Engineering rather than individual components
Developing, integrating and operating pitch systems more quickly
KEBA pitch systems are pre-qualified, modular system solutions for wind turbines that combine hardware, software and engineering into an integrated pitch design – for faster development, reduced complexity and greater system reliability. The solution combines an axis box with a pitch servo drive and energy backup system, a pitch motor including encoder and brake, PLC integration and fieldbus communication, as well as engineering, simulation and validation.
Benefits for turbine manufacturers and operators:
- Faster development and time-to-market thanks to standardised documentation
- Cost efficiency through fewer system components
- Greater efficiency and safety thanks to pre-qualified components
- Retrofit capability with local manufacturing and support
- Greater system stability and lower maintenance costs
What do KEBA pitch systems include?
The Pitch System Design provides a comprehensive guide to the construction and integration of state-of-the-art pitch technology into wind turbines. The PitchOne System Design incorporates optimised and pre-qualified core components that enhance the performance and durability of the wind turbine.
Our engineering team will assist you in evaluating and designing your system to ensure it is perfectly tailored to your specific requirements . A ready-to-use documentation package, including an E-Plan, bill of materials and drawings, facilitates implementation.
In addition bespoke engineering services are offered, including motor and backup sizing as well as software support for integration into turbine automation, to develop tailor-made solutions..
Fewer components. Less cost, less complexity.
The integration of PitchOne reduces development, wiring, and maintenance efforts by integrating features such as DC-DC converters, safe I/O, and power management.
Up to 20% smaller power components thanks to the integrated DC Boost function.
With PitchOne the following are eliminated:
- External safety controls
- Additional 24V supplies
- Multiple wiring components
- additional interfaces
This makes it possible to:
- Smaller power components
- More compact control cabinets
- Less maintenance
- Reduced system costs
Greater safety and higher availability through integrated functional safety
PitchOne integrates certified safety functions such as Safe Feathering Run, Safe Gear Monitoring and DC/DC Monitoring directly into the pitch system, thereby enabling controlled turbine operation even in the event of grid fluctuations or faults.
Enhanced security monitoring
The safety functions Safe Blade Position Monitoring (SGM) and internal power supply monitoring (DC/DC Monitoring) are included. These functions detect critical faults at an early stage and help ensure safe and reliable plant operation.
Safe feathering run (SFR)
Controlled safety run in the event of a fault
with customisable profiles for different load conditions, reducing material stress and enhancing operational safety.
Safe Pitch Service Mode (SPSM)
Supports maintenance work by ensuring safe axis movements during servicing. Reduces servicing times and helps to improve system availability.
Safe Final Position Run (SFPR)
Blades can be individually positioned in predefined positions, thereby reducing the load and synchronising the restart.
PitchOne TÜV Certification
The PitchOne offers a range of safety functions in accordance with EN ISO 13849 und IEC 61508 to ensure the safety of the wind turbine and the safety of service personnel. The Pitch system (2oo3) ensures safety level PLe in accordance with ISO 13849.
Technical Specifications
PitchOne
 | Energy Backup System
 | Pitch-Motor
 |
|---|---|---|
| Maximum Power: up to 57 - 176 kVA | Rated capacity: 10F | Rated torque: 25,5 Nm |
| High Voltage Ride Through (HVRT)Withstand Capability: up to 140 % - 180 % | Max. rated voltage / string voltage: 160 V / 800 V | Peak torque: 87 Nm |
| Peak Output Current: up to 65 - 230 Arms | Max. cont. Current / peak current: 7-11 A (dT 15-40°C) / 200 A | Operating temperature: -20° C/+60° C |
| Energy Storage Voltage: up to 550 V | Projected life Time: 8-10 years | Brake with static torque: 65 Nm |
| Energy Storage charging/discharge current: up to 150 A/450 A | Project cycle life: 500 000 cycles (160V, 25°C, -20% cap.) | Corrosion class: C4-H |
Typical applications
The realized projects can be applied to other turbine designs or retrofit concepts.
Wind turbine OEMs
Development of a modular pitch system for wind turbines with a focus on short development times, simple turbine qualification and flexible adaptability. The TÜV-certified drive technology and a design-validated system reduce the qualification effort. In addition, customer-specific engineering enables the engine and backup system to be optimally designed for different turbine requirements.
Realized projects:
- DesignIn Project
- Indian OEM
- Pitch system produced locally in India
Retrofit projects of existing plants
Development of a pitch retrofit solution to reduce downtime and obsolescence risks. By modernizing existing systems, performance losses are minimized, the service life of wind turbines is extended and cost-intensive repowering measures are avoided.
Realized projects:
- Retrofit solution for existing fleet
- USA based partner network
- Designed for local manufacturing capabilities (Europe, US, India, China)
FAQs
Everything you need to know about our BluePrint solution for pitch systems.
Here are the answers to the most frequently asked questions.
You might also be interested in
TÜV Certification for Pitch Servo Drives
Pitch systems in wind turbines must meet the highest safety standards.
PitchOne Overview
Learn more about the innovations and benefits of the pioneering PitchOne servo drives for wind turbines.
Pitch Control and Yaw
Learn more in our blog article about our pitch control and yaw systems for the optimal design of wind turbines.
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