Modern innovative wind turbine technologies and a high international reputation require structures development processes, highly motivated staff and much space for creative work.

Based on LARUS technologies, the design process begins with the engineering and layout of machine elements. Further development phases are:

• Definition of subsystems
• Modelling and dynamic simulation
• Development and design of the electrical systems
• Modelling and simulation of the wind turbine's grid behaviour
• Development and design of operational management and safety systems
• Consideration regarding wind park requirements

At W2E, system thinking and the strategy of wind turbine platforms are consistently applied in the development and layout of the hub and spinner, of nacelle and housing, of the cabin cover and the tower.

Definition of subsystems

When it comes to the integration of subsystems such as bearings, drives, lubrication, cooling and hydraulic systems, W2E builds on many years of experience and close cooperation with suppliers in the machine and plant engineering industry.

Modelling and dynamic simulation

To prepare for the certification process and for optimizing operation of the wind turbines, W2E tests the mechanical systems and components  according to the Guidelines of Germanischer Lloyd (GL) and the German Institute for Building Technology (DIBt), using calculations and simulation processes. In this, W2E uses modern wind-specific software. Test procedures such as MultiFlexible Body Dynamics simulation (complete design loads) with extreme and operating loads, the finite elements method (FEM) for simulating the demands of unit components, and dynamic drive train analysis are conducted according to the latest standards. They form the basis for the verification management of systems and components.

Development and design of the electrical systems

W2E is developing electrical systems, analyzing and evaluating various interfaces and designing intelligent solutions for the low-load, non-friction, quiet operation of the wind turbine. The following systems are examined in particular:

• Energy conversion, energy transfer and distribution
• Low-voltage distribution and control
• Yaw system
• Cables and wiring
• Safety systems
• Pitch system
• Backup systems
• Lightning protection, grounding and electromagnetic compatibility

Modeling and simulation of the wind turbine`s grid behaviour

Following the BDEW Medium-Voltage Directive, the Transmission Code 2007 as well as other grid codes, W2E supports its customers by measuring the behaviour of the wind turbine during power outages. 

At the same time, modeling of the wind turbine's behaviour in the grid of electrical utilities is performed. Modeling includes the wind turbine's controllers and the converter to present the momentary values of the physical values to be examined, such as currencies, voltages, performance, moments and rotational speed.

In simulation, the behaviour at short circuiting  and in voltage drops, such as Fault-Right-Through (FRT) is replicated. Basis is the PowerFactory system by DIgSILENT. Objectives in Germany are unit and plant certificates.

For the 2.5 MW wind turbines, a PSS/E model for wind park projects can already be called upon.

High-resolution modeling of the drive train, energy conversion (generator / inverter) and the pitch system  is performed as well.

Development and design of operational management and safety systems

The  central core of every wind turbine is operational management. Here, the smooth, safe and high availability of the wind turbine is accomplished through distinct structuring and interface definition as well as clear system thinking - by means of intelligent control cycles and much experience in the programming of control processes.

The safety-oriented machine control is defined via LARUS Safe®, a Safe Matrix System developed by W2E in accordance with the Norm ISO 13849-1. By means of event-oriented differentiated activation, forces and moments as extreme loads are reduced.

As well, fire protection and aircraft warning lights are developed and adapted for each wind turbine platform.

Considerations regarding wind park requirements

W2E looks at the interface between an individual wind turbine and wind park management in relation to control and the collection of operating data.