In the realm of wind energy, reliability and safety are paramount, especially under the most extreme conditions. The barrier fan, a critical component in wind turbines, relies on advanced control systems to ensure stable and efficient operation. Among these, the Beckhoff CX9020 Embedded Controller stands out for its robust performance in controlling pitch systems, even in environments with extreme temperatures.
Dongfang Electric Wind Power Co., Ltd. (DEW), based in Deyang City, Sichuan Province, is a leading company 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 units—both direct-drive and doubly-fed—to domestic and international clients. A key innovation in their operations has been the integration of Beckhoff’s PC-based control technology into wind turbine pitch systems, allowing them to maintain high performance and efficiency across various conditions.
The pitch system plays a vital role in managing wind turbine performance by adjusting blade angles according to different operational states. When wind speeds are below the rated level, precise adjustments ensure optimal aerodynamic efficiency, even in unstable conditions. When wind speeds exceed the rated threshold, the system adjusts blade angles to maximize power output while keeping it within safe limits. In emergency situations, such as severe faults, the pitch system can automatically feather the blades to stop the turbine, ensuring the safety of the entire unit.
To meet the demanding requirements of extreme environments, DEW developed its own pitch system, using AC servo drives and motors for their simplicity, reliability, and cost-effectiveness. The system includes three identical axis control units, each with a backup power supply, a pitch motor, redundant encoders, and limit switches. At the heart of this system is the Beckhoff CX9020 embedded controller, equipped with EtherCAT terminal modules, providing fast response times and flexible communication interfaces.
The CX9020 is designed to operate in a wide temperature range of -25°C to +60°C, making it ideal for harsh environments. It runs custom-developed software that controls blade pitch, monitors real-time status, and manages fault codes. The system also uses the EL6751 CANopen slave terminal module to enable seamless communication between the main controller and the fan master controller, ensuring reliable data exchange.
Additionally, the CX9020’s RS485 interface monitors the backup power charger, while its network interface supports online access for software updates and diagnostics. This level of integration and flexibility significantly enhances system reliability and ease of maintenance.
Programming the system was made easier with Beckhoff’s TwinCAT software, which supports multiple IEC 61131-3 languages and advanced programming tools. Engineers at DEW reported a significant reduction in development time, thanks to the support from Beckhoff China. As Li Bo, an R&D engineer at DEW, stated, “TwinCAT helped us streamline our software development process.†He also highlighted the potential for future collaboration between DEW and Beckhoff to further advance China’s new energy sector.
With over 7,000 wind turbines delivered globally, DEW continues to lead in wind power control systems, leveraging cutting-edge technologies like the Beckhoff CX9020 to maintain a competitive edge in the renewable energy market.
Wenzhou Hesheng Electronic Co., Ltd. , https://www.heshengelec.com