In the heart of Deyang City, Sichuan Province, Dongfang Electric Wind Power Co., Ltd. (DEW) stands as a leading force in green energy, railway electrification, environmental technology, and heavy industry. Since 2004, DEW has been at the forefront of wind turbine manufacturing, delivering over 7,000 turbines—both direct-drive and doubly-fed—to domestic and international clients. The company has successfully integrated Beckhoff’s advanced PC-based control technology into its wind turbine pitch systems, setting a new benchmark in wind power control solutions.
The pitch system plays a critical role in managing and optimizing wind turbine performance. It adjusts the blade angle based on real-time wind conditions, ensuring maximum aerodynamic efficiency during low wind speeds and maintaining optimal power output when wind speeds exceed the rated level. In emergency situations, such as severe faults, the pitch system automatically retracts the blades to stop the turbine, safeguarding the entire unit. This reliability is essential, especially under extreme environmental conditions where system durability and availability are key.
At the core of this advanced pitch control system is the Beckhoff CX9020 embedded controller. With an operating temperature range of -25°C to +60°C, it is designed to perform reliably in harsh environments. The CX9020, paired with EtherCAT terminal modules, ensures fast response times, efficient diagnostics, and flexible communication. The system also features a redundant safety chain design, enhancing both performance and safety.
Dongfang Wind Power developed its own pitch system, using AC servo drives and motors for their simplicity, reliability, and cost-effectiveness. The system consists of three identical axis control units, each responsible for one blade, along with backup power supplies, pitch motors, and redundant encoders. The CX9020 serves as the main control unit, communicating with the drive units via the EL6751 CANopen slave terminal module. Additionally, the RS485 interface monitors the backup power charger, while the network interface supports online updates and fault analysis.
Programming the pitch system was made easier with Beckhoff’s TwinCAT software, which supports multiple IEC61131-3 languages. Engineers at Dongfang Wind Power significantly reduced the development cycle with the support of Beckhoff China. As Li Bo, an R&D engineer at DEW, noted, “TwinCAT helped us streamline our programming process and accelerate project timelines.â€
With over 7,000 turbines delivered globally, Dongfang Wind Power continues to lead in innovation, leveraging cutting-edge control technologies to enhance wind power efficiency and safety. The collaboration between DEW and Beckhoff exemplifies a shared commitment to advancing China’s renewable energy sector. Together, they are shaping the future of wind power control systems, driving progress in sustainable energy solutions.
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