Detecting wire breaks in post-tensioned tendons of wind turbines: A signal energy spectrum analysis approach

Abstract

In the wind industry, recent advancements have led to the research and development of wind turbines featuring hybrid towers, a novel combination of steel tube and precast concrete segments. These concrete modules, which absorb the high stresses caused at the intersection between the tower and its foundation, are commonly joined with post-tensioned tendons. This study focuses on the identification of wire breaks in post-tensioned tendons through the application of acoustic emission testing. Measurements involve the evaluation of wire breaks under controlled laboratory conditions and the analysis of the dynamic operational environment of a functioning wind turbine. The investigation encompasses the development and assessment of a methodology based on principles of discrete Fourier transformation and Parseval’s theorem for analyzing the frequency-dependent energy distribution of acoustic signals. This analytical approach extends to the examination of wire breaks generated under varying stress levels as well as the operational noise within the actual wind turbine. The findings demonstrate a notable concentration of energy within the frequency range of 5-20 kHz in the wire break signals. In contrast, the operational noise signals show a distinct pattern, presenting an extreme value distribution within the 0-2 kHz range. The developed methodology exhibits robustness, even in the presence of high background noise levels, establishing itself as a valuable tool for wire break detection. Additionally, its potential for integration with machine learning algorithms offers the prospect of automated wire break detection, enabling further advancements in structural health monitoring for wind turbines.