/ Condition monitoring solutions / Wind turbine monitoring system

Structural Health Monitoring and Condition Monitoring of Wind Turbines

Dewesoft data acquisition systems are used on offshore wind turbines for online wind turbine condition monitoring and wind turbine structural health monitoring with the aim to achieve the reduction of the cost of wind energy and optimize ROI.

The condition monitoring system provides distributed high-channel-count and remote monitoring. We provide a turn-key solution from DAQ systems, and data loggers, to sensors together with Windows-based data processing and high-level cloud-based monitoring software.


Complete Turn-key Solution: Dewesoft condition monitoring system is a complete solution including highly accurate signal conditioning systems, data acquisition and processing software, sensors, and accessories that are used in structural health and condition monitoring of wind turbine towers.

Totally Distributed System: Dewesoft DAQ devices are designed to be distributed under any condition. EtherCAT technology allows devices to be placed near the sensors and connected with a single cable for power, data, and synchronization. The cable can span up to 100m between DAQ nodes or virtually unlimited using EtherCAT to fiber optic converters.

Support for Any Sensor: Input amplifiers offer support for any strain gauge, low-frequency accelerometer, temperature, weather, wind power, and wind turbine performance monitoring sensors.

Perfectly Synchronized: All data channels are synchronized well below microsecond accuracy, required for deep structural analysis.

Amazing Dynamic Range: With dynamic ranges up to 160dB, our customers are claiming they can see fish hitting the structure.

Wide Variety of Configuration: From extremely rugged IP67 units with very high dynamic range to cost-effective solutions offer a tailored approach for virtually any structure with the possibility to monitor and analyze thousands of data points.

Powerful Software: DewesoftX software offers real-time diagnosis, pre-processing, and data reduction with powerful math. A wide variety of storage options are possible with powerful visualization choices.

Open Interfaces: Using DewesoftX, data is available in a wide variety of formats, from exported data to live OPC UA interface or modern cloud data services.

Remote Operation: The entire system can be remotely operated offering triggered storing, alarms, and other monitoring features with capabilities to store data locally or at distant remote locations.

Condition Monitoring Of Wind Turbines

Wind turbine condition monitoring is aimed at detecting changes in wind turbine behavior as early as possible. The main goal is to predict developing faults in order to minimize performance degradation and economic cost. It is performed by constant monitoring of specific parameters and comparing them to parameters obtained during “normal” operational behavior.

Condition Monitoring is focused on monitoring wind turbine drivetrain components. Dewesoft offers condition monitoring solutions for any kind of rotating machinery like shafts, bearings, gearboxes, and generators.

The most commonly used sensors for Wind Turbine Condition monitoring are:

  • Accelerometers to detect bearing faults, and gear tooth failures.
  • Temperature sensors to detect overheating.
  • Pressure sensors.
  • Rotational speed sensors - to perform order tracking analysis in variable speed wind turbines.
  • Current clamps to measure current signals for identification of faults in generators.
  • Oil-based sensors - to detect water content, debris, particle concentration.

Structural Health Monitoring Of Wind Turbines

Condition Monitoring in the case of structural components, like foundations, blades, and towers, is termed Structural Health Monitoring. Failures of Wind Turbine Structural components can significantly affect the wind turbine operational costs and in some cases can result in a complete loss of the turbine (tower collapse).

Offshore wind turbines are particularly exposed to harsh environments (wind, wave load, stress, corrosion) and higher risk. Therefore it is essential to perform monitoring of the structural components to reduce maintenance costs and avoid catastrophic failures.

The most common sensors for Wind Turbine Structural Health Monitoring are:

  • Accelerometers to perform OMA (Operational Modal Analysis).
  • Strain gauges to verify design assumptions under applied loads
  • Temperature sensors - especially in combination with strain gauges for temperature compensation.
  • Inclinometers to monitor the stability of the tower.
  • Anemometers - to monitor wind speed and direction.
  • Wave radars - to monitor wave height.

Dewesoft can offer a complete SHM solution for monitoring all the necessary parameters (vibration, strain, inclination, temperature measurements) needed to assess the condition of wind turbine structural components.


Vibration Monitoring Of Wind Turbines

Wind turbine vibration monitoring is the most commonly used technique in Wind Turbine condition monitoring due to the fact that most damages in rotating machinery are reflected as higher vibration levels at frequencies specific to a developing fault.

In the case of Structural Health Monitoring vibration data is collected to perform the Operational Modal Analysis technique in order to detect developing faults. Changes in geometric and stiffness properties are reflected as changes in modal properties like modal shapes, damping ratios, and natural frequencies.

Dewesoft offers state-of-the-art 3-axial accelerometers with integrated data acquisition (IOLITE-3xMEMS-ACC) specifically designed for vibration monitoring of structures. DewesoftX data processing software offers a wide range of vibration math capabilities. Export options are available to facilitate the performance of Operational Modal Analysis and assessment of structural health.


Monitoring Instrumentation For Wind Turbines

  • Acceleration and inclination measurement: Dewesoft IOLITEiw-3xMEMS-ACC-INC is a triaxial MEMS accelerometer and static inclinometer with an EtherCAT interface. Offers 8 g measurement range for wind turbine vibration analysis.
  • Cabinets: Dewesoft can provide custom-made cabinets with all instrumentation preinstalled.
  • Industrial PC: We can provide our own or 3rd party industrial computers, This will run our DewesoftX software for acquisition of the installed sensors. Power Supply and UPS are available as well.
  • Cables: A single CAT6 cable is used for daisy-chaining the EtherCAT devices. We offer inexpensive to high-end robust cables (UV resistant, Oil resistant, Ozone resistant, Water and humidity resistant, Shielded, Flame retardant, Low emission of smoke and other acidic gases, halogen-free), as well as off-shore certified (MUD-resistant following NEK 606) cables.
  • Mounting brackets: Custom-made mounting brackets and other accessories can be provided by Dewesoft.
  • Other accessories: Cable tear protection can be provided to prevent bending or squishing of the cable. Cable clamps (also with magnets) to fix cables on towers where cable trays are not available can be provided upon request.


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