A wind farm was experiencing premature failures on their wind turbine generators. After an initial inspection of a particular generator, it was determined that the rotor connection had failed prematurely. Wind turbines that utilize DFIG generators (wound rotors) have a 61% failure rate in the rotor connection due to the inability to accommodate centrifugal expansion of the rotor winding/banding during operation.
IPS recommended installing our patent pending engineered upgraded rotor connection. This upgraded rotor connection accounts for the centrifugal expansion of the rotor winding/banding during operation preventing low cycle fatigue and eliminating main lead failure modes. The upgraded rotor connection life expectancy is 2+ times longer than the OEM, but also minimizes downtime and maintenance costs since the upgrade can be performed up-tower.