Beckhoff Automation GmbH & Co. KG

Reliable condition monitoring: integrated in three steps
The central control system is an embedded PC with connected I/O modules, EtherCAT as an integrated communication system and the TwinCAT automation software. The modularity of Beckhoff's hardware and software components enables the configuration of a needs-based control system for each wind turbine and allows subsequent changes or extensions without great expense – such as retrofitting condition monitoring.
This is because the operation and maintenance of modern wind turbines cause considerable costs. To ensure competitiveness, operators must minimize failure risks, reduce maintenance costs, and increase plant availability and energy efficiency. Not only for offshore wind turbines and plants in remote regions, but for all turbines, monitoring gearboxes and generators with condition monitoring is therefore recommended. Beckhoff uses powerful processors of modern PC technology and EtherCAT as a fast communication system to seamlessly integrate condition monitoring into the control system. The vibrations of bearings or electrical machines are detected by Beckhoff measurement technology terminals and transmitted to the control system via EtherCAT. Configuration, programming and diagnostics are carried out with TwinCAT in one and the same system.
Control-integrated condition monitoring
Control-integrated condition monitoring is superior to classic, hardware-based condition monitoring solutions due to improved error detection and a holistic system view.
High-frequency data acquisition via EtherCAT terminals
To monitor the grid voltage, the Beckhoff EL3783 power measurement terminal with oversampling function for condition detection of a 3-phase AC voltage network and the EL1252 digital input terminal with time stamp function for the exact timing of fast binary control signals are available in the wind turbine control system.
When retrofitting the wind turbine with condition monitoring, the turbine control system only needs to be expanded with a terminal block with the corresponding EtherCAT measurement technology terminals. The EL3751 EtherCAT terminal is a multifunction input for analog measurement technology. The EL3632 enables the direct connection of various accelerometers via an IEPE interface and takes over the high-precision vibration measurement. The EL3356-0010 can be used to evaluate strain gauges. The recording of the raw data is synchronous in time (We also recommend the integration of special solutions from established third-party providers in this market. In addition to direct integration into our control platform, the user has access to the extended diagnostic options, expert opinions and many years of experience of these providers in monitoring issues.
If preset, component-related threshold values are exceeded, the condition monitoring system triggers alarms that provide information about wear, imbalances or impermissible operating conditions. Continuous machine monitoring can be done online. Trends in the key figures are analysed and translated into recommendations for action, such as for the planning of maintenance intervals.
Control-integrated condition monitoring
• Time-synchronous recording of all data clearly