Test facility for torsionable

cables and connections

in wind turbines
Cable loop – the key component in the wind turbine

Strong torsional forces act on the cable loop and cause stressing of all power and data connections in the loop. During
a planned life cycle of around 20 years, these cables are subjected to up to 15,000 torsion cycles. These enormous
stresses applied to the cables require not only quality but also reliable tests.

Test facility conducts tests under real-life conditions

In order to minimize operational disruptions and downtimes which can result in high costs, tests must be carried out under
the most realistic conditions possible. The designed test facility with a 16-meter high elevator shaft is perfectly suited for
realistically recreating the loop, with the connection of the tower and nacelle of a wind turbine. The facility has a installed
length of 12 meters that enables the torsional movement to be reproduced precisely. All fixture points of cables and con-
ductors are modelled after actual components. A servo drive at the top of the structure rotates the freely suspended cables
over their entire length. In the lower part of the loop as well, the cable is bunched and twisted as in an actual wind turbine.
Cameras monitor the processes inside the facility, measuring the abrasion and detecting any damage to the cables that
might be caused by torsion and vibrations.

Better investment protection thanks to reliable tests

The verification this test facility provides gives the turbine operator greater investment protection.
The test facility is used for a wide range of tests, and delivers valuable findings with regard to the suitability of different
cable designs and materials.

Brugg Cables, specialist for technically

advanced cables
Brugg Cables has special technical expertise in the En-
gineer to Order (ETO) area, designing and manufacturing
individual parts according to precisely defined customer
requirements. Brugg Cables deploys its entire technical
know-how and experience and partners projects through
all stages of development, design, purchasing, production,
testing and logistics acccording to the customer’s specific
requirements right up to installation on site.
Test facility for torsionable cables and connections

In the 16-meter high test facility, cables are subjected to up to 15,000 torsion cycles, based on a life span of around 20 years.The
connections used meet the most exacting demands in terms of torsional strength and withstand very high temperature varia-
tions. All customized solutions are designed, manufactured and tested according to precisely defined customer requirements.

Technical details test facility Value

Max. test height: up to 12 meters

Max. testing capacity: 32 cables in the practical test

Speed of rotation: Test speed in the range 0-20°/sec. (variably adjustable)

Torsion angle: Angle range +/- 1080°( variably adjustable)

Loop simulation: Actual conditions; according to specifications of wind turbine manufacturer

Cable connections: Ring cable lug, cable grips or according to customer’s requirements

- Video-monitored test
- Voltage tests (low/medium voltage) in the voltage laboratory
Tests:
- Fiber-optic cable tests
- Detailed analysis on complete test lengths

Customized Test offering Tests are set up and implemented according to customer’s specifications
Switzerland (Head office)
Brugg Cables Industry AG
Klosterzelgstrasse 28
CH-5201 Brugg
Tel. +41 56 460 31 00
Fax +41 56 460 35 36
info.industry@brugg.com

Brugg Cables Academy

Klosterzelgstrasse 28
CH-5201 Brugg
Tel. +41 56 460 33 33
info.academy@brugg.com

Please find more details on the courses currently offered in the online documentation www.bruggcables.com/academy.

Branch offices

China Italy United Arab Emirates

Brugg Cables (Shanghai) Co. Ltd. Brugg Cables Italia Srl Brugg Kabel AG – Abu Dhabi
Building No. 7 SaiTe Industrial Park Via G. Giacosa, 31 P.O. Box 51769
No. 1300 Jun Gong Road IT-20127 Milano Saiid Omran Power Building 93
Shanghai, 200433 Tel. +39 02 28 97 04 04 Hamdan Street,Tourist Club Area
P.R. China info.it@brugg.co 4th Floor, 041
Tel. +86 21 5506 2530 Abu Dhabi / UAE
info.cn@brugg.com Kuwait Tel. +971 2 671 73 02
Brugg Cables info.ae@brugg.com
Brugg Cables (Suzhou) Co. Ltd. Salwa, Block 12
Building No.2 Street No 7, House No 76 Brugg Cable LLC Dubai
No. 88 East Jinling Road Floor No 1, Flat No 1 P.O. Box 28896
WeitingTown P.O. Box 2191 Dubai
Suzhou Industrial Park 22022 Salmiya/Kuwait United Arab Emirates
P.P. China Tel. +965 2566 32 71 Tel. +971 4 334 55 40
Tel. +86 512 6287 7718 info.kw@brugg.com info.uae@brugg.com
info.cn@brugg.com
Poland USA
Germany, Austria, Benelux Brugg Cables Sp. z o.o. Brugg Cables, LLC
Brugg Kabel GmbH ul. Rokitniańska 4 25 Anderson Road
Daimlerstrasse 8 PL-66-300 Międzyrzecz P.O. Box 5231
DE-71701 Schwieberdingen Tel.+48 95 78 07 886 US-Rome, GA 30162-5231
Tel. +49 7150 9 1635 0 info.pl@brugg.com Tel. +1 706 235 8755
info.de@brugg.com info.usa@brugg.com

India
Brugg Cables India Private Limited
Suite 1008, IRIS Tech Park, Sector 48
Sohna Road
Gurgaon 122001
Haryana, India
Tel. + 91 124 3308682
Subject to change 07.2015

info.in@brugg.com

Find more detailed information about our products and services on www.bruggcables.com. A company of the Brugg Group.