Wind Power Cable, Insulation Material : PVC, Packaging Type : ROLL

Wind power cables are critical components in both onshore and offshore wind farms. They are subjected to a unique combination of mechanical, environmental, and electrical stresses that standard industrial cables cannot endure. Their design is optimized for reliability and longevity, minimizing maintenance in hard-to-access locations like the nacelle and tower.

1. （Core Design Challenges）

• Torsional Stress: The most defining requirement. Cables inside the tower must twist and untwist as the nacelle yaws to face the wind. They are rated for thousands of torsion cycles (e.g., ±180° to ±360° per meter for 5,000 cycles).

• Flexing and Bending: Cables in the nacelle, especially those leading to the hub, experience continuous movement due to blade pitch adjustments and vibrations.

• Harsh Environments:

  • Onshore: Wide temperature swings, UV exposure, ozone, and potential exposure to lubricants.

  • Offshore: Additionally, salt spray, high humidity, and potentially more aggressive chemicals require enhanced resistance.

• Long Distance Power Transmission: Cables running down the tower must efficiently transmit medium-voltage power from the generator to the base with minimal losses.

2. （Key Design & Construction）

• Conductors: Fine-stranded, highly flexible tinned copper conductors are standard. Tinning provides extra corrosion protection, crucial for offshore applications.

• Insulation: Cross-linked materials are preferred for their durability and thermal stability.

  • XLPE (Cross-Linked Polyethylene): Excellent electrical properties and moisture resistance, commonly used for power conductors.

  • EPR (Ethylene Propylene Rubber): Superior flexibility and crack resistance, often used for control cables.

• Jacket (Sheath): The jacket is critical for longevity. Common materials include:

  • Specialized PVC: Formulated for low-temperature flexibility and weather resistance.

  • Polyurethane (PUR): Offers exceptional abrasion resistance, oil resistance, and cut-through strength.

  • Chlorinated Polyethylene (CPE) or Polychloroprene (Neoprene): Provide excellent overall weather, ozone, and oil resistance.

• Torsion Optimized Construction: The internal components (conductors, insulation, fillers) are cabled together with a specific lay length and direction to allow them to move relative to each other during twisting without damage. A central strain relief element is often included.

3. （Common Types）

• Low Voltage Power Cables: For power distribution within the nacelle (e.g., for motors, pumps).

• Medium Voltage Power Cables: For transmitting power from the nacelle down the tower to the base. These are designed for higher voltages (e.g., 20kV, 35kV).

• Control & Data Cables: For transmitting signals from sensors (e.g., anemometers, vibration sensors) and for pitch control systems. Often shielded (Foil + Braid) for EMI protection.

• Hub Cables: Specifically designed for the extreme flexing required inside the spinning hub.

4. （Applications）

• Onshore and Offshore Wind Turbines

• Nacelle Internal Wiring

• Tower Cables (Yaw Cables)

• Blade Pitch Control Systems

• Sensor and Monitoring Systems