The Weidmüller BLADEcontrol® system provides timely warnings of blade damage and icing, and achieves greater profits and less risk through continuous monitoring of rotor blades .
To monitor the rotor blades of wind turbine generators, Weidmüller has developed an innovative system using the BLADEcontrol® product family. BLADEcontrol®'s sensitive sensors detect initial damage and freezing of the rotor blades. Therefore, taking appropriate action at the right time can prevent system failure. In the event of major damage, BLADEcontrol® sends a signal to the installed controller, immediately stopping the unit and preventing blade breakage. This system consists of sensors distributed on the rotor blades, a hub measurement unit, a WiFi-optional data transmitter with a contact nacelle, an evaluation and communication device, a data backup server, and a visualization system in an internet-connected environment. BLADEcontrol® can be used in both new and existing systems. It is easy to install or retrofit.
The rotor blades of wind turbines are under high stress. Gusts, storms, frost, or lightning can cause invisible minor damage, which is not easily seen from the ground and is usually only detected during routine maintenance. This significantly increases the amount of maintenance work required. The worst-case scenario is shutting down the wind turbines for several weeks, meaning the turbines will not generate electricity.
Weidmüller's BLADEcontrol® monitoring system accurately detects damage. 24 hours a day, 365 days a year, BLADEcontrol® continuously records the condition of each rotor blade. It can even detect minute changes after damage has occurred. Therefore, it can identify problems earlier than manual visual inspection and prevent them from developing uncontrollably. This reduces costly maintenance risks and increases the overall economic efficiency of the system.
In addition to damage to the blades themselves, BLADEcontrol® can also detect aerodynamic imbalances, loose blade components, and misalignment of the hub or blade pitch. This ensures reliable operation and high power output. The BLADEcontrol® monitoring system has been continuously certified by Germanischer Lloyd (now DNV GL) since 2008. It has consistently been the leading product designed for rotor blades in terms of both damage detection and operational familiarity.
Understanding when icing will have a significant impact
Cold and darkness make winter a peak season for power generation. As temperatures drop, icing sensors on the nacelle issue icing warnings, causing many wind turbines to automatically shut down. Compared to the nacelle, various icing conditions are more likely to affect the rotor blades, where different icing sensors are located. BLADEcontrol® directly measures the degree of icing on the rotor blades. The blade tips traverse cold air at wind speeds reaching 250 km/h. The system directly measures the icing level before the rotor blades are completely covered by ice.
The location of ice formation can be accurately detected, and help prevent overlooked freezing risks or unnecessary installation risks outside of service.
BLADEcontrol® can detect when the rotor blades reach the critical point of icing. Importantly, it can also detect when the risk has passed. Therefore, the wind turbine can be restarted at any time of day or night. Its automatic restart function is officially certified and recognized by DNV GL.
BLADEcontrol® is based on a simple physical principle: the accumulation of ice alters the natural vibration behavior of the rotor blades, and the additional weight it generates, in turn, reduces the frequency of vibration. Thanks to a highly sensitive sensor system and specialized evaluation methods, the system can accurately measure ice thickness within the millimeter range. Measurements can be performed both while the device is running and when it is stationary, allowing the device to be checked before each startup to ensure it is fully thawed.
By detecting early damage, repair and replacement costs are effectively reduced.
Although visual rotor blade monitoring can detect obvious damage caused by external factors, the moment when the blades are damaged may have already passed.
This can lead to further defects that may worsen. Weidmüller's BLADEcontrol® can detect damage in its early stages.
The system can detect even the slightest changes by precisely measuring the oscillation frequency of the rotor blades. This type of detection can also reflect internal damage to the rotor blades, including invisible damage caused by exposure to harsh weather conditions and external factors.
Accelerometers inside each rotor blade perform precise, highly sensitive, multi-dimensional, and compact measurements within a single module. BLADEcontrol® collects the data in the hub and then transmits it to the nacelle. An evaluation unit mounted at the base of the tower continuously analyzes and records the data. It detects damage, categorizes it according to severity, and then relays the information.
BLADEcontrol® transmits all critical status information directly to the turbine controller, ensuring the turbine shuts down at the appropriate time. All detected damage information is simultaneously transmitted to the Weidmüller monitoring center. Here, experts evaluate the data and provide specific operational recommendations to users. Users can access the turbine's operating status online at any time. An intuitive traffic light system reflects the rotor blade status: green for normal operation, yellow for minor damage, and red for severe damage. Additional failures, such as blade misalignment or dynamic imbalance, are identified and published online by the Weidmüller monitoring center, enabling optimal planning of necessary maintenance and helping to avoid high subsequent costs.
BLADEcontrol® System
The BLADEcontrol® system consists of the following components:
Sensor (RB): An element integrated into the rotor blades and hub to measure the vibration of the rotor blades and the fan.
Hub Measurement Unit (HMU): A hub processor for centralizing measurement data and transmitting it to the evaluation communicator.
Contact Cabin (APNAC): Component that transmits data between the wheel hub measuring instrument and the WiFi evaluation communicator (the contact cabin is optional).
Evaluation Communication Unit (ECU): A processor that uses a database server to measure, evaluate, process, and transmit data to evaluate communication.
Database Server (DBS): A database processor that controls user communication by evaluating communicators, storing and managing persistent data.
WebVIS (Web Visualization System): In an internet environment, it visualizes the user interface graphically, making the current and past states of wind turbine rotor blades concrete. Granting user access permissions is achieved by transmitting access data, which consists of a username and password.
The system architecture can be customized to meet the needs of wind power equipment manufacturers. Weidmüller's BLADEcontrol® can be used with both newly built and existing systems. Installation and retrofitting are easy.
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