Wind Power Converter 2.5 MW — Enclosure & System Design

Full-power converter enclosure for 2.5 MW onshore wind turbines — from mechanical concept to series-ready design. Installed in the turbine tower base.

2.5 MW Wind Power Converter — concept design pilz

Sector
Power Electronics / Renewable Energy

Product
Full-power converter enclosure · 2.5 MW · 690 V · Onshore

Scope
Mechanical design, cooling system, busbar routing, documentation

Period
2012 – 2014

The task

A 2.5 MW full-power converter for onshore wind turbines requires an enclosure that is robust under harsh conditions, service-friendly in confined tower spaces, and thermally optimised for continuous high-power operation. The design had to accommodate a complete water cooling system, a DC/AC copper busbar network, and a plug-in rack system — all within a welded steel frame.

Our contribution

Complete 3D mechanical design in SolidWorks — from concept to production-ready documentation:

• Welded steel frame with plug-in rack system (60+ assemblies)

• Water cooling system — cooling plates, manifold pipes, hydraulic brackets, seal frames

• Copper busbar network DC / grid / PE

• Reactor mounting, drawing set + BOM Rev.06, test & acceptance specification

Wind Power Converter Steel Frame — concept design pilz

The result

A series-ready full-power converter enclosure for 2.5 MW onshore wind turbines — complete with 3D model, 2D drawings, BOM, and test & acceptance specification.

Active Harmonic Filters — from concept to series production

Power quality devices, developed entirely from a single source — from conception to on-site installation. Manufactured several thousand times, in use across industries.

Aktive Harmonische Filter – Produktdesign concept design pilz

Sector
Power Quality / Industry

Devices
Active Harmonic Filters — air- and water-cooled, multiple power classes

Our part
Conception · development · engineering · design · production equipment · on-site installation

Series & deployment
Manufactured several thousand times — ships, chip production, automotive industry

The task

Harmonics put a strain on industrial power grids — causing losses, interference and compliance problems. Active harmonic filters compensate for them in real time. What was needed was a device family that is compact and service-friendly , robust for harsh environments, scalable across many power classes, in air and water cooling — and ready for series production for high volumes.

Our contribution

We were responsible for the complete device development — everything from a single source:

• Conception & industrial design

• Development & engineering — enclosure, mechanics, cooling (air & water)

• Consistent design across all power classes

• Production equipment for series manufacturing

• On-site installation and commissioning

• Validated by thermal simulation

AHF – Konstruktion und Aufbau

The result

The Active Harmonic Filters went into real series production: manufactured several thousand times and in use across industries — from ships to chip production and into the automotive industry. A scalable product family (air- and water-cooled, multiple power classes) that has proven itself in continuous operation under harsh conditions.

Aktiver Harmonischer Filter 690V im realen Einsatz

Capabilities applied

Industrial design · engineering · thermal (air & water) · series development · production equipment · on-site installation

Your power quality or series project?

From concept through engineering to series production — let's talk about it.

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