Energy technology: wind power, generators, large engines

Aligning solar panels in relation to the course of the sun increases the energy yield, and therefore the plant effectiveness. Inclination sensors ensure that the panels are always properly aligned.

Test rigs have been developed for load tests on wind turbine rotor blades and simulate the real loads caused by high winds and weather. The tip of the rotor blade can be distorted by up to 10m due to mechanical loads. Draw-wire sensors are used on the test rig for measuring the distortion. Two sensors per traction point measure the deflection and torsion of the rotor blade. The draw-wire sensors operate with measuring ranges between 3 m and 10 m. The digital signal output is provided for further simulations.

In order to monitor rotor behavior in the generator, capacitive displacement sensors measure the gap between stator and rotor. Despite high temperatures and electromagnetic fields, capacitive sensors from Micro-Epsilon provide unmatched accuracies. In addition to continuous measurement for predictive maintenance, the measurement can also be used when setting the generator.

In order to control air supply, the air flaps automatically open and close depending on the temperature. Draw-wire displacement sensors monitor the position of the open air flap.

Acceleration sensors are used in wind turbines in order to monitor the tower oscillation. When the oscillation is too strong, the rotor blades are removed from the wind.

In order to monitor the supporting moments, eddy current displacement sensors measure the distance between the nacelle and the tower, which enables early recognition of any fluctuations. Therefore, the plant can be switched off in time when the wind load is too high.

Laser triangulation sensors measure the distance from the foundation in order to detect the tower movements. High measuring rates enable to detect vibrations directly. Depending on the number of sensors installed, detailed evaluations about the vibration behavior can be determined. When the tower movement is too strong, the rotor blades are removed from the wind in order to avoid possible damage.

Eddy current displacement sensors measure the axial, radial or tangential deflection of the clutch disc. These robust sensors are designed for harsh ambient conditions and, due to their extremely compact size, can also be integrated in restricted installation spaces. The sensor provides stable measurement results despite high pressures and temperatures.

The gearbox temperature in wind turbines is measured continuously during operation. Heating up of components may indicate a potential problem with a component. If a certain threshold is exceeded, subsequent remedial action can be started or maintenance planned.

With regard to predictive maintenance, the oil gap should be measured, i.e. the distance between the bearing surface and the shaft filled with lubricants. Despite pressure, high temperatures and lubricants, robust eddy current sensors from Micro-Epsilon can provide a permanent statement about the lubricating gap based on high measurement accuracy.