Generator
Generator condition monitoring with IoT records vibration, temperature and power data on the generator and detects faults before unplanned downtime. Operators of hard-to-reach wind turbines plan maintenance work in a targeted way and avoid unnecessary trips.
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Generator condition monitoring in wind turbines: detect faults early
Codestryke uses the iCOMOX sensor box from Arrow, which measures vibration, magnetic field, acoustics and temperature. Because the sensors measure several times per second, an edge device on site filters and compresses the data and sends only changes in readings to the cloud. Depending on the location, data is transmitted via NB-IoT, by cable using Power over Ethernet or through a SmartMesh IP wireless network. For Woodward Kempen, Materna records all power and sensor data at the frequency converter between generator and grid and transfers it to the Amazon Web Services IoT platform, by cellular network onshore and by cable or satellite offshore. A self-learning application identifies patterns in this data: unusual fluctuations in power generation indicate a problem with the generator.
Both examples come from wind power generation, as remote reading and as condition monitoring with acoustic, temperature and vibration monitoring. Woodward Kempen has equipped around 18,000 turbines with its frequency converters and, with Materna's solution, offers predictive maintenance to operators of onshore and offshore wind farms, eliminating technically unnecessary trips to the turbines. For an energy company, Codestryke built a condition-based monitoring solution intended to reduce downtime of generators, turbines and pipes to a minimum and lower the cost of routine maintenance.
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Generator condition monitoring: frequently asked questions
How can wind turbine generator failure be predicted?
Impending generator failure shows up in patterns in the power and sensor data, which a self-learning application identifies. In Materna's solution for Woodward Kempen, the data is recorded at the frequency converter between generator and grid. Unusual fluctuations in power generation indicate a problem with the generator. The operator can then schedule tailored maintenance at short notice and send technicians to the turbine with the right tools.
What role does the wind turbine converter play in generator monitoring?
The frequency converter is the interface between power generation in the turbine and the transmission grid, making it a key measuring point. Woodward Kempen has equipped around 18,000 turbines with its converters. Materna records all power and sensor data there and transfers it to the Amazon Web Services IoT platform. When the converter develops a fault, independent root cause analysis is needed, and the same data also reveals problems with the generator.
How does IoT reduce the effort of wind turbine generator maintenance?
IoT reduces maintenance effort because work is planned according to measured condition rather than fixed intervals. Offshore, weather and sea conditions make every visit difficult and logistics costs are high. For the wind farms with Woodward Kempen converters, technically unnecessary trips are eliminated and technicians arrive with the right tools. The energy company Codestryke worked for also wanted to avoid staff costs for routine maintenance carried out even when there were no problems.
How does generator vibration monitoring work?
Generator vibration monitoring uses a sensor box that records vibration as well as magnetic field, acoustics and temperature. Codestryke uses the iCOMOX sensor box from Arrow for this. Because the sensors measure several times per second, an edge device forwards only changes in readings to the cloud. Depending on the location, the box sends data directly to the cloud via NB-IoT, by cable using Power over Ethernet or via a SmartMesh IP wireless network.
More assets in “Machinery and Equipment”
Pump
Pump monitoring with IoT records vibration, temperature, pressure and energy consumption of running pumps. Operators detect damage and faults before a pump fails and plan maintenance by condition rather than at fixed intervals.
Compressor
With IoT, compressor maintenance follows actual condition: sensors record current consumption, pressure, temperature and running times. Operators detect creeping damage and unused running time early and cut energy and service costs.
Electric motor
Motor condition monitoring with IoT continuously measures the vibration, temperature and current draw of electric motors. Operators detect imbalance, bearing damage or winding faults early and replace motors based on condition rather than after a failure.
Packaging machine
OEE software automatically records run times, downtime, speed and rejects on packaging machines from the machine signals. Operators see where their lines lose performance, and machine builders use the same data for remote access and digital services.
Refrigeration system
A refrigeration monitoring system makes service plannable: temperatures, refrigerant circuit pressures, compressor status and energy consumption flow into a platform in real time. Operators and service partners detect faults early, avoid unnecessary site visits and reduce excess consumption.
Air conditioning system
Commercial air conditioning systems in offices, retail branches and data centres can be monitored remotely with IoT. Operators see energy consumption, temperatures and faults in one place, detect failing compressors or refrigerant shortages early and plan service visits precisely.
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