Transportation of energy inside wind turbines is set to become more cost-effective with Nexans’ new solution in low-voltage aluminium loop cables and associated accessories. The flexible system, available for connections up to 1 kV, can withstand the torsional cycling caused by nacelles rotating with the wind. By producing lighter, more flexible cable, this development highlights the cost-effectiveness of wind energy globally, taking the renewable energy sector a step forward in its vision of providing reliable green energy worldwide.
Nexans has developed this WINDLINK® solution, including aluminium loop cables, connectors and lugs for wind turbine generators that are lighter than traditional copper cables. This cable forms a loop in the nacelle so it can withstand torsion as the nacelle moves with the wind. It then transports power down from the nacelle to the fixed section along the tower to the transformer. This new flexible aluminium loop solution complements the existing offer for a lower fixed section in aluminium rigid cable.
The lower density of aluminium means these cables are about 40% lighter than traditional copper counterparts and therefore easier to install inside wind turbines. The system’s design life is expected to match the wind turbine generator life.
The new aluminium loop cables and their special accessories have been in development for three years, including rigorous lab testing. Nexans faced the challenge of developing flexible aluminium cables and accessories that could withstand nacelle movement and were more cost-effective, lighter, and more flexible. Nexans tested multiple aluminium alloys to find the best-performing solution. In torsional tests, the chosen aluminium cables withstood at least ±100 degrees/meter of torsion for at least 2,000 cycles while delivering performance comparable to traditional copper cables. Nexans has also developed the connectors and lugs that have undergone ageing testing in a third-party laboratory.
The complete solution will be manufactured at Nexans’ Bohain plant in France and at the Hof factory in Germany.
Original announcement: Nexans
Image: Courtesy of Nexans
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