High Reliability Contact Technology for Harsh Environments

Wind turbines face some of the harshest environments, both inland and offshore. Life expectancy of wind parks generally exceed twenty years, therefore, the reliability of wind turbines ultimately depends on the applied interconnect systems. Connector manufacturers need to take into account the effects of extreme temperatures, vibrations, salt spray, humidity, dust and EMI/EMC.



Hypertac interconnect solutions for wind turbines are built upon the unique Hypertac Hyperboloid contact technology, which has been proven in very harsh environments such as Aerospace and Defence. The shape of the contact is formed by hyperbolically arranged contact wires, which align themselves elastically as contact lines around the pin, providing a high number of linear contact paths. The inherent electrical and mechanical characteristics ensure unrivalled performance in terms of number of mating cycles, shock and vibration immunity, long life and low rate of wear, low insertion and extraction force, low contact resistance (5 million) and high current rating (up to 750 amp).



Hypertac's specialised engineering team enables them to respond quickly to customer requirements and add value by providing them with the most reliable interconnect solutions available in today's market. Hypertac offers a wide range of standard connectors as well as customised connector solutions for wind parks. The portfolio comprises of high power and signal metal, plastic and stainless steel connectors, cable assembly together with complete interconnect solutions. The interconnections meet sealing to IP67 or higher if requested. The new Hypertac M12 circular connector series has been designed to meet smaller space requirements with excellent performance and high reliability.



Varying climate conditions place increasing strains on wind parks. The probability of data transfer breakdown caused by contact interruptions will escalate. Interruptions affect functional operation and can cause wind turbines to shutdown. Hypertac has designed the M12 connectors with integrated Hypertac? hyperboloid contact technology to prevent this. This technology has been proven to withstand vibrations and high temperature fluctuations during the start of a space shuttle and therefore guaranties the highest performance and reliability.



The following types of Hypertac M12 series are available:

· 3way connectors, unshielded/shielded for wires 0.25 mm² to 0.75 mm²

· 4way connectors, unshielded/shielded for wires 0.25 mm² to 0.75 mm²

· 5way connectors, unshielded/shielded for wires 0.25 mm²



Hypertac's new M12 interconnect system covers various designs: female and male cable connectors - straight or angled, female and male receptacles and extension cords. Furthermore, special types and configurations can be developed to meet bespoke customer requirements. The M12 series meets sealing to IP67 when mated.



Gauging stations on the nacelle are the control centre of the wind turbine. These stations have to withstand extreme weather conditions including high wind speed, humidity, salt spray, dust and temperature extremes on a daily basis. A contact interruption necessarily leads to a breakdown and might become a hazard for the wind turbine. For this reason the use of high reliability, high quality and long-life interconnect solutions is essential. Hypertac's ruggedised M23 stainless steel connectors and M17 series perfectly fulfil these technical requirements and meet sealing to IP67 when mated.



Wind turbines are difficult to access so they require long life-cycle connector systems. Hypertac's self-cleaning and vibration proof interconnect solutions are designed to 'fit and forget' so that maintenance work can be reduced to a minimum throughout the long life-span of a wind turbine.