Putting giants to the test
The heart of the facility in Lindø is the 560-ton test load unit. It is 16 meters long, 9 meters wide, and more than 8 meters high. It was specifically developed by the three project partners to simulate the extreme loads that the rotor bearing arrangements of wind turbines are subjected to on land and, most importantly, on the high seas. In the overall drivetrain, the rotor bearing system plays an especially important role: it has to support all the forces and moments from the rotor, which can be up to 300 meters in diameter.
“From the first product sketch to manufacturing and validation in real-world operating conditions – as the global market leader for wind turbine bearings, we contribute decisively with our comprehensive system understanding to ensuring that our customers’ turbines generate wind power ever more efficiently, reliably, and economically. This holistic approach – we call it ‘closed loop engineering’ – sets us apart from our competitors in the market,” said Sascha Zaps, CEO Bearings & Industrial Solutions, Schaeffler AG, at the inauguration.
“The market is calling for safe and robust solutions. With this forward-looking commitment in Lindø, we are making sure it receives them. Our customers benefit from a partner that combines innovation and cost efficiency with maximum safety.”
Uwe Wagner, Chief Technology Officer of Schaeffler AG, said: “Our broad range of product families and manufacturing technologies form the foundation on which we continually impress our customers with technological innovations. We achieve this across a wide variety of market sectors – from two-wheelers and automotive to rail technology and renewable energies. The test rig in Lindø is another milestone through which Schaeffler, as a Motion Technology Company, sets new standards and strengthens its leadership role in the global competition.”
Cooperation with partners and customers is an important part of Schaeffler’s holistic closed loop engineering approach. In Lindø, the Motion Technology Company teamed up with LORC and R&D Test Systems. LORC is an experienced test facility operator and the owner of the state-of-the-art facility at Odense Port in Munkebo. The aim of the Danish company is to promote innovation in the field of renewable energy, ranging from full-scale testing of wind turbine nacelles, drivetrains, main bearings, blade bearings, components, and structures to industrial-scale battery storage systems. R&D Test Systems is a renowned developer of test rigs for the wind power industry.
What is closed loop engineering?
Schaeffler has been offering reliable bearing solutions for on- and offshore wind turbines for around 40 years. Rolling bearings from Schaeffler are found in every second to third wind turbine worldwide. Schaeffler takes a closed loop engineering approach for its wind turbine bearings. Besides engaging in the pure development of bearing solutions, the Schaeffler experts also support turbine development with system simulations, testing, and field measurement campaigns. The findings gained flow back into the further development of customers’ projects, design tools as well as the development of new bearing solutions. The experts from Schaeffler work closely with developers from OEMs to increase the reliability of wind turbines and make wind power more cost-effective.
Schaeffler played a big part in defining the specifications for the world’s most powerful test facility and will be its first user. From now on, it will test rotor bearing arrangements for the coming generations of wind turbines here exclusively in cooperation with wind turbine OEMs. “Development is rapid; we are now talking about turbines with a rated output of 25 megawatts. The demands on our wind turbine bearings are keeping pace with this,” says Bernd Endres, Vice President Regional Business Unit Wind.
The Ideal Solution for Every Bearing Support Concept
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.
Read more about Schaeffler's various bearing solutions here.
“Reliability is a decisive factor for us and our customers, especially in the offshore sector. We are at the forefront with our engineering tools and manufacturing technologies. This new test facility, which we can use now thanks to the excellent and trusting cooperation with LORC, enhances our infrastructure for testing and validation. It is where we will take innovations to market maturity,” says Bernd Endres. “Some scenarios cannot be simulated on the computer. With our closed loop engineering approach, we ensure that all models and computations are backed up by real-world tests. This gives our customers a level of reliability that is unique in the market and forms the basis for safe, durable wind turbines.”
