Torque Sense and Smart Check sensors from Schaeffler record torque, speed, vibration and temperature information. This data is transmitted via a gateway and combined and processed using algorithms that Bonfiglioli has developed specifically for this application. Users can then use the data on the Bonfiglioli cloud platform. The collected information is clearly displayed for the operator via the dashboard. Maintenance measures can thus be carried out in a load-oriented manner and unplanned downtimes of the system can be minimized, while operating costs can even be more than halved.

In the dashboard, the operating personnel can continuously monitor the status of the geared motor based on the data, and the remaining service life of the drive is also estimated. Abnormal behavior of the azimuth drive is reported just as naturally as critical states. On this basis, the maintenance intervals can be optimized to the actual requirements and necessary repairs can be carried out at the appropriate times. At the same time, the control of the drives can be optimized, thus avoiding overloads. The result is a reduction in unplanned downtimes and thus an increase in the economic efficiency of a system.

Concrete figures using the example of a 2.3-megawatt wind turbine make this clear, as Gaetano Ciaravella, Mechatronics & IoT Manager at Bonfiglioli, reported at a conference: Currently, the availability of a wind turbine over time drops from 95 percent in the first year to 82 percent in its 20th year of life, with a median of 88.5 percent. At the same time, the yields of a wind turbine are also falling by around seven percent per year due to falling kilowatt-hour prices. The operating costs account for around 75 percent of the total initial investment in the 20 years of life. Around 50 percent of the operating and maintenance costs are attributable to unplanned interventions.

In concrete terms, this means that operating costs of around 1.6 million euros are estimated for a 2.3-megawatt wind generator over 20 years, of which up to 1.1 million euros are attributable to unscheduled repairs and maintenance. With a relatively small investment in the new system from the cooperation between Bonfiglioli and Schaeffler, operating costs can therefore be reduced by up to 60 percent.

In reality, there are certainly other advantages that are difficult to quantify based on the available data. They result from the possibility of adapting the electronic drives in relation to environmental and operating conditions (temperatures, wind hours/year), which has a direct and positive effect on the productivity of the wind generator. as