The reliability of energy and data cables has the potential to increase the economic efficiency of wind turbines. With the TRM triflex Rotation Module (TRM), igus has introduced a new type of cable guide that reliably protects cables in flexible energy chains made of high-performance plastic when the nacelles rotate by up to 1 800°. The compact system is the result of a design study and can be pre-fitted and customised to individual applications.
Innovative cable guidance from igus allows for reliable rotary movement of power and data cables in wind turbines’ nacelles.
Wind turbines are often located in remote areas, making maintenance work expensive – especially for offshore turbines. It is therefore important to limit the risk of failure in all components of the systems. This also places high demands on the installation of the numerous cables that supply the generator, gearbox and control systems in the nacelle with power and data from the ground.
"As the nacelles of wind turbines are constantly moving to align themselves optimally with the wind, the cables are exposed to heavy loads over time. A cable break is extremely disruptive in this environment and usually requires an expensive and time-consuming repair," says Michael Berteit, Sales Manager Engineering Projects and Installation Service at igus. "We developed the TRM in a design study. It is an innovative and compact cable guidance system that safely guides the cables and reliably protects them when the nacelle rotates. This increases the reliability of wind turbines and thus their economic efficiency." The pre-series version of the new module was introduced to the market in October last year.
Rotary movements of up to 1 800°
The TRM system is located in the upper tower end of the wind turbine, directly under the nacelle. Inside, five triflex energy chains run parallel to each other, carrying energy and data cables. The e-chains can move in three dimensions and have flexible chain links made of high-performance plastic that form a ring-shaped structure. This allows the triflex to perform a rotational movement around a central axis.
"When the nacelle rotates, the upper part of the TRM moves in synchronisation with the energy chain. A movable support structure inside the system ensures that the energy chain always maintains its bend radius and is always securely positioned," Berteit explains. With this controlled guidance, the cables can perform rotational movements of up to 1 800° without tangling or kinking. "This enables the operators to turn the nacelle up to five times around its own axis in one direction without being forced to work quickly against the wind. Hence, it keeps the alignment of the system safe and energy efficient.”
Pre-fitting saves assembly time
Another goal for igus was to save space and installation time for users of the new cable guidance system. "We have designed the module to be compact. With an external diameter of just 1 300 mm and an installation height of less than 1m, it requires only minimal space around the rotary axis," says Berteit.
In addition, users can conveniently equip the system with the required cables on land or receive it fully harnessed from igus. Here, igus offers cables from the chainflex range. They permanently withstand torsional loads, function reliably under adverse environmental influences such as large temperature fluctuations and thus further increase the reliability of wind turbines.
"With the pre-fitted rotating energy supply, the assembly time on site at the plant, which is often associated with very high costs, can be reduced by up to 50%," Berteit highlights.
For more information visit: www.igus.co.za
