Software-Solutions for yield optimization


“Our applications use the information from the rotor blade and directly address important optimization potentials of our industry.”



  Bernd Kuhnle, CSO fos4X GmbH


Applications for optimization of wind turbines

Turbine Load Control

Protect your turbines from overloads, optimize energy yield while staying inside your load design envelope and estimate the virtual age of your turbine with Turbine Load Control.


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Rotor Ice Control

Safely shut down and automatically restart your turbines in case of ice events with Rotor Ice Control. Optimize your heating cycles efforts and effectiveness with precise ice mass measurements.


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Turbine Integrity Control

Detect relevant damages at an early stage and minimize the negative effects with the structural health monitoring system fos4Blade Turbine Integrity Control.


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Turbine Load Control

Blade Load Monitoring with Turbine Load Control

The precise knowledge of the real loads makes it possible to prevent overloading and to operate the wind turbine in a load-optimized manner. In particular, the bending moments of the individual rotor blades and the rotor moments represent important information.

Accurate statements about the virtual age of the turbine also enable an optimization of the annual energy yield within the permissible loads as well as an extension of the company beyond the design life. Thanks to their high stability and synchrony, the measurement data can be used as a direct input for advanced control concepts in series applications such as individual blade control (IPC).

A key role in this is the determination of the rotational matrices for bending moment calculation during operation.

With longer rotor blades, active load reduction mechanisms are becoming increasingly important. Using an existing turbine design for new locations is often the first step.

With reliable blade load measurement, critical system loads can also be minimized and new systems can be designed cost-effectively. In addition, the knowledge of the exact load and the virtual age of the system allows optimized turbine operation and a prolonged service life of the turbine.

Depending on the application scenario, at least one strain sensor in the blade root of each rotor blade and correspondingly a three-channel measuring device is necessary.

If bending moments and in-plane and out-of-plane rotor moments are to be recorded, at least two strain sensors per blade and a six-channel measuring device are necessary.

Three strain sensors per rotor blade are best suited for optimal cost efficiency with maximum availability and precision.

Rotor Ice Control

Optimization of wind turbines with ice detection Rotor Ice Control

Rotor Ice Control is a software solution based on the vibration analysis of the rotor blades.

The rotor blade is a spring-mass system whose natural frequencies vary depending on the weight. From a change in the oscillation behavior, the weight of an ice layer forming on the rotor blade can thus be determined.

Rotor Ice Control is certified by DNV-GL for automatic stopping and restarting also for class M turbines.

The comprehensive performance spectrum of the Rotor Ice Control software offers both turbine manufacturers and operators a relevant added value:

The ice detection prevents possible ice shedding by switching off the turbine in a timely manner. However, the mass signal is also increasingly used for controlling de-Icing systems in order to keep the blades ice-free efficiently and safely. In some locations, depending on the ice mass, a reduced operation of the turbine is controlled. After the ice is defrosted, the ice detection system can also start the system automatically.

Rotor Ice Control significantly optimizes the operation of wind turbines at icing locations.

A two-dimensional vibration sensor (preferably fiber optic) per rotor blade is the basic prerequisite. In addition, an edge computer is necessary to determine the vibration parameters (eigenfrequencies).

We offer a “plug-and-play” solution with a control cabinet to enable a particularly fast integration into new generations of wind turbines as well as retrofit installation for existing systems. Retro-Fit is installed within one day.

Turbine Integrity Control

Condition monitoring with Turbine Integrity Control

The software is a collection of various damage indicators, which can be used for turbine control and in particular for emergency shutdown.

Turbine Integrity Control monitors the condition of the rotor blades and other turbine components. Based on this, for example, flags can be set via a field bus if structural blade damage occurs. In this way, blade damage is detected at an early stage and changes can be used for maintenance planning.

This allows minor repairs to be postponed and also serious impacts on energy yield and turbine integrity can be averted.

Structural damage is a threat to your turbine investment and the profitability of a wind park. Turbine Integrity Control helps you to identify damage early and minimize its financial impact.

In addition, annual energy production is increased through improved maintenance planning and associated increased availability.

At the end of the planned service life, it is possible to decide on the continued operation of the system by determining the “virtual age”.

A two-dimensional vibration sensor (preferably fiber optic) per rotor blade is the basic prerequisite. In addition, an edge computer is necessary to determine the vibration parameters (eigenfrequencies).

We offer a “plug-and-play” solution with a control cabinet to enable a particularly fast integration into new generations of wind turbines as well as retrofit installation for existing systems. Retro-Fit is installed within one day.