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PitchOne System BluePrint

A scalable pitch system featuring pre-qualified components, detailed

engineering documentation (ePlan, BOM, circuit diagrams), and inte

grated PLC software support for seamless turbine automation and

rapid commissioning.

Highlights

BluePrint

• Introduce the latest pitch technology to your wind turbine.

• Ready-to-Start Documentation Package: Prepare

documentation including e-Plan, BOM (Bill of Materials) and drawings.

• Customized Energy Backup Design.

System Design

• Evaluate the design of the system.

• Optimized and Pre-qualified Core Components: Ensure

core components are optimized and pre-qualified.

• Customized Engineering: Motor and Backup dimen-

sioning, SW-Support of integration in turbine automation.

System Design

• Evaluate the design of the system.

• Optimized and Pre-qualified Core Components: Ensure

core components are optimized and pre-qualified.

• Customized Engineering: Motor and Backup dimen-

sioning, SW-Support of integration in turbine automation.

Pitch – System Design Your Guide to Construction

Our Pitch System Design provides a comprehensive guide for the construction

and introduction of the latest pitch technology into your wind turbine.

With the PitchOne System Design, we offer optimised and pre-qualified core

components that increase the performance and durability of the wind turbine.

Our team supports you in evaluating and designing the system so that it is

perfectly tailored to your specific requirements.

A ready-to-use documentation package, including e-plan, bill of materials,

and drawings, facilitates implementation. Additionally, we offer customized

engineering, including motor and backup sizing as well as software support

for integration into turbine automation, to develop solutions tailored to your

needs.

Load data evaluation

• Professional load profiling

Based on operational or simulated data

(e.g. Hawk), including torque-speed graphs and reference cycles.

• Scenario-based interpretation

Covering diverse operational conditions.

Full drivetrain design

• Motor & drive selection

Tailored choice based on thermal loads, peak current and torque reserves.

• Thermal continuous load analysis

Ensures overload protection and long-term durability.

• Peak current handling

Critical for short-term load surges and dynamic conditions.

• Torque reserve calculation

Buffer for sudden load changes and safety-critical scenarios.

Selection & customization of pitch motors

• Industrial motor platform

Cost-effective and field-tested.

• Wind-turbine-specific enhancements

Custom shafts, seals, and thermal protection for harsh environments.

Verification & qualification

• Automated test sequences

Reliable performance validation using dedicated test benches.

• Compliance documentation

Traceable results for functional and safety certification.

We offer more than just a motor and pitch drive with

corresponding software. Based on real load profiles and

simulation-driven analyses, we select the most suitable

motor from our extensive product portfolio for the

customer‘s application and customize it. Each motor

type is comprehensively tested on our auto-mated test

benches – ensuring maximum operational safety, load

resilience, and system efficiency.

4 steps of KEBAs motor dimensioning process

• Load Data Analysis

• Drive Train

• Pitch motors

• Design Verification & Qualification

Professional motor dimensioning for pitch systems

We provide complete dimensioning of pitch motors – from

selecting the optimal motor to qualification on our test benches.

Based on real load data or simulations, we deliver tailored

configurations for motor and pitch drive. We rely on proven

industrial motors, which we optimize through specific adaptations

for optimal performance in wind turbines. Our automated testing

programs ensure every motor delivers high performance, reliability,

and readiness for peak loads. With our system engineering approach,

we cover the entire chain – for maximum safety and efficiency in your

pitch system.

CAM2 contains all the components for communication

with the surrounding environment as well as features

for user programming and the storage and processing

of diagnostic data. The module is the central communi-

cation interface to the Drive Module (DRM).

To install the CAM in the drive module

· Disconnect the pitch servocontroller from all supply

voltages

· Insert the CAM in the drive module (1)

· Secure the CAM using the securing screw (2)

· Switch on again the supply voltages

The following functions are available:

// Direct hardware support for the real-time field bus PROFINET.

// Interfaces for service and diagnostics (non-real-time

Ethernet) and for Safe Cross Communication (SCC)

between the three servocontrollers in a pitch system.

// Onboard flash memory for central firmware handling as well

as the non-volatile storage of process and diagnostic data

// User programming (CODESYS) to customize the system to

the specific customer requirements.

// Digital and analogue interfaces (not for safety) for the inter-

action with the pitch system. These include PLC-compatible

digital inputs and outputs, analogue current inputs, as well

as the temperature measurement inputs.

// IO-Link master for the connection of intelligent IO-Link

sensors and actuators.

// HMI interfaces via buttons, switches and LEDs.

Highlights

• Compact design – fits into any pitch system

• Flexible peak power with fan-less heat-sink model

• Full motor output voltage even at low energy storage voltage

• Fanless cooling concept outside the cabinet

• Fast backup energy charging via bidirectional

• DC/DC converter

• TÜV certified pitch system with Performance Level E for Safety Run

Leading technology

Find out about the benefits of the trailblazing new PitchOne platform.

Read more about our approaches toward lowering of levelized cost of

electricity (LCoE), lowering the service costs, and how to customize the

drive for your cost-efficient Pitch system solution.

Your benefits at a glance

• High HVRT availability

• Lower costs at the turbine construction level

Technical highlights

• 45 kW peak power with fanless heat sink

• Broad HVRT tolerance with 140 % UN

• High operating voltages even for LVRT load cases

• Safe software updates and remote maintenance

• Quick charging of back-up energy storage

• TÜV-certified emergency pitching safety function – performance level E

• Modular, easy-to-service interfaces

Safe, energy-efficient multi-axis drive system

KeDrive D3 is one of the most compact multi-axis-drive systems

with integrated safety technology. As a modular all-in-one

system, it can be configured easily and quickly using a modern

tool suite. The latest technology, greatest cost effectiveness and

maximum availability are typical features of this innovative drive

solution

Features:

• Compact, continuous form factor

• Modular, scalable system layout

• 1. 2 and 3-axis drive modules from 1.5 A – 250 A

• Up to 300% overload capacity

• Active and passive supply units from 10 kW – 140 kW

• Integrated safety technology as per PLe, cat 4 or SIL3

• Energy storage and expansion modules

• Servomotors for a very wide range of load cases

Unlimited motion

Optimized for positioning, speed- or torque-controlled operation is also possible

as an alternative. Preset versatile motion solutions with axis-internal profile

generation facilitate commissioning.

• Motion block table with intelligent follow-up job logic

• CANopen drive profiles according to DS402

• Position- or speed -synchronous electronic gear

• Path optimized rotary table operation

• Freely programmable motion profiles with the PLC

• Jog and homing mode

Features

The c-line Drives offer hardware and software solutions tailored to your application

as well as partnership-based services.

CANopen for free

In accordance with the motion profile DS402. the drive is parameterized and the

operating modes are controlled. Access to all data allows comprehensive machine

and drive diagnostics.

Precise motor control

The control technology also compensates for cogging and friction torques as well as

spindle pitch errors. In addition, filters for damping mechanical vibrations can be

parameterized.

Integrated mains filter

The mains filter is already integrated at the factory to comply with legal standards.

This also reduces the number of components in the control cabinet and simplifies installation.

System-Partnership

Professional project management is an important component for mutual success,

so that you stay on time and within budget. The faster the “time to market” the better.