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update: 23.07.2010 page 1© ifm electronic gmbh

Wind power

written by:Martin KlugePeter KnaackGlobal Key Industries

Application examples in a wind turbine


Wind power

Rotor

Nacelle

Tower

Rotorblade

General design of a wind turbine


Wind power

Design of a nacelle

1 Rotor blade

2 Blade bearing

3 Rotor Hub

4 Main bearing rotor

shaft

5 Ventilation system

6 Gearbox

7 Generator

8 Transformer

9 Control cabinet

10 Hydraulic unit

11 Lubrication system

12 Yaw drive & motor

Source: ifm electronic

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8

12

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Wind power

Overview of the applications in a wind turbine 1/2

� Speed monitoring of the generator using inductive s ensors 6

� Overspeed monitoring of the drive shaft using speed monitors 7

� End position monitoring of the rotor blades 8

� Safety end position monitoring of the rotor blades 9

� Position monitoring of the nacelle using absolute e ncoders 10

� Nacelle yaw (azimuth) positioning using inductive s ensors 11

� Pressure monitoring of the hydraulic power unit 12

� Pressure monitoring of the hydraulic system 13

� Temperature monitoring of the hydraulic oil 14

� Level monitoring on the hydraulic system 15


Wind power

Overview of the applications in a wind turbine 2/2

� Level control of the lubrication system 16

� Pressure monitoring of the lubricant system and the cooling circuits 17

� Temperature monitoring of the lubricant and the coo lant 18

� Stabilised switched-mode power supplies for the 24 V DC voltage supply 19

� Reliable connection technology for difficult applic ations 20

� Control system ecomatmobile 21

� Possible applications of Condition Monitoring Syste ms 22

� Basic structure of an ifm condition monitoring sys tem 23

� Condition monitoring of the drive train 24

� Condition monitoring of the rotor blades 25

� Diagnosis of pumps and motors in the periphery (of fshore) 26


Wind power

Speed monitoring of the generator using inductive s ensors

IFM & IGM inductive sensors:� e.g. IFM204 or IGM204

� Extremely high EMC compatibility (high immunity to lightning)

� Temperature range from -40 oC to +85 oC

� High protection rating IP 67 / IP 69K

� Vibration resistance to EN 60068-2-6 Fc

� Continuous shock resistance to EN 60068-2-29 Eb

To avoid overvoltage the speed of the generator mus t be within certain limits. For reliable speed detection inductive ifm sensors of the IFM and IGM series are used.


Wind power

Overspeed monitoring of the drive shaft using speed monitors

DD20xx monitor:� Connection of inductive sensors

� Setting range 1...60000 (0.1...1000 Hz)

� DIN rail mounting

� 2 relay outputs, 2 transistor outputs

� Analogue output (0...20 mA, 4...20 mA)

� Programmable

Overspeed monitoring of the main drive shaft is crit ical to the safe operation of a wind turbine. By using an inductive sensor connected to the ifm DD series speed monitor, a reliable and cost effective speed monitoring solution is implemented. This allo ws safe breaking of the turbine in high wind speed conditions.

vibration sensor

inductive sensors


Wind power

IGM inductive sensors:� e.g. IGM204






The rotational speed of the wind turbine can be con trolled even to a standstill via the position of the rotor blades. Fo r reliable query of the max. end positions ifm's inductive sensors are used instead of mechanical switches.

End position monitoring of the rotor blades


Wind power

Safety end position monitoring of the rotor blades

Fail-safe inductive sensor GI:� e.g. GI701S

� Suitable for operator and machine safety

� Reliable end position monitoring on moving machine parts

� Connection of the sensors to safety PLCs, bus systems and logic modules possible

� Certified to IEC 62061 SILcl2

To avoid damage to the hydraulics of the blade pitc h control themaximum end position of the rotor blades is monitor ed using inductive fail-safe sensors from ifm. The fail-safe sensors are self-monitoring and tamper-proof. Owing to the applied w indow technology no special counterparts, e.g. magnet or mechanical target, are required thus ensuring that these sensors are e asy to use.


Wind power

Information about the exact position and orientatio n of the nacelle must be available at any time, even after a power f ailure.ifm electronic offers absolute encoders of the RM s eries for this important task.

Position monitoring of the nacelle using absolute en coders

RMxxxx encoders:� Cable entry for axial and radial use

� Vibration resistance up to 30 g

� Housing protection IP 64

� TTL interface


Wind power

Nacelle yaw (azimuth) positioning using inductive s ensors

IGW & IGM inductive sensors:� Increased noise immunity

� Long sensing ranges

� Gold-plated contacts

� Wide range of mounting accessories

The nacelle may rotate around its axis up to 3 time s. Then it has to be moved back into its initial position. The number of rotations is reliably detected via pulses from inductive ifm sen sors of the IGW or IGM series.


Wind power

Pressure monitoring of the hydraulic power unit

PP75xx pressure sensors:� Extremely robust and reliable

� Excellent EMC resistance

� Shock resistant up to 1000 g

� Repeatability [%] < ± 0.1

� Two switching outputs

� Other product families that can be used: PK, PA, PN

If there is no oil pressure or if it is too low, th e rotor blade adjustment may not operate reliably. If a low pressure level i s detected, the pressure sensors transmit an alarm signal to the co ntroller.

Source: "ewiger-fuhrmann.de"


Wind power

The central hydraulic system in a wind turbine is c ritical to the operation of the wind turbine. Therefore only selec ted pressure sensors are used such as ifm pressure sensors of th e PN series with various output functionalities.

Pressure monitoring of the hydraulic system

Pressure sensors PNxxxx:� E.g. PN5 or PN7: 1 switching output

(PN5) or 1 switching output and 1 function check output (PN7)

� Drift-free operation for more than 100 million pressure cycles

� Setting and measured values indicated on a 4-digit 10-segment display

� Other product families that can be used: PK, PP, PA


Wind power

For an optimum hydraulic supply, the oil temperatur e must not fall below or exceed certain limit values. The ifm tempe rature sensors transmit signals to the controller when detecting t hat these limits have been reached.

Temperature monitoring of the hydraulic oil

TR2432 temperature sensor with TTxxxx probe:� Various lengths enable various deflection

depths

� Combined analogue/binary output or switching output

� Freely programmable hysteresis or window function

� Robust mechanics with high vibration and shock resistance


Wind power

Permanent level monitoring of the hydraulic oil is very important. ifm sensors of type LK10xx can be used for this purpose . Units of the type LL80xx have the advantage of additional leakag e monitoring.

Level monitoring on the hydraulic system

Level sensors LK10xx:� Freely programmable operating

switching output and additional switching output as overflow protection

� Easy medium selection via the user menu and direct indication of the current level by means of LED display

� LT80xx series with integrated temperature monitoring

� Various probe lengths available


Wind power

To ensure reliable operation of the mechanical driv e train components, minimum pressures must be maintained. F or pressure monitoring ifm's pressure sensors of the PK series a re a robust alternative to mechanical pressure switches with an excellent price / performance ratio.

Pressure monitoring of the lubrication system and t he cooling circuits

PK75 or PK65 pressure sensors: � Complementary or two separate

switching outputs

� Set point, reset point and switching status clearly visible

� Very simple switch point setting with simple turn via two setting rings

� High bursting pressure guarantees maximum safety


Wind power

Inductive sensors IFMxxx:� E.g. IFM213






Wind power stations must function absolutely reliab ly and must in no case fail due to an avoidable fault, e.g. insuff icient lubrication. To detect the minimum level on the metal ring of th e diaphragm, inductive sensors of the IFM series are preferably used. They function reliably even under extreme operating cond itions.

Level control of the lubrication system


Wind power

For optimum monitoring of the lubricant and coolant temperature,temperature sensors with precise switch point setti ng are required. The ifm´s TK series can be set via the setting rings without the system temperature being applied. This saves time a nd costs.

Temperature monitoring of the lubricant and the coo lant

TK61 or TK71 temperature sensors:� Easy switch point setting using two

setting rings for optimum readability

� Excellent response time: T05 = 1 s and T09 = 3 s

� Mechanical locking prevents inadvertent switch point manipulation

� Switch points freely adjustable from -25 °C to 140 °C


Wind power

For the supply of all connected sensors and control components 24 V DC power supplies are used. ifm's switched-mode po wer supplies are available with a wide range of input voltage fo r use worldwide.

Stabilised switched-mode power supplies for 24 V DC voltage supply

DNxxxx switched-mode powerSupplies:� All power supplies meet the highest

requirement specified in the EMC standards

� The wide-range inputs of 90...260 V AC for one-phase and 340...576 V AC for three-phase power supplies allow use worldwide.

� All units are short-circuit proof, overload protected and open circuit protected


Wind power

Reliable connection technology for difficult applic ations

M12 sockets EVCxxx:� Nut secured against shock and vibration

due to saw tooth contoured vibration protection

� The mechanical end stop protects the O-ring against destruction

� Optimum sealing even when mounted without tools

� LEDs clearly visible even in cases of high light exposure

The sensors used in the wind power stations are som etimes subjected to extreme operating conditions. The ecolink sockets ensure a reliable, tight and vibration-protected connection. Screened versions are also available:e.g. E11855: M12 socket, straight, 8x0.25 mm², PUR , 10 m


Wind power

Control system:� Analogue and digital I/Os with

diagnostic function

� Temperature range from -40 oC to +85 oC (depending on the load)

� High protection rating IP67

� CAN interfaces with CANopen- and SAE J1939 protocol

� Freely programmable with CoDeSys 2.3 to IEC 61131-3

Control system ecomatmobile

From the controller with high protection rating to safety controllers of category 3 and CabinetController for direct use in the na celle.ecomatmobile controllers are a universal and cost-opti mised solutionfor every application.


Wind power

Possible applications of Condition Monitoring Syste ms

Rotor• Fatigue, crack formation

• Blade adjustment error

• Damages (e.g. via lightning strike)

Gearbox• Wear, break in teeth

• Displacement, eccentricity of toothed wheels

Bearings, shafts• Wear, defects of bearing shells and rolling elements

• Fatigue, crack formation in shafts

Generator/network coupling• Winding damage

• Rotor asymmetries, bar break

• Overheating

Nacelle adjustment• Yaw error (drive & motor)

• Monitoring of the friction bearing

Tower vibration• System performance

• Environmental influences

• Crack formation, fatigue

Wind power

Basic structure of an ifm condition monitoring syst em

Wind turbinecontroller

Binary signals:• Pre-alarm• Main alarm

Control system and other connectionsvia Ethernet• Operational data logging• Long-term trend records• Teleservice

Ethernet interface• OPC server• octavis software

Maximum length of the sensor cable: 30 m

Maximum point-to-point length: approx. 100 m


Wind power

To predict premature failure in the drive train (ma in rotor bearing, gearbox, and generator), a condition monitoring sys tem is required. The condition monitoring system from ifm electronic , consisting of the VSE0xx diagnostic electronic and the VSA0xx vib ration sensors is flexible due to its modular structure. It can be configured for your exact application requirement and budget.

Condition monitoring of the drive train

VSE0xx efector octavis diagnostic electronics & VSA0xx vibration sensor:

� Up to 4 vibration sensors per VSE diagnostic electronic

� 2 VSE0xx diagnostic electronics and up to 8 vibration sensors can monitor a complete drive train

� Integrated Ethernet TCP connection

� Internal memory for determining alarm limits


Wind power

Changes in the condition of the rotor blades caused by cracks and ice formation are detected via the changes in vibra tion and can be directly evaluated by the diagnostic electronics.

Condition monitoring of the rotor blades

VSE002 efector octavis diagnostic electronics & VSA001 vibration sensor:

� One vibration sensor per rotor blade

� Central evaluation via diagnostic electronics with Ethernet interface in the rotor control cabinet

� Additional evaluation of external sensors (VSE100, binary and analogue)


Wind power

Diagnosis of pumps and motors in the periphery (offshor e)

In a wind turbine there are often motors and pumps in the peripherywhich have to be monitored regarding damage to rolling ele mentbearings, unbalance and cavitation. efector octavis p rovides theuser with an optimum plant availability by permanently mo nitoringthese aggregates. Furthermore alignment errors can be det ected and meshing can be monitored.

efector octavis VE1xxx:� E.g. VE1001 or VE1002

� Detection of damage to rolling elementbearings by frequency analysis

� up to 20 frequencies in the spectrum, freely selectable, diagnostic leveladjustable

� Compact dedesign: Sensor, evaluationand diagnosis in one unit


Wind power

� Position sensors and object recognition� Inductive sensors, capacitive sensors, magnetic sensors,

cylinder sensors, valve sensors, safety technology, photoelectric sensors, object recognition, encoders

� Fluid sensors and diagnostic systems� Level sensors, flow sensors, pressure sensors,

temperature sensors, diagnostic systems

� Evaluation systems, power supplies and switching ampl ifiers

� Bus system AS-Interface

� Identification systems� RF-identification systems, optical identification systems

� Control systems

� Connection technology

Product overview of ifm electronic

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