In view of the frequent and costly failures of power converters in wind turbines, a large consortium of research institutes and companies has joined forces to investigate the underlying causes and key driving factors of the failures. This paper presents an exploratory statistical analysis of the comprehensive field data provided by the project partners. The evaluated dataset covers converter failures recorded from 2003-2017 during almost 7400 operating years of variable-speed wind turbines of different manufacturers and types, operating at onshore and offshore sites in 23 countries. The results include the distribution of failures within the converter system and the comparison of converter failure rates among turbines with different generator-converter concepts, from different manufacturers as well as from different turbine generations. By means of combined analyses of converter-failure data with operating and climate data, conditions promoting failure are identified. In line with the results of a previous, much smaller study of the authors, the present analysis provides further indications against the wide-spread assumption that thermalcycling induced fatigue is the lifetime-limiting mechanism in the power converters of wind turbines. Instead, the results suggest that humidity and condensation play an important role in the emergence of converter failures in this application.

This review article aims to provide an overview and insight into the most relevant aspects of wind energy development and current state-of-the-art. The industry is in a very mature stage, so it seems to be the right time to take stock of the relevant areas of wind energy use for power generation. For this review, the authors considered the essential aspects of the development of wind energy technology: research, modeling, and prediction of wind speed as an energy source, the technology development of the plants divided into the mechanical and electrical systems and the plant control, and finally the optimal plant operation including the maintenance strategies. The focus is on the development in Europe, with a partial focus on Germany. The authors are employees of the Fraunhofer Institutes, Institute for Energy Economics and Energy Systems Technology and Institute for Wind Energy Systems, who have contributed to the development of this technology for decades.

The frequent power-converter failure experienced in wind turbines has a strong economic impact through both the related turbine unavailability and the maintenance cost. Up to now, the prevailing mechanisms and causes underlying the converter failure in wind turbines are mostly unknown. Their identification is, however, a prerequisite for the development of effective solutions. This paper describes a multi-track empirical approach to failure analysis including systematic field-data evaluation, exploration of the real converter operating environment, and post-operational laboratory investigation of converter hardware. The analysis is carried out for two widelyused multi-MW wind turbines with low-voltage, IGBT-based converters (topology 1: doubly-fed induction generator with partially rated converter, topology 2: induction generator with fully-rated converter). The findings suggest that the principle failure mechanisms of power electronics found in other applications, namely solder degradation and bond-wire damage, play a minor role in the investigated types of wind turbines. Instead, the analysis reveals indications of insufficient protection of the converter hardware against the environment (salt, condensation, and insects) as well as indications of electrical overstress.Index Terms-wind turbine, converter, reliability, failure, root-cause analysis, power electronics I. INTRODUCTIONOWER converters are a frequent source of failure in modern wind turbines. In a reliability field-study on pitchcontrolled, variable-speed onshore wind turbines with rated capacity ≥850 kW, in which more than 31000 downtime events were evaluated, the frequency converters were found to Manuscript

Power converters are among the most frequently failing components of wind turbines. Despite their massive economic impact, the actual causes and mechanisms underlying these failures have remained in the dark for many years. In view of this situation, a large consortium of three research institutes and 16 companies, including wind-turbine and component manufacturers, operators and maintenance-service providers has joined forces to identify the main causes and driving factors of the power-converter failures in wind turbines to create a basis for effective remedial measures. The present paper summarizes and discusses the results of this research initiative, which have been achieved through the evaluation of converter-specific failure and operating data of a large and diverse worldwide wind-turbine fleet, field measurements as well as post-mortem investigation of returned converter components. A key conclusion of the work is that the thermal-cycling induced fatigue of bond-chip contacts and die-attach solder, which is a known issue in other fields of power-electronics applications and which has been widely assumed to be the principle damage mechanisms also in wind turbines, is no relevant contributor to the observed converter failures in this application. Instead, the results indicate that environmental factors such as humidity and contamination but also design and quality issues as well as human errors play an important part in the incidence of these failures.

Abstract:Oil condition monitoring is a common practice in the wind industry. However, the published research about oil degradation in wind turbine gearboxes is limited. This paper aims at providing new information on the oil degradation process by analyzing wind turbine gearbox oils aged in the laboratory and in the field. Oil samples were analyzed in the laboratory and two sensors were used to determine the oil condition by means of dielectric constant and conductivity measurements. Additionally, micropitting tests were carried out for three oils with different base stocks. The results of this study show that viscosity changes of the oils from the field were not significant.Extreme pressure additives depletion and the increase of the iron content are among the most relevant degradation indicators. The oil sensors used in this study provided limited information on the oil degradation process. The accuracy of the sensors was affected by the oil type and its measurement range. The results of the micropitting tests showed that even aged oils exhibited a high micropitting resistance.

The signal of the drive train mechanical torque can be a very informative input for new technologies on the wind turbine, helping further reducing the cost of energy. However, measuring the mechanical torque is not an easy task even during a test campaign on a prototype. In case of the long‐term measurement for operational purpose of use on the turbine, it is often considered as technically and economically not feasible. This paper discusses possible ways of the torque measurement and presents a test campaign where two different methods of torque measurement are conducted. One of the methods measures the shear strain signal using strain gauges at one section of the turbine main shaft. The other method measures the torsional deformation between two positions of the drive train, with an incremental encoder measuring the angular position of the drive train at each position. The tests are conducted on an 8‐MW wind turbine drive train under tests on the nacelle test bench “DyNaLab” of Fraunhofer IWES. During the tests, different load steps of torque and other load components are applied to the drive train. The measurement results from both measuring methods are presented and analysed. In the end, technical and economical feasibilities are discussed for both methods of torque measurement; some suggestions are also given respectively.

This paper presents the design and implementation of a hardware-in-the-loop testing framework, for electrical certification of wind turbine nacelles on a dynamometer test rig. This is to enable a realistic test environment in the laboratory, comparable to that in the field. Assessment of electrical properties of wind turbines are usually executed in the field for the complete prototype, however, in the laboratory, missing system components have to be emulated and the effect of test rig’s own actuators are to be attenuated. Therefore, implementation of an adequate real-time wind turbine simulation tool, an efficient control system for the test rig drive train, and a real-time automation system are considered and presented here. Furthermore, execution of type certification experiments according to national and international guidelines is described here and illustrative measurements are provided. The measurements in this case are obtained at Dynamic Nacelle Laboratory, while testing with the Enercon E-115E2 turbine. The results achieved demonstrate successful test execution in the laboratory and declare the advantage of test rigs.

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