From monitoring to maintenance support: a critical review of wind turbine condition monitoring systems and their integration into maintenance practice
1 Faculty of Engineering, University of Nottingham, Nottingham, UK
2 School of Computing and Engineering, University of Huddersfield, Huddersfield, UK
3 School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, China
4 Key Laboratory of Nondestructive Testing of the Ministry of Education, Nanchang Hangkong University, Nanchang, China
  • Volume
  • Citation
    Yan R, Yang W, Zhang L, Yan R, Wen G, et al. From monitoring to maintenance support: a critical review of wind turbine condition monitoring systems and their integration into maintenance practice. Mechatronics Tech. 2026(2):0006, https://doi.org/10.55092/mt20260006. 
  • DOI
    10.55092/mt20260006
  • Copyright
    Copyright2026 by the authors. Published by ELSP.
Abstract

Although condition monitoring systems (CMS) provide detailed information about the health of critical wind turbine components, their practical application in wind farm operations and maintenance (O&M) remains limited, significantly diminishing their value. The reasons for this situation are not merely technical issues, rather, a complex interplay of various factors besides the condition monitoring algorithms themselves. The purpose of the paper is to investigate these reasons and propose a potential solution. Through in-depth analysis, two gaps are identified. The first gap is the Data-Model Gap, in which operational wind turbine data do not adequately satisfy the assumptions and quality requirements of condition monitoring algorithms. The second is the Model-Decision Gap, where the CMS output fails to provide sufficient information to support maintenance decisions. Based on this, a Data-Model-Decision Gap (DMDG) framework is further developed to explain how maintenance requirements can be used to determine the CMS outputs and, subsequently, the wind turbine condition monitoring data that are needed to produce these CMS outputs. Such a CMS design logic reverses the usual data-to-model development sequence by starting from understanding what kind of CMS outputs can actually support decision-making in practical wind farm O&M. This new CMS design approach emphasizes the alignment of data, models, and decision processes through an iterative and integrated design strategy. Research findings indicate that merely improving algorithm accuracy is insufficient to enhance the practical value of CMS. Bridging the aforementioned gaps is the key to transforming the CMS design from “monitoring-oriented” to “decision-oriented” and in the end, providing “prescriptive maintenance solutions”. This change is critical for unlocking the full potential of CMS in wind farm O&M.

Keywords

wind farm; condition monitoring system; operation and maintenance; decision making

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