Energies, Vol. 19, Pages 619: From Blade Loads to Rotor Health: An Inverse Modelling Approach for Wind Turbine Monitoring
Energies doi: 10.3390/en19030619
Authors:
Attia Bibi
Chiheng Huang
Wenxian Yang
Oussama Graja
Fang Duan
Liuyang Zhang
Operational expenditure in wind farms is heavily influenced by unplanned maintenance, much of which stems from undetected rotor system faults. Although many fault-detection methods have been proposed, most remain confined to laboratory test. Blade-root bending-moment measurements are among the few techniques applied in the field, yet their reliability is limited by strong sensitivity to varying operational and environmental conditions. This study presents a data-driven rotor health-monitoring framework that enhances the diagnostic value of blade bending-moments. Assuming that the wind speed profile remains approximately stationary over short intervals (e.g., 20 s), a machine-learning model is trained on bending-moment data from healthy blades to predict the incident wind-speed profile under a wide range of conditions. During operation, real-time bending-moment signals from each blade are independently processed by the trained model. A healthy rotor yields consistent wind-speed profile predictions across all three blades, whereas deviations for an individual blade indicate rotor asymmetry. In this study, the methodology is verified using high-fidelity OpenFAST simulations with controlled blade pitch misalignment as a representative fault case, providing simulation-based verification of the proposed framework. Results demonstrate that the proposed inverse-modeling and cross-blade consistency framework enables sensitive and robust detection and localization of pitch-related rotor faults. While only pitch misalignment is explicitly investigated here, the approach is inherently applicable to other rotor asymmetry mechanisms such as mass imbalance or aerodynamic degradation, supporting reliable condition monitoring and earlier maintenance interventions. Using OpenFAST simulations, the proposed framework reconstructs height-resolved wind profiles with RMSE below 0.15 m/s (R² > 0.997) under healthy conditions, and achieves up to 100% detection accuracy for moderate-to-severe pitch misalignment faults.