- Turbine converter test bench sets new milestone for extended grid capability
With today’s inauguration of a state-of-the-art generator converter test bench at its Rostock site, the Nordex Group is focusing on expanding and strengthening its technological expertise in grid integration for its wind turbines.
The new test bench will enable faster, more comprehensive testing and development of high-performance converters; a critical component in modern wind turbine electrical systems. Converters transform turbine-generated electricity into power that can be fed into the grid while regulating frequency and voltage. They play an essential role in maintaining grid stability and protection, making them a key component in the efficient and stable use of renewable energies in the changing energy mix of electricity grids.
Converters also play a key role in flexibly adapting to evolving international grid requirements and in implementing grid forming strategies that that will underpin future grid stability. Each country has unique grid topologies and specifications from grid operators that are continuously evolving, placing new demands on wind turbines.
With systems installed in more than 40 countries, the Nordex Group has harnessed extensive engineering expertise in power electronics and in meeting different grid requirements over the years. With its new test bench, the Nordex Group is now also focusing specifically on its turbine converter in-house development and quality assurance. 'With the new test bench, we at Nordex are strengthening our ability to develop our own converter solutions to meet the changing international requirements of continuously growing grid connection specifications; the grid codes,' explains Helmut Resing-Wörmer, Head of Test and Prototype at the Nordex Group. 'We’re testing under real-world conditions in Rostock to ensure our systems’ reliability and grid compliance. Grid compliance is a decisive competitive advantage, and the converter represents another core component and competence for Nordex.'
'By building in-house development capabilities and expertise in converter technology, we’re laying the groundwork for flexible, tailored grid integration solutions, thereby ensuring the future viability of our products,' adds Dr. Christian Wessels, VP Global Electrical Engineering at the Nordex Group.
Traditionally, grid connection testing has been conducted exclusively in the field using turbine prototypes, which can be time-consuming and challenging. The Power-Hardware-in-the-Loop (PHIL) test bench enables comprehensive grid compliance testing of electrical drive systems. Equipped with an advanced grid simulator, the test bench allows Nordex to simulate a wide range of grid conditions, including voltage, power and frequency fluctuations, voltage dips or grid faults, doing away with the need for field testing. This makes it possible to obtain valid measurement results very early in the development cycle and save time. Power connection tests are then continued in the field. With this approach Nordex ensures that current and future turbine generations can be reliably integrated into the power grids and comply with applicable grid codes faster in the respective markets, while at the same time complexity and new grid requirements are increasing.
The inauguration event welcomed representatives from government, research institutions, and partner companies, including Ms. Kerstin Deller, Head of the Energy Research Subdivision at the Federal Ministry for Economic Affairs and Energy.
The Nordex Group has invested over EUR 4 million to build the test facility in Rostock. The test bench was executed by R&D Test Systems from Denmark and Ingeteam Power Technology from Spain as well as regional and local companies from Mecklenburg-Western Pomerania, including Ingenieurbüro Wollboldt and GTN Getriebetechnik Nord, and WISAG Elektrotechnik Berlin-Brandenburg The RKL Rostock Competence Center for Power Electronics and the University of Rostock also provided support. 'In recent years, an engineering network of companies and research institutes has established itself in Mecklenburg-Western Pomerania and particularly in Rostock, focusing on grid integration and grid stability. With the expansion of wind energy facilities, these plants are becoming increasingly important for the stability of the power grid. Our current investment in the converter test bench will support the energy transition to achieve set climate targets,' adds Resing-Wörmer.
The Nordex Group Rostock facility manufactures nacelles, hubs, drive trains, and control cabinets for all turbine models, and houses the company’s Blade Competence Center with its rotor blade test rig. The new converter test bench further expands Rostock’s role as a Nordex center of excellence.
The Nordex Group in profile
Nordex Group has installed approximately 57 GW of wind energy capacity across more than 40 markets and generated consolidated revenue of approximately €7.3 billion in 2024. The company currently employs more than 10,400 people. Its manufacturing network includes facilities in Germany, Spain, Brazil, India, the United States, and Mexico. Its product portfolio focuses on onshore turbines in the 4-7 MW+ range, designed specifically for land-constrained and grid-constrained markets.
Source: Nordex
