Wind Industry
Smarter Bolt Monitoring for Safer, More Efficient Turbines
WIND
Bolted joints are critical to the structural integrity of wind turbines. Yet, they remain one of the most failure-prone components across turbine systems. From the tower to the drivetrain, these connections experience constant stress from wind loading, rotation, and vibration. Especially as turbines continue to scale in size and power output. Continuous preload monitoring turns this hidden behaviour into actionable signals, helping maintenance focus where it matters most.
Forcesure
Smarter, Safer Wind Energy
Traditional inspection methods depend on torque checks and periodic sampling, which often fail to capture preload loss as it develops. This leaves operators vulnerable to undetected degradation, costly downtime, and higher technician costs.
At Forcesure, we design sensor-based technologies that transform invisible forces into actionable data. By making bolt load, tension, and stress measurable in real time, we enable turbine operators and maintenance teams to move from scheduled inspections to condition-based strategies. Improving efficiency, safety, and asset longevity.
Our Solutions Provide the Foundation for:
- Detecting preload loss before it leads to fatigue or failure
- Reducing technician exposure by enabling remote monitoring
- Validating bolt tension immediately after installation or tightening
- Supporting condition-based maintenance strategies backed by real data
Connectivity
Databolt is connected with
a small connector on top of
the bolt to measure the
bolt force in real-time.
Measurement
Databolt is integrated with
a force measuring sensor,
capable of delivering real-time
insights into bolt tension.
Welded Housing
The housing is micro-welded
and injected with UV resin
to prevent any dust or water
from entering the sensor.
Databolt
Databolt in Wind Turbines
Databolt is part of a broader mission to offer continuous, real-time measurement of bolt load visibility. It replaces standard fasteners or can be integrated directly into new turbine designs, giving operators live access to preload data through wireless IoT communication.
Installed across critical joints, Databolt not only confirms preload at installation but also tracks bolt behaviour over extended periods under real-world operating conditions. This long-term visibility allows operators to identify emerging risks, optimise inspection cycles, and strengthen overall turbine reliability.
Wind Turbines
Key Applications
- Tower flange bolts
- Blade root connections
- Yaw system fasteners
- Gearbox and drivetrain mounts
Your Benefits
Value for Operators
By integrating smart bolting technology into turbine maintenance strategies, operators can take a more proactive and data-driven approach to asset integrity. while cost savings and performance improvements will vary depending on turbine size, layout, and inspections cycles, the shift toward real-time insights offers long-term strategic value.
- Minimize unscheduled repairs by catching preload loss early
- Reduce technician exposure by lowering reliance on manual checks
- Improve quality control during installation and commissioning
- Build historical datasets to guide future turbine design and maintenance