Detecting potential issues in wind turbine blades before they become major or catastrophic problems is a growing focus for 8.2 within condition monitoring. Traditionally used to monitor gearboxes and drivetrain systems, condition monitoring technology is now being adapted to detect hard-to-see defects in turbine blades, which are constantly exposed to harsh environmental conditions.

Wind turbine blades, often exceeding 50 meters in length, have various failure points. Common issues include holes at the blade tips, bond line failures, interior structural cracks, and leading-edge erosion. Monitoring these areas requires understanding how different blades, based on their manufacturer and design, may fail. The goal of blade condition monitoring is to address these serial issues across similar turbine models rather than attempting to solve every potential issue.

Effective blade condition monitoring follows three principles: targeting specific failure modes, using direct measurement techniques beyond SCADA data, and ensuring the solution works at scale for thousands of turbines worldwide. To address this, equipment must be durable, easy to install, and operate efficiently in challenging weather conditions.

A key failure mode involves the blade root insert, where bolts secure the blade to the hub. If the bushing holding the bolt loosens, it can lead to fatigue and eventual blade failure. Repairing such damage is difficult, often requiring complete blade replacement. Catastrophic failures can shut down entire wind farms, sometimes resulting in government intervention.

While visual and drone inspections are commonly used, they are costly and may miss hidden cracks or defects. 8.2 uses the ecoPITCH monitoring system, which tracks the blade joint's integrity, monitoring around 3,000 blades worldwide. This system can detect issues early, allowing repairs before they become too severe.

Adapting strain sensors, originally designed for pitch bearings, to monitor blade cracks is part of the ongoing development of the system. By expanding predictive maintenance to blade monitoring, wind farm operators can reduce unplanned repair costs, which are often significant, making their operations more efficient.

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