Combined temperature and vibration monitoring device for wind turbines

Abstract

A condition monitoring device for wind turbines, consisting of a microcontroller for processing sensor data, an infrared temperature sensor for non-contact measurement of component temperatures, a vibration sensor for detecting rotation signals, a wireless communication module for transmitting measured values ​​and warning messages, and a power supply, wherein the device analyzes temperature and vibration characteristics to detect anomalies and support preventive maintenance.

Description

AREA OF INVENTION

[0001] The invention relates to devices for condition monitoring of wind turbines, which integrate non-contact temperature measurement, vibration measurement, embedded data processing and wireless connectivity for real-time condition assessment and predictive maintenance. BACKGROUND OF THE INVENTION

[0002] Wind turbines operate under variable mechanical and environmental stresses that accelerate the wear of bearings, gearboxes, generators, and brakes. Unplanned failures cause costly downtime and consequential damage. Therefore, continuous condition monitoring is essential to detect anomalies early and proactively plan maintenance. Vibration analysis is a proven diagnostic method for rotating machinery. Accelerometers and spectral methods identify imbalance, misalignment, and bearing damage. Modern systems utilize triaxial sensors and machine learning to improve fault classification and remaining service life prediction. Temperature measurements complement vibration analysis, revealing lubrication deficiencies, frictional heat, and thermal runaway in components such as bearings and brake interfaces.Non-contact infrared sensors like the MLX90614 enable safe and precise measurements on moving parts without mechanical coupling. Integrating temperature and vibration into a single compact, networked device allows for validation of readings from different sensors and more robust detection under varying wind and load conditions. This supports predictive maintenance strategies used in the wind energy industry to maximize availability and energy yield. SUMMARY OF THE INVENTION

[0003] The invention relates to a combined condition monitoring device, CCM_WTGSTMote, consisting of a TI MSP430 microcontroller board as the main processing unit, an ESP-01 Wi-Fi communication board for network connectivity, an MLX90614 infrared temperature sensor for non-contact temperature measurement, a vibration sensor for rotational condition diagnostics, and a power supply suitable for nacelle or tower mounting. The device acquires synchronous temperature and vibration data, performs internal preprocessing and analysis, and transmits condition indicators and alerts to a remote monitoring platform for wind turbines. Embedded algorithms calculate spectral and statistical vibration characteristics and correlate them with temperature trends to detect anomalies.This enables preventive measures such as planned lubrication, torque reduction or shutdown before a catastrophic failure, thus maximizing uptime and optimizing operational efficiency. DETAILED DESCRIPTION

[0004] The CCM_WTGSTMote incorporates a TI MSP430 microcontroller board configured as the main processor for sensor connectivity, signal conditioning, feature extraction, and local decision logic. Its low-power architecture enables continuous monitoring with deterministic timing for synchronous sampling of multiple inputs. An MLX90614 infrared temperature sensor allows for non-contact measurement of component surfaces. It integrates a thermopile, a 17-bit ADC, and a digital interface to achieve high accuracy and resolution in the typical temperature range of -20 to 120 °C. It is suitable for bearings, housings, and brake elements in rotating assemblies. The vibration sensor element can be a single- or three-axis accelerometer mounted near bearings or gears, capturing characteristic error frequencies at sufficient sampling rates.Preprocessing includes anti-aliasing filtering, windowing, and FFT-based spectral analysis to calculate RMS, kurtosis, crest factor, and band energy. The MSP430 combines temperature and vibration measurements to enhance diagnostic reliability. It differentiates transient load effects from permanent faults by comparing temperature rises with vibration signatures that indicate wear or misalignment under variable wind conditions. Connectivity is provided via an ESP-01 Wi-Fi card, which transmits aggregated measurements, raw data, and alerts to a monitoring system. Where Wi-Fi is unavailable, the module can communicate with alternative gateways, ensuring secure telemetry for fleet monitoring.The device supports wireless configuration of sampling rates, thresholds, and feature sets, as well as firmware updates to provide enhanced anomaly detection and fault classification models tailored to specific turbine models. Power is supplied via a nacelle-compatible, conditioned source with overvoltage and undervoltage protection. Optionally, power can be harvested from the turbine's auxiliary power lines or the environment to extend operating time. Installation kits include mounting brackets and alignment aids to position the MLX90614 with a clear line of sight to the target components and to mount accelerometers for optimal transmission accuracy. This ensures reproducible measurements across different turbines and operating cycles.The remote platform aggregates device data across multiple systems, captures temperature and vibration indicators, uses machine learning for early fault detection, and generates maintenance orders that reduce downtime and spare parts costs. By combining non-contact temperature measurement and vibration diagnostics in a single compact sensor, the system delivers robust, real-time condition information for wind turbines, thereby improving their reliability and energy production through predictive maintenance.

Claims

[1] A condition monitoring device for wind turbines, comprising a microcontroller for processing sensor data, an infrared temperature sensor for non-contact measurement of component temperatures, a vibration sensor for detecting rotation signals, a wireless communication module for transmitting measured values ​​and warning messages, and a power supply, wherein the device analyzes temperature and vibration characteristics to detect anomalies and support preventive maintenance. [2] Device according to claim 1, wherein the microcontroller comprises a TI MSP430 configured to perform synchronous sampling, spectral analysis and feature extraction of vibration signals while simultaneously reading digital temperature measurements from the infrared sensor. [3] Device according to claim 1 or 2, wherein the wireless communication module comprises an ESP-01 Wi-Fi card configured to transmit aggregated health indicators, raw data snapshots and configuration updates to a remote monitoring platform for wind turbines. [4] Device according to one of the preceding claims, wherein the infrared temperature sensor comprises an MLX90614 with integrated thermopile and 17-bit ADC, enabling accurate non-contact temperature measurement in the range of -20 to 120 °C for monitoring bearings and housings.