ZF Friedrichshafen AG Wind Energy Service Ready for the Next Level of Wind … · 2012. 10. 22. · tion as a top-tier global supplier of innovative and durable gearboxes to about

Ready for the Next Level of Wind Energy

ZF Wind Power Antwerpen NVDe Villermontstraat 92550 Kontich, BelgiumPhone + 32 3 450 58 00Fax + 32 3 450 58 [email protected]

ZF Friedrichshafen AGDivision Industrial TechnologyBusiness Unit Test Systems94030 Passau, GermanyPhone +49 851 494 5529Fax +49 851 494 [email protected]

ZF Friedrichshafen AG Wind Energy ServiceBusiness Unit ZF ServicesVincenz-Wiederholt-Strasse 1059439 Holzwickede, GermanyPhone +49 2301 91 229 73Fax +49 2301 91 229 [email protected]

www.zf.com/windpower [email protected]

Driveline and Chassis Technology

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Enabling the Power of Wind

ZF Wind Power: Ready to make the difference

Increasing global electricity consumption in parallel with expected exhaustion of fossil fuel sources are inciting a new era of environmental awareness there-by setting pathways to employ renewable energy sources such as wind energy. As one of the world leaders in the development and production of high precision and high performance gearboxes for wind turbines, ZF Wind Power (formerly Hansen Trans-missions) aims at establishing interactive partner-ships with clients and end users, embracing design, manufacturing and customer services, thereby bring-ing mutual benefit.

The next level of wind energy

Drawing upon a proven track record and expertise as an industrial gearbox manufacturer since 1923,

ZF Wind Power became an early entrant into the wind power transmission business in the late 70s, when large-scale wind power development was still in its infancy. Since then, the company has consis-tently confirmed its pioneering role at the cutting edge of wind power transmission technology. Over decades, ZF Wind Power has carved out a reputa-tion as a top-tier global supplier of innovative and durable gearboxes to about all of the world’s lead-ing gear-driven wind turbine manufacturers. Ever since ZF Wind Power first entered the wind turbine market in the late 1970s, its manufacturing plants have catered almost 25,000 gearboxes, with a power capacity ranging from 1.5 to 6.15 MW.

ZF Wind Power: the Successful Integration of Technology Leaders

Hansen Transmissions: It all started in 1923...

…with the founding of „La Mécanique Générale“, a small workshop in Antwerp producing spare parts for gear units. Under the influence of the visionary engineer David Hansen, the company’s activities gradually shifted towards the production of customized gear units.

The Breakthrough: Hansen Patent

The breakthrough came in 1950 when David Hansen invented the concept of „gear unit standardization“, patented worldwide as the “Hansen Patent”. After successful patent application Hansen founded its subsidiary “MGH” (Machinery & Gear Hansen), soon acknowledged as innovation leader in industrial power transmission technology. In 1966, La Méca-nique Générale and MGH merged and in 1972 the name was changed into „Hansen Transmissions“.

Pioneering spirit with an eventful past

In 1969, HTI joined Thomas Tilling Ltd., which was later on acquired by BTR plc in 1983. In 1993, the Hansen group merged with the Brook Crompton Group - an electric motor manufacturer - to Brook Hansen. In February 1999, BTR Plc and Siebe Plc merged and changed names to Invensys. After acqui-sition by financial investor Allianz Capital Partners, Hansen was acquired by wind turbine manufacturer Suzlon in 2006.

A Bright Future ahead with ZF Friedrichshafen

In 2011, ZF acquired 100% of Hansen Transmissions. ZF, who for years has been the leading worldwide automotive supplier for driveline technology with the highest quality and process standards, will now apply their expertise into the wind market.

For centuries, people have used the power of wind for sailing ships, milling grain and pumping water. More recently, wind turbine technology has enabled us to harness this energy source for generating electricity.

In 2011 one of the world’s leading automotive industry suppliers, ZF, acquired the global leader in gearboxes for wind turbines, Hansen Transmissions. The result is a combined track record of almost 200 years of experience in automotive & industrial applications.

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Meeting the Individual Needs of the Global Wind Energy Market

ZF Global Footprint

ZF Wind Power currently operates 4 state-of-the-art manufacturing plants with an annual output capacity of approximately 10,000 MW. The company has a global footprint with a manufacturing presence in Belgium, India, China and the US, worldwide sales and service operations and a more than 1,500 strong workforce.

Globally present, locally anchored

ZF delivers original spare parts for wind turbine gearboxes paired with fast, comprehensive services, upgrade and maintenance support embedded in a seamless network of contracting partners and owned subsidiaries in order to maximize turbine operational availability and overall wind farm operating efficien-cy, minimize down-time for repairs, maintenance and servicing. This leads to a reduction of overall lifetime cost and optimization of economic payback time of wind power investments.

Technology Innovations –Delivering Custom-Built Solutions

Bundling know-how and competencies

Over three decades of knowhow in the wind indus-try and long-term partnerships with the world’s lead-ing wind turbine manufacturers and operators, have enabled ZF Wind Power to confidently meet any challenge customers may address – from highest efficiency standards, sustained durability, reliability and extended longevity of gearboxes to weight- reduced gearboxes with low-noise performance.

Manufacturing excellence: combining skill and precision

Producing multi-megawatt gearboxes efficiently in serial production with a consistent high level of quality and reliability requires excellence in manu-facturing, logistics, assembly and testing. ZF Wind Power is continuously investing to excel in its core activities of heat treatment, gear grinding and hous-ing machining, resulting in state-of-the-art gearboxes.

Seamless Integration of Design and

Manufacturing Processes

These critical activities are all performed in-house. Gearboxes are co-designed, co-developed and custom-built to precise specifications from customers worldwide. ZF ensures maximum control over quality and provides at the same time a high level of flexibility.

With state-of-the-art manufacturing plants and worldwide service locations, ZF Wind Power is dedicated to delivering custom-built solutions and services on a global scale.

The prevailing trend within the wind industry towards ever more powerful, reliable, and available turbines in challenging operating conditions requires far-reaching customization of all vital components.

Gainesville, USA

Vernon Hills, USA

Lommel, Belgium Taastrup (Copenhagen), DenmarkDelft, Netherlands

Lenton (Nottingham), UK Dortmund, Germany

Passau, Germany

Coimbatore, India

Tianjin, ChinaBeijing, China

Coslada (Madrid), Spain

Assago (Milan), Italy

Antony (Paris), France

1x 4 MW

1x 4 MW

5x 4.0 - 13.2 MW

validation test

1x 2.4 MW

2x 4.1 MW

2x 4.1 MW

Services (sales)

Sales office (OEM)Production (test systems)

Production (wind power transmissions)

Services (sales & workshop)

Test rig capacity (MW)4 5

The Next Level of Services: a Fully Integrated Service Offering

ZF Services: your specialized service partner

ZF Services understands the customers´ need of to-tal reliability for maximum productivity. ZF Services offers fast and individual solutions for multi-brand mechanical drivetrain repair and service. As a lead-er in wind turbine gearbox design and development, ZF Wind Power wants to ensure that all customers and partners gain maximum benefit from their investment in renewable energy. Therefore, in addi-tion to producing the world’s most innovative and reliable gearboxes, ZF does everything to keep them operating at the highest possible efficiency level - 24/7. Consequently, ZF manages the global wind energy service network under a single responsibility with dedicated wind service resources within the Business Unit ZF Services.

Serving your needs

ZF Services stands for customer-oriented and flexible service of the complete mechanical drivetrain for wind turbines based on a number of specific solutions for repairs, upgrades, and extensive support programs such as video-endoscopic damage analysis, testing capability dedicated for wind service, mobile vibra-tion measurements, as well as the replacement of individual components directly at onshore and offshore plants. Low lifetime cost combined with high availability and minimum downtime is the key to a short payback of investments in wind power in the wind energy business. ZF Services integrates the advantage of using genuine ZF parts and carrying out repairs and service in its specially equipped regional wind service centers or via its global field service team on-site.

The Next Level of Testing:Unrivalled Testing Capabilities

ZF offers a variety of test rigs – for inhouse testing and companies worldwide. Decades of experience and know-how are the base for high performance development and series test rigs.

In this rapidly growing market segment, ZF Wind Power continues to focus on developing innovative and highly reliable products and services by applying the necessary skills, resources, and technologies.

ZF Test Systems, an independent system supplier

ZF Test Systems, the independent system supplier for advanced test systems, offers test rigs for nacelles, drive trains and other wind turbine components as turnkey facilities with CE-marking, thus obviating any safety risks and customersneed for expensive interfaces.

The next level of test rigs

ZF test rigs are used for research and development as well as for series production and service of wind power gearboxes and nacelles. Our test rigs offer the following testing functions: endurance strength, over-load behavior, efficiency, service life and wear, tem-perature behavior, structure-borne noise, air-borne noise, function, run-in test under load application, noise and cleaning of oil circuit. ZF Test Systems provides test rigs from 0.5 MW to 18 MW.

ZF Dynamic bearing system test rig

This test rig is the most advanced facility of its kind to test real size bearings in their actual arrangement as built in the gearbox, under representative wind turbine loading and environmental conditions. The flexible test rig design reproduces the same shaft and housing deflection as the real gearbox and enables the verifica-tion of bearing behavior and loadability of bearing assemblies.

DORoTe: unveiling the unexpected

ZF’s “Design Operational Robustness Test” philosophy – DORoTe – has been developed to assess the robust-ness of a new gearbox design with respect to the operational conditions as specified by the customer. This test philosophy takes principles of accelerated life testing (HALT) one step further by incorporating dynamics and transients of wind turbine applications.

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