The TRM triflex Rotation Module allows for reliable rotary movement of power and data cables in nacelles of up to 1,800°

The reliability of energy and data cables has the potential to increase the economic efficiency of wind turbines. With the TRM triflex Rotation Module (TRM for short), igus is therefore launching a new type of cable guide on the market that reliably protects cables in flexible energy chains made of high-performance plastic when the nacelles rotate by up to 1,800°. The compact system is the result of a design study and can be pre-fitted and customised to individual applications.

Wind turbines are often located in remote areas, making maintenance work expensive – especially for offshore turbines. It is therefore crucial for the systems to be fail-safe. This also places high demands on the installation of the numerous cables that supply the generator, gearbox and control systems in the nacelle with power and data from the ground. “As the nacelles of the wind turbines are constantly moving so as to align themselves optimally with the wind, the cables are exposed to heavy loads over time. A cable break is extremely annoying in this environment and usually requires an expensive and time-consuming repair,” says Michael Berteit, Sales Manager Engineering Projects and Installation Service at igus. “In a design study, we developed the TRM – an innovative and compact cable guidance system that safely guides and reliably protects the cables when the nacelle rotates. This increases the reliability of wind turbines and thus their economic efficiency.” The pre-series version of the new module is being configured and will be available from October 2024.

Rotary movements of up to 1,800°

The TRM works as follows: the system is located in the upper tower end of the wind turbine, directly under the nacelle. Inside, five triflex energy chains run parallel to each other, filled with energy and data cables. The e-chains can move in three dimensions and have flexible chain links made of high-performance plastic that form a ring-shaped structure. This allows the triflex to perform a rotational movement around a central axis. “When the nacelle rotates, the upper part of the TRM moves in synchronisation with the energy chain. A movable support structure inside the system ensures that the energy chain always maintains its bend radius and is securely positioned at all times,” explains Berteit. Thanks to this controlled guidance, the cables can perform rotational movements of up to 1,800° without tangling or kinking. “This enables the operators to turn the nacelle up to five times around its own axis in one direction without being forced to work quickly against the wind. This keeps the alignment of the system safe and energy-efficient.”

Pre-fitting saves 50% assembly time

Another goal of igus was to save users of the new cable guidance system space and installation time. “We have designed the module to be compact. With an external diameter of just 1,300mm and an installation height of less than 1m, it only requires minimal space around the rotary axis,” says Berteit. In addition, users can conveniently equip the system with the required cables on land or receive it fully harnessed from igus. Here, igus offers cables from the chainflex range. They permanently withstand torsional loads, function reliably even under adverse environmental influences such as strong temperature fluctuations and thus further increase the reliability of wind turbines. “Thanks to the pre-fitted rotating energy supply TRM, the assembly time on site at the plant, which is often associated with very high costs, can be reduced by up to 50%,” emphasises Berteit.