Review of WindEnergy Hamburg 2024

Innovative Solutions Highlight the World's Leading Trade Fair for the Wind Industry

WindEnergy Hamburg 2024 concluded after four dynamic days filled with engaging discussions. During this period, approximately 40,000 visitors explored the exhibition halls. The spotlight was on the increasing power density of wind turbines, a decisive factor for the planned expansion targets for renewable energies.

As a market leader and strategic development partner, Schaeffler actively contributed to these conversations. With over 40 years of experience, we not only provide optimal bearing solutions for wind turbines, but also drive the advancement of multi-megawatt turbines through our comprehensive system expertise.

Let the solutions showcased at WindEnergy Hamburg inspire you.

Closed Loop Engineering
Cost-effective wind turbines depend on reliable components that enable ever-increasing power density. As engineering partner for turbine and gearbox manufacturers, Schaeffler leverages comprehensive system knowledge to advance the development of wind turbines. Using state-of-the-art simulation, real-world testing, and field-based measurements, we do more than improve our products – we optimize the entire drivetrain.
World’s most powerful main bearing test facility
To ensure the reliability of our wind turbine bearings, we subject them to comprehensive testing. That’s why we are currently engaged in a significant expansion of our bearing testing capacity. In cooperation with LORC and R&D Test Systems, the world’s most powerful test bench for wind turbine main bearings is being built in Lindø, Denmark. Schaeffler played a major part in defining the specifications. The new test rig enables us to test the wind turbine bearings under realistic conditions - far beyond conventional standards.
Hydrodynamic plain bearings in series production
Modern, high-performance wind turbine gearboxes operate with as many planets as possible in order to be able to handle the constantly increasing torques. Extremely robust hydrodynamic plain bearings from Schaeffler enable this power density to be achieved in the smallest possible installation space. We are capable of not only calculating and simulating traditional rolling bearings but also the new hydrodynamic plain bearings for gearboxes, which are now being produced in series.

Revolutionary repair solution
Our split asymmetric spherical roller bearing makes it possible for the first time to replace the rotor bearing directly in the nacelle. Disassembly of the rotor star and the entire drive train is no longer necessary. This means that replacement costs can be more than halved and older turbines can continue to operate economically.
Energy revolution with green hydrogen
For energy-intensive industries, green hydrogen is a beacon of hope on the path to a climate-neutral future. Electrolyzers equipped Schaeffler's innovative stacks are at the heart of hydrogen production. Modular systems enable decentralized hydrogen production on an industrial scale. The Hydron Powerstack K series covers a range of applications from 1kW to 1MW and is produced to the highest quality standards at Schaeffler production sites in Europe.

Reliability made by Schaeffler
Applications & Products
Sector Highlights
Services
Publications
Contact

Reliability made by Schaeffler

At Schaeffler, all our efforts are driven by a clear goal: to improve the reliability of wind turbines. From our Wind Power Standard to the optimal design of bearings using state-of-the-art calculation and simulation tools, and through to realistic testing, we prioritize quality and durability. Discover how our solutions are shaping the future of wind energy.

Schaeffler Wind Power Standard
With our highest quality standard for products and processes we ensure optimum quality and reliability worldwide, and provide the wind power sector with quality standards that we have already successfully established in the automotive and aerospace industries. We work closely with our customers and suppliers throughout the entire process chain to ensure that our high standards are met.
Optimum design with state-of-the-art calculation and simulation programs
Our specialists work in close cooperation with wind turbine developers, manufacturers, and operators. State-of-the-art calculation and simulation programs ensure that optimum designs for bearings for wind power applications are produced. The entire system is considered, from individual rolling bearings and their components and adjacent construction through to the entire power transmission system, which is displayed and optimized using multi-body simulation programs developed in-house.
Realistic tests on Schaeffler’s ASTRAIOS
One of the world’s largest, most up-to-date, and most powerful large-size bearing test rigs enables large-size bearings of up to 15 tons and with outside diameters up to 3.5 meters to be tested. ASTRAIOS simulates the real loads and moments that occur in a wind turbine. This means we are making a major contribution to shortening development times for wind turbines, as well as making the design process more reliable and increasing the cost-effectiveness and safety of these turbines.

Innovative solutions for preventing white etching cracks (WEC)
Schaeffler has comprehensive testing facilities for creating WEC, analyzing the causes, and developing solution concepts for reducing the risk of WEC. The solution that Schaeffler recommends is to use Durotect B coated rolling bearing. The advantages that our Durotect B coating system offers include increased protection against WEC, which has been statistically verified by extensive experience in the field.
High equipment availability due to condition monitoring
We offer products and services for all aspects of condition monitoring, e. g. remote monitoring and diagnosis, offline measurements, endoscopy, thermography, and torque measurement. This means the costs for maintenance activities can be reduced and the availability of wind turbines can be increased.

Applications & Products

Rotor Shaft
The rotor shaft bearing support is of central importance in wind turbines. This is where all the forces act that are induced by the wind. The rolling bearings are subjected to highly-dynamic loads and operating conditions. In partnership with customers, Schaeffler develops the most efficient bearing support for each case.
Learn more
Gearbox
Increasing megawatt ratings require larger and higher capacity gearboxes. The operating conditions for rolling bearings in wind turbine gearboxes cannot be compared with those for industrial gearboxes.
Learn more
Generator
Generators in wind turbines are subject to high vibration loads. This additional permanent load has a negative influence on the cages and places strain on the lubricant.
Learn more

Wind Tracking and Blade Adjustment
Wind turbines must be aligned optimally to the wind in order to prevent extreme loads and allow cost-effective operation. Wind turbines adjust automatically due to active systems with azimuth drives and gearboxes.
Learn more
Simulation, Calculation and Test
Our specialists work in close cooperation with wind turbine developers, manufacturers, and operators. State-of-the-art calculation and simulation programs ensure that optimum designs for bearings for wind power applications are produced. The entire system is considered, from individual rolling bearings and their components and adjacent construction through to the entire power transmission system, which is displayed and optimized using multi-body simulation programs developed in-house.
Learn more

Sector Highlights

Innovative technologies for efficient wind turbines
In cooperation with LORC and R&D Test Systems, the world's most powerful test facility for wind turbine main bearings is being built in Denmark. As a market leader and strategic development partner with more than 40 years of experience, Schaeffler is rising to the challenge and will contribute actively to the development of multi-megawatt wind turbines. With its "closed loop engineering" aprroach, Schaeffler is driving the development of efficient and reliable multi-megawatt turbines, making a significant contribution to the progression of the energy transition.
Learn more about this project