Wind Turbine Monitoring for Foundations and Tower Bases
The 6D sensor measures tilt and settlement at the base of the mast in a single installation, with repeatability of ±50 µm and ±0.1°, wirelessly and without requiring a power connection to the structure.
The reference object and sensor are each secured with two screws to the mast base, the foundation, or the junction between the foundation and the tower. No special tools are required, and no structural modifications are needed. Activation is triggered by placing a magnet against the device or connecting the battery cable. The system remains operational during installation.
Once the sensor is active, it wirelessly transmits data on tilting and settlement to our data hub. Data is transmitted via LTE-M and Wi-Fi. The movement history can be viewed at any time as a timeline, without anyone needing to be on-site.
You define the critical values for each measurement point in advance. If these values are exceeded, our system sends an email notification to the designated recipients. The complete history of changes is also available as documentation for the next equipment inspection.
There is a sensor to suit every measurement point and motion pattern.
The solution for monitoring at the base of the mast. Measures tilt and settlement at the same measurement point in six dimensions with a single installation. The tilt of the tower is the key measurement.
For measurement points at the foundation-to-tower transition where the crack width and displacement (excluding rotational components) are to be measured.
Specific differences compared to spot inspections and conventional sensor technology.
Tilt and settlement at the same measurement point within a single sensor. Other sensor systems require multiple devices or multiple setups to capture the same motion profile at the base of the mast. Patent EP3792587B1.
A system remains in place for years. With a battery life of ten years, our sensors continuously monitor slow foundation movement without requiring battery replacement during standard inspection intervals.
If a threshold is exceeded, our system automatically sends an email notification. Progressive foundation movement is detected early, before it compromises the safe operation of the system.
The sensors operate without wiring and without an external power connection to the tower. Data is transmitted via LTE-M and Wi-Fi, and the sensors are mounted with two screws. Even on the hard-to-reach base of a wind turbine, no on-site visit is required to retrieve the data.
Selected wind power monitoring projects using our sensors.
Real-time structural monitoring following a tunnel fire to enable rapid reopening during ongoing restoration work.
Wireless 3D measurement of concrete segments in tunnel construction.
Continuous monitoring of structural movements in the historic reception building during the critical construction phase
High-precision building monitoring of settlement and crack development to assess damage caused by subway construction work.
Monitoring of bearing and abutment movements and structure temperature during operation.
“Following a tunnel fire, the 3D sensors from SuessCo Sensors FlexCo were deployed to monitor the affected tunnel arch segments. Continuous monitoring made it possible to maintain temporary operations until final repairs could be completed. As part of the safety management plan, alarm thresholds were defined, and a specific group of people would have been notified via email and SMS if the alarm threshold was reached. The system stands out for its precise measurements and the wireless remote transmission of data to a portal that experts can access at any time without disrupting operations.”
Reinhold Czizsek, Engineer
Asset Management, ASFINAG Bau Management GmbH
“Our collaboration with SuessCo Sensors has always been professional and solution-oriented. For expert assessments, the continuous measurement data from the SuessCo sensors is a major advantage, as changes can be objectively documented and reliably evaluated." "With the XT 3D sensors, we receive precise and stable measurement data wirelessly in three dimensions. This enables reliable remote monitoring of sensitive tunnel areas and significantly reduces our on-site workload."
Mohammed Ismail
Geomatics Engineer, TABERG Engineering and Consulting Firm, LLC
"Thanks to the high-precision sensors from SuessCo Sensors, we have been able to continuously monitor changes in the Palm House. This data helps us protect this wonderful building and its historic structure."
Helmut Heninger, B.S. in Engineering
Austrian Castle Administration
"SuessCo's sensors have proven to be extremely precise and easy to install. What is particularly impressive is that they withstood the extreme conditions of the Swedish winter without any problems. Our collaboration with SuessCo has always been reliable and professional."
Paul Collins
Sales Manager, GEOFIX Sweden
"With the SuessCo 6D sensors, we always have up-to-date measurements available. This naturally saves us money and improves quality."
Georg Gotthart
Plant Technician, Bridge Construction, ÖBB
For the mast base, the 6D sensor is the primary solution because it measures both tilt and settlement simultaneously. Any incipient tilt of the tower is recorded with a repeatability of ±0.1°. If only the crack width and displacement—without any rotational component—need to be measured at the junction between the foundation and the tower, the 3D sensor is sufficient.
No. Our sensors measure displacement, tilt, and settlement—that is, static and slow movements at the foundation and mast base. They do not measure vibrations caused by rotor operation. The focus is on tracking settlement and tilt over the course of the turbine’s operational life.
Yes. Installation at the base of the mast or on the foundation does not require the system to be shut down. The sensor is secured with two screws and is ready for operation once the magnet is attached or the battery cable is connected.
When used for hourly measurements, the 6D sensor has a battery life of ten years. The 3D sensor has a battery life of ten years when used for daily measurements. This allows for the tracking of slow foundation movement over long periods of time without needing to replace the battery.
All measurement values are available in the Datahub as a CSV export. You can use the history of settlement and tilt as documentation for the next inspection. Any anomalies between inspections become apparent over time.
You define the critical thresholds for each measurement point in advance. If these thresholds are exceeded, our system automatically sends an email notification to the designated recipients. This allows you to initiate an unscheduled inspection before the foundation movement deteriorates to a critical level.
