Wind Energy This is How Pneumatics Make Wind Turbines More Sustainable

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ITV Industrie-Teile Vertriebs GmbH

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Wind turbines place special demands on pneumatics: temperature fluctuations, vibrations, and pressures up to 3,600 psi are among them. Stricter environmental regulations have now initiated new developments in connectors.

Wind turbines are a central pillar of the energy transition in Germany. In 2024, they generated around 142 terawatt-hours of electricity, which corresponds to about 29 percent of the total gross electricity generation. This makes wind energy the currently most important single energy source in the German electricity mix. For wind turbines to operate reliably and economically, a multitude of precisely coordinated components is required in the background—including pneumatic systems.

The manufacturers of the plants value flexibility and speed in their suppliers. This is also evident at ITV GmbH, for example: the medium-sized company develops pneumatic solutions for industrial applications, including wind turbines. A growing share of 40 to 45 percent of orders consists of customized special solutions. These are implemented within four to six weeks—from order receipt to delivery. The produced quantities range from 500 to 20,000 units per order. For wind turbines, specific requirements regarding pressure, temperature, and materials must be met.

Pneumatics for Extreme Conditions

Wind turbines are in constant interaction with their environment, which poses significant challenges: temperature differences, salty air, vibrations, or high rotational forces affect the systems. Areas such as power electronics and gear technology are particularly sensitive. High temperatures and friction forces arise during operation in these areas, which need to be controlled and dissipated to prevent damage and failures.

Pneumatic connectors play a central role here: they enable the safe and loss-free transmission of cooling fluids and ensure that lubricants reach exactly the places where they are needed—quickly, efficiently, and pressure-resistant. This contributes to the long service life of the systems and low maintenance costs.

Curtailment of Wind Turbines

An important aspect in the operation of wind turbines is the so-called curtailment. This occurs when the grid infrastructure cannot fully absorb the generated energy, for example, due to grid bottlenecks or overproduction. In 2022, around 7.2 terawatt-hours (TWh) of wind power were curtailed in Germany to ensure grid stability. In 2023, this amount increased significantly: 10,479 gigawatt-hours (GWh) of green energy were curtailed. These figures highlight the challenges in the German power grid and underscore the importance of systems that enable quick and secure shutdown or throttling of wind turbines. Such systems are essential to ensure grid stability and optimize the efficiency of energy generation.

But also for reasons of species and nature conservation, the operation of wind turbines must be regulated: During the mating or breeding seasons of certain bird and bat species—usually between March and August—wind turbines are deliberately shut down to avoid collisions. Pneumatics play an important role in the safe and rapid implementation of such measures.

Requirements for Pneumatics are Increasing

Pneumatic connectors today have to perform significantly more than in the past. Pressures of up to 50 bar prevail in cooling systems, and even up to 250 bar in high-pressure lubrication applications. At the same time, the components are expected to be permanently tight, vibration-resistant, and durable. New regulatory requirements are also added, particularly in the area of environmentally harmful substances.

A current topic is the reduction of lead in technical components according to the EU directive RoHS. Manufacturers are therefore faced with the challenge of developing lead-free alloys that exhibit the same mechanical properties and the necessary machinability as conventional brass. Critical in this context is close coordination with material suppliers—ideally during the procurement phase. This way, problems in later production steps can be avoided. At the same time, policymakers are called upon to create clear and uniform conditions that combine sustainability, legal certainty, and innovation capability.

Reliable Wind Energy Thanks to Pneumatics

The wind energy sector relies on robust, efficient, and sustainable technologies—not only for electricity yield but also for smooth operation under extreme conditions. Pneumatic connectors are a central element of this infrastructure: they enable reliable control of cooling and lubrication circuits, reduce downtime, and thus contribute to the economic efficiency and long lifespan of modern wind turbines. (dm)

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