Siemens Gamesa (SG) is among the world’s leading wind turbine manufacturers, with nearly 100 GW installed worldwide. In connection with establishing a new factory in Cuxhaven, Germany, SG recognized the need for a faster and more flexible test system to future-proof the production of wind turbine generators.
A test system that could easily be reconfigured to measure future—possibly radically different—generator models, and that in the long term could be rolled out to the many other diverse production lines at the factory.
Siemens Gamesa needed a more flexible and future-proof test system for generator production that could handle long test sequences, different generator models, and interchangeable measurement instruments—without compromising measurement accuracy.
Implementation of GPower ProFactory based on NI TestStand and Switch Executive, combined with Devizer instrument drivers and the development of specialized measurement equipment for precise generator testing.
A modular and scalable test system that gives Siemens Gamesa greater production flexibility, precise and stable measurements, and the ability to easily replace instruments and reuse test setups across production lines.
With ProFactory, we have a complete system for testing our wind turbine generators. While we previously faced challenges with automated testing in terms of system flexibility and repeatable measurement results, GPower has developed a safe and modular test system in which we can easily and quickly replace our instruments while still performing highly accurate measurements.
– Roar Poulsen, Siemens Gamesa
The requirements included, among other things, that a test could be paused and resumed later, because generator tests are very time-consuming and the production line could then be used for suddenly arising needs. It was also important to no longer be dependent on specific measurement instruments, but instead have the option to replace instruments depending on availability—without compromising the measurement results.
Generators of the high quality that SG produces are tested with high voltages and currents, and their insulation resistance must be verified in the giga-ohm range. A 200-ton generator also has a certain physical size, so all measurements must be accurate and stable over long cables. Therefore, in addition to meeting the high requirements for test system flexibility, we also had to contribute our extensive know-how in physics and measurement technology—for example, in the selection of measurement instruments, relays, connections, and measurement methods that met the very high requirements for stable generator testing.
A key objective was, for example, to develop a new instrument for measuring resistance in the generator windings, as no existing measurement instrument could meet the requirements for measurement current and accuracy.
GPower is a competent and preferred supplier that—besides being leading experts in test and measurement—also succeeds in managing project management across everything from schedules and budgets to subcontractors.
– Roar Poulsen, Siemens Gamesa
The project was completed in the summer of 2020, when the system was integrated into the electrical and mechanical installations. The complete system is now installed at SG’s factory, where it tests generators for their wind turbines.
As a result, it will not be possible to complete purchases today, and throughout the day only the Danish version of the website will be available.
If you have any questions, or if you would like to make a purchase during the day, you are—as always—very welcome to contact us:
Gabrielle, Marketing Manager: +45 5190 5790.
Thank you for your understanding—we look forward to welcoming you to our new website!
