© vladim_ka, stock.adobe.com
Beckhoff provides system solutions for wind turbines based on PC and EtherCAT technology that have been tried and tested worldwide, automating more than 140,000 wind turbines all over the world up to a rating of 25 MW.
With our modular range of system components, you can implement open and scalable control architectures, supporting not only pitch control and inverter, gearbox, and brake control, but also wind farm networking. Integrated safety features and real-time condition monitoring ensure your systems are future-ready.
Get a head start in wind turbine engineering with Beckhoff:
- real-time capability: high-speed, end-to-end communication via EtherCAT
- openness: integration of standard fieldbuses and Ethernet-based systems
- flexibility: scalable topologies for various system concepts
- holistic approach: safety and condition monitoring integrated directly into the control system
- industry expertise: more than 20 years of experience and specific software blocks
Our technologies for your wind turbine
Universal control platform for wind turbines
With PC-based control, all control tasks are available to you on a single, centralized platform. All data is consolidated in an embedded PC located in the base of the wind turbine tower, for example. This PC collects and processes data, checks the grid feed-in, and communicates with the control room. Safety and measurement technology as well as condition monitoring are integrated into the controller via I/O modules. The converter in the base of the tower, the I/O system for operational management in the nacelle, and the pitch controller in the hub are connected to the master computer via EtherCAT. This creates a seamless system that eliminates the need for isolated secondary controls. Hardware and engineering costs are reduced, availability is increased, and your wind turbines are made more efficient.
How you benefit from PC-based control:
- integration: universal control platform for operational management, pitch control, wind farm networking, and yaw system
- scalability: modular range of components for all system concepts and performance classes
- openness: compatibility with industrial communication standards such as IEC 61400-25, Ethernet TCP/IP, and OPC UA
High-speed communication for wind turbines
EtherCAT provides the performance required for end-to-end automation of modern wind turbines. The fieldbus supports rapid response times, precise time synchronization, and the integration of even complex subsystems including inverters as well as safety and measurement technology.
EtherCAT is also setting the standard for wind farm networking. Fiber optic cables allow systems to be connected with cable redundancy over distances of up to 20 km. This allows setpoints to be quickly distributed throughout the entire grid and grid parameters to be efficiently controlled.
How you benefit from EtherCAT:
- range: fiber-optic networking up to 1.5 km with multi-mode technology and up to 20 km with single-mode technology
- efficiency: networking without complex switch and hub structures
- transparency: high-frequency monitoring of current and voltage values with up to 20,000 samples/s
For measurement technology, condition monitoring, and network diagnostics
With XFC, you can capture measurement data at high speed and with time-based synchronization. Beckhoff measurement technology, condition monitoring, and network diagnostics terminals use oversampling technology to capture raw data at rates of up to 100 kHz and transfer it directly to the CPU. This ensures that all measurement data is retained – without preprocessing in the terminal or data loss.
EtherCAT distributed clocks can be used to synchronize all measured values within a time window of significantly less than 1 µs, both in your wind turbine and across the entire wind farm. You get precise measurement timestamps for a reliable analysis of plant status, network behavior, and diagnostic events.
How you benefit from XFC:
- analytic depth: optimized condition monitoring, diagnostics, and structural monitoring
- deterministic processing: high-speed signal processing in microseconds
- full transparency: no preprocessing of measurement data in the terminal, no loss of information relevant to diagnostics
Direct integration of functional safety
With TwinSAFE, you can integrate functional safety to meet the most demanding requirements directly into the control architecture of your wind turbine. Safe I/Os, TwinSAFE Logic, and Safety over EtherCAT combine safety and standard communication in a single, integrated system.
A specific highlight for wind turbine engineering is the EtherCAT Terminal EL3452-0090. This 3-phase power measurement terminal monitors generators up to 690 V AC without an upstream voltage transformer and provides relevant measurement values including current, voltage, power, frequency, THD, and harmonics. When used in combination with XFC technology, it is also possible for the terminal to transmit the times of the last voltage and current zero-crossing to the controller, thereby triggering the appropriate switching operations.
How you benefit from TwinSAFE:
- certified safety: Safety over EtherCAT meets safety requirements up to SIL 3
- less wiring: secure signals are transmitted via existing EtherCAT communication
- greater diagnostic depth: power/quality analysis for evaluating network distortions, signal quality, and harmonics
AMP800: Compact. Dynamic. Low wear.
The yaw system aligns the wind turbine’s nacelle with the wind. Electric drives and hydraulic braking systems are often combined for this purpose. When active wind tracking is enabled, the braking system is in permanent use. This results in significant wear and high maintenance costs. Using the existing electric drive systems to build up the required counter-torque and clamp the mechanism results in less wear and is more efficient.
Beckhoff’s AMP8000 distributed drive system is a compact alternative solution that integrates servo functionality directly into the motor. This saves space, weight, and wiring in the nacelle. At the same time, the drive power is flexible for adaptation to the system design.
How you benefit from AMP8000:
- higher yield: dynamic wind tracking without restrictive braking strategies
- reduced expenditure: less maintenance and wiring plus easier installation
- more safety: integrated TwinSAFE functions and safe behavior during voltage dips
Beckhoff product highlights for your wind turbine
Automation software for the wind industry
You can implement standardized and modular software system structures for wind turbines with the TwinCAT 3 Wind Framework. The framework combines proven Beckhoff control technology and wind energy expertise in encapsulated modules for programming and configuring your system.
Subsystems including inverters, pitch control, and other system components are mapped as standalone modules. Status, parameters, commands, measured values, user actions, and events can be managed, analyzed, and documented centrally. This creates a reusable software architecture for development, operation, and diagnostics.
How you benefit from TwinCAT 3 Wind Framework:
- engineering: PLC library and sample applications simplify programming
- expandability: easy replacement, reuse, and expansion of modules
- better diagnostics: monitoring, event management, and SQL-based data storage create transparency
Ultra-fast networking for wind farms
With EtherCAT infrastructure components from Beckhoff, you can set new standards for speed in wind farm networking. In the event of a voltage dip (LVRT), this system can identify the setpoints for connected systems in less than 1 ms and adjust the regulation of current, voltage, and frequency.
Matching EtherCAT components mean that the existing Ethernet infrastructure based on fiber-optic technology can be used for this purpose – and over distances of up to 20 km. With this technology, you can even synchronize the power switches (IGBTs) of inverters within a wind farm as needed, regardless of the specific control system used.
Multi-mode:
Single-mode:
For the coupling of existing control systems, the following communication modules are used:
Powerful, flexible, and compact for DIN rail mounting
CX series Embedded PCs provide a compact and scalable control platform for wind turbines. Mounted on DIN rails, these PCs establish a direct connection between industrial PC technology and the Beckhoff I/O level. They can be used for operational management, pitch control, measurement technology, and other tasks.
The CX family includes various CPU classes designed for different performance requirements – from compact controllers to high-performance solutions for complex system components. The new and compact CX8200, for example, delivers strong performance with an Arm® Cortex®-A53 dual-core processor running at 1.2 GHz and supports 1-Gbit Ethernet, USB 3.0, and Beckhoff RT Linux®. The CX9240 expands the range even further and features four processing cores, 2 GB of RAM, and two independent 1-Gbit Ethernet interfaces.
How you benefit from Beckhoff Embedded PCs:
- matching performance class: from compact controllers for decentralized tasks to high-performance control systems
- modular expansion: integration of I/Os as well as fieldbus and communication interfaces
- service-friendly operation: quick updates and easy on-site replacement
Quick to integrate, compliant with standards
With TwinCAT 3 Power Control (TF8360), you can implement certified power plant controllers for wind turbines efficiently and in compliance with standards with minimum engineering effort. These certified software blocks help you to meet the requirements of low-, medium-, and high-voltage grids.
The solution runs on Beckhoff CX series Embedded PCs and integrates seamlessly into the open automation architecture. Using popular communication standards and interfaces such as IEC 61850, IEC 60870, MQTT, OPC UA, EtherCAT, PROFINET, PROFIBUS, or CANopen, the power plant controller is designed for flexible integration into turbines, farm networks, and control rooms.
How you benefit from power plant control with Beckhoff:
- grid stability: reactive power control for voltage stability and active power control for frequency stability
- immunity to interference: built-in fault ride-through functionality
- flexible hardware platform: featuring 6 available CPU classes from the Beckhoff CX series and unlimited communication options
Integrated network monitoring and power measurement
With EtherCAT power measurement terminals, you can integrate grid monitoring and power measurement directly into the control system of your wind turbine.
The electrically isolated EL3453 measures 3-phase current and voltage up to 5 A and 690 V. The terminal transmits the resulting average values to the CPU after every half a grid period (10 ms). These include values such as power, frequency, cos φ, and, of course, current and voltage.
The EL3783 is equipped with the same physical properties, but measures current and voltage at a frequency of 20 kHz. From this raw data, all average values can be calculated on the CPU – for example, with the help of the TwinCAT power monitoring library TF3650. Grid analyses up to the 110th harmonic are possible.
How you benefit from I/O power measurement terminals:
- rapid fault detection: early detection of voltage dips
- integrated analysis: power and grid quality data is processed directly in the controller
More data for higher wind power efficiency
With TwinCAT Analytics and TwinCAT Condition Monitoring, you can systematically leverage the operating and measurement data from your wind turbine. Vibrations, temperatures, speeds, and performance data are recorded, analyzed, and displayed directly in the controller. This provides a foundation for reliable diagnostics and predictive maintenance.
The TwinCAT condition monitoring library provides the necessary algorithms for analysis, statistics, and classification. TwinCAT Analytics supplements the workflow from raw data acquisition through analysis and beyond to the dashboard. This makes it possible to detect wear, imbalance, or undesirable operating conditions at an early stage and to plan maintenance measures more effectively.
How you benefit from TwinCAT Analytics and condition monitoring:
- higher diagnostic reliability throughcombined analysis of operating and measurement data
- easy integration: direct integration of algorithms, third-party software, and dashboards into the TwinCAT control platform
- predictive maintenance: data-driven recommendations for longer system life cycles and higher availability
Beckhoff solutions for the wind industry
© Goldwind
Seamless control from the base of the tower to the rotor hub
Operational management and pitch control are among the key factors for ensuring that wind turbines operate safely, efficiently, and in compliance with grid requirements. With Beckhoff, you can use these control levers consistently and effectively. At the base of the tower, an embedded PC processes all relevant data and communicates with the control room, the wind farm network, and higher-level systems. EtherCAT connects the converter, the I/O level in the nacelle, and the pitch controller in the hub at high speed and with time synchronization.
Beckhoff’s open automation architecture supports the flexible integration of safety, measurement, and diagnostic functions. Compact control systems are available for rotor blade adjustment, including collective and individual blade adjustment.
Advantages at a glance:
- direct communication between the base of the tower, nacelle, hub, and control room
- EtherCAT reduces engineering and wiring work
- integrated safety functions with TwinSAFE
- flexible pitch control using standard components for various system configurations
© Ula, stock.adobe.com
Fast communication for stable wind farm networks
As wind farms grow in size, the requirements for interconnecting wind turbines are on the increase. Setpoints must be distributed quickly across the entire network, measured values must be precisely synchronized, and network events must be processed immediately. EtherCAT provides a powerful foundation for this, making it possible to identify setpoints for all systems on the network in less than 1 ms and to adjust current, voltage, and frequency accordingly.
The network can be set up with fiber-optic cables and cable redundancy. Even long distances can be covered without any loss of speed. For communication with control rooms, grid operators, and power suppliers, TwinCAT also supports industry-standard telecontrol protocols including IEC 61400-25 and IEC 60870.
Advantages at a glance:
- rapid setpoint distribution on the wind farm network with response times under 1 ms
- fiber-optic networking with cable redundancy over long distances of up to 20 km
- precise synchronization of measured values to a time window of less than 1 µs
- open interfaces for heterogeneous system architectures and telecontrol protocols
© Beckhoff
Making smart use of status data
The operation and maintenance of modern wind turbines incur high costs – especially when malfunctions are detected too late or when a one-size-fits-all approach is taken to scheduling maintenance intervals without considering the status of the turbine. Beckhoff therefore integrates powerful condition monitoring directly into the control platform: vibrations from bearings, gearboxes, or generators are recorded via EtherCAT measurement terminals and evaluated together with operating data including temperature, pressure, power, and speed.
You get a transparent view of your system: raw data is transmitted with time synchronization and can be analyzed using TwinCAT Condition Monitoring – via spectral analysis, statistical parameters, or threshold monitoring, for example – and used for predictive maintenance.
Advantages at a glance
- early detection of critical states for increased system availability
- combined analysis of measurement and operating data for fewer false alarms
- flexible expansion of the EtherCAT segment for easy retrofitting
- diagnostics integrated in the control system for lower maintenance and system costs
