Gears for Wind Gearboxes

The conversion of speed and torque takes place in the geared components. In the further development of these components, Winergy has continuously improved materials, processes, and methods in recent years.

The introduction of inductively hardened internal gears represents an optimal solution in terms of cost and power density. In line with the V-model, Winergy, together with its development partners, has examined the process at the metallurgical level. Furthermore, the gearings were validated on component test benches, and subsequently, the components were thoroughly tested in extensive gearbox tests. Field experience from several small series confirms the robustness of the technology.

Winergy has found a way to design gears more compactly while maintaining the same robustness against tooth root breakage. This was made possible by combining modern simulation methods with customized manufacturing tools. This evolutionary step was validated by intensive gear testing and by analyzing field data from more than 400 GW of installed wind gearbox capacity.

Understanding the natural variation in material quality and the loads to be endured is a key factor in achieving higher power densities. Here, Winergy has developed the latest methods along the entire value chain to offer an optimal product in terms of reliability and cost.