Bench Talk

How Renewable Energy Runs Better with Smart Sensors

(Source: Jack Tamrong /stock.adobe.com)

Equipment failures in alternative energy systems can have serious consequences. A single pump malfunction could force an entire hydropower plant to go offline for weeks. In wind power, a gearbox failure does more than just stop the turbines—it can lead to dangerous and costly repairs. In addition to the financial impacts, these outages can cause the public to question the reliability of renewable energy.

Over a two-year period, an analysis of more than half a million operational records found 28 failures in components like generators, bearings, gearboxes, and transformers.^[1] These incidents highlight the variety and complexity of challenges faced by alternative energy systems. Many of these challenges stem from the environments in which these systems function. Wind turbines and hydropower plants operate in harsh conditions and are exposed to extremes of temperature, moisture, and mechanical stress. When something goes wrong, remote locations and difficult access make repairs complicated and costly.

Predictive maintenance helps prevent these costly disruptions, but manual inspection of such installations is slow, labor-intensive, and ineffective at times. For example, visual inspections of wind turbines from the ground provide little information about the condition of gearboxes and generators, while climbing the tower is time consuming and poses significant risks for engineers. Despite these difficulties, operators need to understand the condition of critical components to catch small problems before they become big failures.

In this blog, we detail the challenge of precise, early fault detection of critical components within renewable energy systems and explore an IoT sensor solution specially designed for wind and hydropower facilities.

The Engineering Challenge: Keep the Wheels Turning

Wind turbines and hydropower plants rely on mechanical components to generate electricity. In wind turbines, gearboxes and bearings convert rotational energy, while hydropower plants rely on pumps and generators to harness the force of moving water.

All these components endure heavy loads and constant wear. If a minor issue, like a crack or loose bearing, goes unnoticed, it can become a major failure and shut down the entire facility. Repairs can take weeks or even months, leaving energy providers scrambling to restore operations. The consequences can also include energy shortages that disrupt the businesses and communities needing a steady power supply.

Mechanical issues do not just appear overnight. They develop gradually. Early warning signs like subtle vibrations, small temperature fluctuations, or minor drops in efficiency are easy to miss.

Routine maintenance checks might catch these issues, but only if they occur at the right time. Often, by the time a problem is obvious, the damage is already done. To tackle these challenges, engineers need systems that monitor equipment continuously. With advanced sensor technology and predictive analytics, operators can spot potential failures before they happen and keep equipment running smoothly.

Enhancing Reliability with Wireless Vibration Monitoring

Due to the nature of their operation and the consequences of mechanical failures, wind and hydropower facilities must maintain continuous and effective equipment performance. To help in these efforts, TE Connectivity’s IoT Wireless Vibration Sensors enable early detection of potential problems, giving maintenance teams the insight they need to take action before a minor issue turns into a costly breakdown (Figure 1).

These sensors can identify the smallest changes in vibration, making it easier to spot misalignment, bearing wear, and lubrication issues. While traditional wired vibration monitoring systems are capable and can catch these early warning signs, the wireless functionality of TE Connectivity’s sensors eases deployment and provides engineers the scalability necessary in dynamic renewable energy applications, where obtaining a detailed and accurate picture of machine health can be an evolving challenge. The TE IoT Wireless Vibration Sensors offer a wide bandwidth, with superior resolution of up to 10kHz, compared to 4kHz in standard MEMs-based models.

Figure 1: TE Connectivity’s Wireless Vibration Sensors offer a wide bandwidth with superior resolution of up to 10kHz, short and long-range reach with edge computing for user-configurable settings, and 2100mAh battery capacity for up to 10 years of battery life in a compact IP66/67 piezoelectric core design that requires minimal maintenance and supplies excellent stability over the long term. (Source: Mouser Electronics)

Unlike wired monitoring systems, which can be expensive and difficult to install, TE Connectivity’s wireless sensors use industrial communication protocols like LoRaWAN and Bluetooth^®. They can easily integrate into existing infrastructure with minimal disruption and without requiring extensive cabling or costly retrofits. In addition to streamlining integration, these wireless sensors provide advantages in lifespan, durability, and performance.

Battery life is a crucial consideration in remote monitoring applications. In wind farms and hydropower facilities, sensors are often installed in hard-to-reach locations, making it difficult to replace batteries frequently. TE Connectivity’s sensors allow operators to prioritize equipment repairs and failure prevention rather than sensor upkeep. The sensors’ 2100mAh battery capacity provides long operational life of up to 10 years, and their stable, solid-state 1-axis or 3-axis accelerometer piezoelectric design requires little maintenance and delivers excellent long-term reliability.

Renewable energy sites demand rugged, reliable monitoring solutions capable of withstanding tough operating conditions. These wireless vibration sensors feature IP66/67-rated housings that protect against dust, water, and harsh weather conditions. They also meet multiple Atmosphere Explosible (ATEX), National Electrical Code (NEC), Canadian Standards Association (CSA), Conformité Européenne (CE), and Federal Communications Commission (FCC) standards, making them suitable for environments where explosive gases or dust may be present.

TE Connectivity’s vibration sensors are already making a difference in the field. On wind farms, the difficulties posed by manual inspection have made TE Connectivity’s sensors an ideal method for monitoring long-term performance in remote locations. They can be fitted easily, as they are available with a range of mounting accessories, including stud, magnetic, and adhesive options, and their wireless functionality removes the need for physical wiring. The sensors are even configurable after installation using TE Connectivity’s SensorConnect App, allowing them to be updated as required.

In hydropower plants, they detect early signs of pump cavitation and generator imbalance. Since these facilities rely on steady turbine and pump operation, any disruption can impact energy output. By providing real-time machine health data, these sensors help operators catch issues early and avoid consequential shutdowns.

Conclusion

As renewable energy continues to grow, it is necessary to have smarter, more efficient monitoring solutions. Advanced sensor technology is critical in optimizing performance and ensuring long-term reliability.

TE Connectivity's IoT Wireless Vibration Sensors are transforming how maintenance is approached in the renewable energy industry. With wireless LoRaWAN and Bluetooth connectivity, these sensors enable seamless integration into existing infrastructure, eliminating complex wiring and making deployment more efficient. Their long-lasting battery life ensures continuous operation, reducing the need for frequent replacements or maintenance.

By enabling early detection, these sensors improve efficiency, cut costs, and keep systems running reliably. As wind and hydropower continue to expand, advanced monitoring technology will play a key role in safeguarding the sustainability and longevity of renewable energy assets.

[1] https://www.frontiersin.org/journals/energy-research/articles/10.3389/fenrg.2022.904622/full.

Author

David Pike is well known across the interconnect industry for his passion and general geekiness. His online name is Connector Geek.