurrent is determined and addressed, ... and activating a self-diagnostic