Application examples in a wind turbine written by: Martin Kluge Peter Knaack Global Key Industries update: 23.07.2010 page 1
General design of a wind turbine Rotorblade Nacelle Rotor Tower update: 23.07.2010 page 2
Design of a nacelle 1 Rotor blade 2 Blade bearing 3 Rotor Hub 5 4 Main bearing rotor 2 3 4 6 7 8 9 shaft 5 Ventilation system 6 Gearbox 7 Generator 12 11 10 8 Transformer 9 Control cabinet 10 Hydraulic unit 1 11 Lubrication system 12 Yaw drive & motor Source: ifm electronic update: 23.07.2010 page 3
Overview of the applications in a wind turbine 1/2 Speed monitoring of the generator using inductive sensors 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 encoders 10 Nacelle yaw (azimuth) positioning using inductive sensors 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 update: 23.07.2010 page 4
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 coolant 18 Stabilised switched-mode power supplies for the 24 V DC voltage supply 19 Reliable connection technology for difficult applications 20 Control system ecomatmobile 21 Possible applications of Condition Monitoring Systems 22 Basic structure of an ifm condition monitoring system 23 Condition monitoring of the drive train 24 Condition monitoring of the rotor blades 25 Diagnosis of pumps and motors in the periphery (offshore) 26 update: 23.07.2010 page 5
Speed monitoring of the generator using inductive sensors IFM & IGM inductive sensors: e.g. IFM204 or IGM204 Extremely high EMC compatibility (high immunity to lightning) Temperature range from -40 o C to +85 o C 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 must be within certain limits. For reliable speed detection inductive ifm sensors of the IFM and IGM series are used. update: 23.07.2010 page 6
Overspeed monitoring of the drive shaft using speed monitors vibration sensor inductive sensors 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 critical 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 allows safe breaking of the turbine in high wind speed conditions. update: 23.07.2010 page 7
End position monitoring of the rotor blades IGM inductive sensors: e.g. IGM204 Extremely high EMC compatibility (high immunity to lightning) Temperature range from -40 o C to +85 o C High protection rating IP 67 / IP 69K Vibration resistance to EN 60068-2-6 Fc Continuous shock resistance to EN 60068-2-29 Eb The rotational speed of the wind turbine can be controlled even to a standstill via the position of the rotor blades. For reliable query of the max. end positions ifm's inductive sensors are used instead of mechanical switches. update: 23.07.2010 page 8
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 pitch control the maximum end position of the rotor blades is monitored using inductive fail-safe sensors from ifm. The fail-safe sensors are selfmonitoring and tamper-proof. Owing to the applied window technology no special counterparts, e.g. magnet or mechanical target, are required thus ensuring that these sensors are easy to use. update: 23.07.2010 page 9
Position monitoring of the nacelle using absolute encoders RMxxxx encoders: Cable entry for axial and radial use Vibration resistance up to 30 g Housing protection IP 64 TTL interface Information about the exact position and orientation of the nacelle must be available at any time, even after a power failure. ifm electronic offers absolute encoders of the RM series for this important task. update: 23.07.2010 page 10
Nacelle yaw (azimuth) positioning using inductive sensors 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 times. Then it has to be moved back into its initial position. The number of rotations is reliably detected via pulses from inductive ifm sensors of the IGW or IGM series. update: 23.07.2010 page 11
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 Source: "ewiger-fuhrmann.de" If there is no oil pressure or if it is too low, the rotor blade adjustment may not operate reliably. If a low pressure level is detected, the pressure sensors transmit an alarm signal to the controller. update: 23.07.2010 page 12
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 The central hydraulic system in a wind turbine is critical to the operation of the wind turbine. Therefore only selected pressure sensors are used such as ifm pressure sensors of the PN series with various output functionalities. update: 23.07.2010 page 13
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 For an optimum hydraulic supply, the oil temperature must not fall below or exceed certain limit values. The ifm temperature sensors transmit signals to the controller when detecting that these limits have been reached. update: 23.07.2010 page 14
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 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 leakage monitoring. update: 23.07.2010 page 15
Pressure monitoring of the lubrication system and the 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 To ensure reliable operation of the mechanical drive train components, minimum pressures must be maintained. For pressure monitoring ifm's pressure sensors of the PK series are a robust alternative to mechanical pressure switches with an excellent price / performance ratio. update: 23.07.2010 page 16
Level control of the lubrication system Inductive sensors IFMxxx: E.g. IFM213 Extremely high EMC compatibility (high immunity to lightning) Temperature range from -40 o C to +85 o C High protection rating IP 67 / IP 69K Vibration resistance to EN 60068-2-6 Fc Continuous shock resistance to EN 60068-2-29 Eb Wind power stations must function absolutely reliably and must in no case fail due to an avoidable fault, e.g. insufficient lubrication. To detect the minimum level on the metal ring of the diaphragm, inductive sensors of the IFM series are preferably used. They function reliably even under extreme operating conditions. update: 23.07.2010 page 17
Temperature monitoring of the lubricant and the coolant 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 For optimum monitoring of the lubricant and coolant temperature, temperature sensors with precise switch point setting are required. The ifm s TK series can be set via the setting rings without the system temperature being applied. This saves time and costs. update: 23.07.2010 page 18
Stabilised switched-mode power supplies for 24 V DC voltage supply DNxxxx switched-mode power Supplies: 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 For the supply of all connected sensors and control components 24 V DC power supplies are used. ifm's switched-mode power supplies are available with a wide range of input voltage for use worldwide. update: 23.07.2010 page 19
Reliable connection technology for difficult applications 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 sometimes 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 update: 23.07.2010 page 20
Control system ecomatmobile Control system: Analogue and digital I/Os with diagnostic function Temperature range from -40 o C to +85 o C (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 From the controller with high protection rating to safety controllers of category 3 and CabinetController for direct use in the nacelle. ecomatmobile controllers are a universal and cost-optimised solution for every application. update: 23.07.2010 page 21
Possible applications of Condition Monitoring Systems Rotor Fatigue, crack formation Blade adjustment error Damages (e.g. via lightning strike) Gearbox Wear, break in teeth Displacement, eccentricity of toothed wheels Generator/network coupling Winding damage Rotor asymmetries, bar break Overheating Bearings, shafts Wear, defects of bearing shells and rolling elements Fatigue, crack formation in shafts Tower vibration System performance Environmental influences Crack formation, fatigue Nacelle adjustment Yaw error (drive & motor) Monitoring of the friction bearing update: 23.07.2010 page 22
Basic structure of an ifm condition monitoring system Control system and other connections via Ethernet Operational data logging Long-term trend records Teleservice Wind turbine controller Maximum length of the sensor cable: 30 m Maximum point-to-point length: approx. 100 m Binary signals: Pre-alarm Main alarm Ethernet interface OPC server octavis software
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 To predict premature failure in the drive train (main rotor bearing, gearbox, and generator), a condition monitoring system is required. The condition monitoring system from ifm electronic, consisting of the VSE0xx diagnostic electronic and the VSA0xx vibration sensors is flexible due to its modular structure. It can be configured for your exact application requirement and budget. update: 23.07.2010 page 24
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) Changes in the condition of the rotor blades caused by cracks and ice formation are detected via the changes in vibration and can be directly evaluated by the diagnostic electronics. update: 23.07.2010 page 25
Diagnosis of pumps and motors in the periphery (offshore) efector octavis VE1xxx: E.g. VE1001 or VE1002 Detection of damage to rolling element bearings by frequency analysis up to 20 frequencies in the spectrum, freely selectable, diagnostic level adjustable Compact dedesign: Sensor, evaluation and diagnosis in one unit In a wind turbine there are often motors and pumps in the periphery which have to be monitored regarding damage to rolling element bearings, unbalance and cavitation. efector octavis provides the user with an optimum plant availability by permanently monitoring these aggregates. Furthermore alignment errors can be detected and meshing can be monitored. update: 23.07.2010 page 26
Product overview of ifm electronic 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 amplifiers Bus system AS-Interface Identification systems RF-identification systems, optical identification systems Control systems Connection technology update: 23.07.2010 page 27