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- Offer Profile
- For more than 30 years
Winergy is the global leader for innovative drive systems and wind turbine
components. One of three wind turbines installed worldwide is equipped with
one of our gearboxes and couplings for converting wind power into electrical
energy. The product portfolio covers power ratings between 750 kW and
6.5MW. This is complemented by a high quality professional service
portfolio. Production and service locations are located in Germany, China,
India and the US, while the base of service partners is expanded
continuously on a global level.
Pioneered and perfected by Winergy
Winergy, the global market leader, produced its first wind-turbine gearbox in 1981, and since then has continuously worked on technical and quality-related concepts. Setting the standard in the industry for combined helical and planetary stages as well as super-finishing of gears, Winergy has delivered over 70,000 gearboxes to its satisfied customers.
Gearboxes for a wide power range
As the central component of the drive system, the gearbox converts the low speed of the rotor shaft into a high revolution that drives the generator. Winergy offers both standard and customer-specific engineered products in the power range from 600 kilowatts to 6.5 megawatts - always optimized for the given requirements.
Advantages of Winergy gearboxes
- Production and service facilities in all major markets
- Over 30 years of experience
- Every gearbox 100 percent tested prior to delivery
- Compatibility with 50/60 Hz grids, different rotor diameters, and shrinkdisc as well as flange configurations
- Prototype testing in climate chamber and with 200 percent overload
- Gearbox serviceability concepts taken into account during the design phase
- State-of-the-art and innovative products through continuous R&D
- Leading supplier of offshore gearboxes with multi-megawatt experience since 2003 (five megawatts and more)
The wind turbine power pack
To bring the energy generation costs down to a minimum, drive components for wind turbines must be designed to deliver the highest possible efficiency. To meet all customer requirements, Winergy has added a new concept to its product portfolio - The HybridDrive.
Compact and efficient
The direct linkage of the two-speed gear and the permanent-magnet generator shortens the drive train by up to 50%. Despite its compact dimensions, the HybridDrive is extremely efficient. In fact, with an efficiency of >96,5% (measured @ rated power) for gearbox and generator, it has the best efficiency of any existing technology.
Benefits of the Winergy HybridDrive for wind turbines:
- Compact dimensions: Gear unit and generator in a single product
- Best possible efficiency for onshore and offshore use
- Flexible, for use in any nacelle configuration
- Highly maintenance and service-friendly thanks to modular design
- Low dependence on rare earth materials
- Choose between conventional roller bearings and innovative slide bearings.
Multi Duored Gearbox
With its very high power density (Nm/kg) the Multi Duored technology is convincing as a result of its compact design and the reduced costs per kW. In addition to the more compact design, the two output shafts are certainly worth noting. These are coupled to two generators connected in parallel instead of to just one single generator.
When designing this unit, special emphasis was placed on ensuring that service can be performed as efficiently and simply as possible. In the Multi Duored gearbox, the small parts in the area of the bearings, gearing and casting parts are almost all identical. As far as the size and weight of these components is concerned, it was ensured that the capacity limits of the load cranes in the nacelle are not exceeded and also that these parts can be manufactured worldwide. The compact design of the individual parts increases the stiffness of the gearbox as a whole. This is the reason that the gearbox runs smoothly and precisely even during fast power transients. The gearbox can be rotated through 360° around the longitudinal axis to allow all of the modules in the nacelle to be accessed for service. This flexibility means that all of the components are accessible and the gearbox can be completely overhauled locally. Removal and logistical costs are eliminated.
Advantages of the Multi Duored gearbox:
- High power density in a compact and light design
- Great serviceability
- Maintenance and service are possible without having to remove the unit from the nacelle
- Two generators for variable power output
- Scalable up to 12 MW
Making reliable connections
A reliable connection between gearbox and generator is an important factor in successful wind energy production. The coupling does not only transmits the torque, it also protects the attached components against overload and travelling leakage currents. In the process of delivering thousands of high-quality wind couplings, Winergy
has gained a lot of experience and expertise, which are continuously being
incorporated in the development of new products. Winergy's maintenance and wear-free products connect our customers' drive trains over the entire lifetime of the wind turbine, making the investment calculation easy for each wind turbine OEM and developer.
Advantages of Winergy couplings
- Maintenance-free, wear-resistant, no lubrication required
- Nearly unlimited service life
- Comprehensively tested in our testing center
- Excellent power-to-weight ratio and structure-borne noise insulation
- Permissible angular misalignment up to 3°
- Coupling components can be dismounted radially, so connected machines stay in place
- Available in an electrically insulating version with overload protection
Added value through systems expertise
- Decades of
experience and perfectly matched components
Thirty years of experience and a product portfolio that produces
complete systems have formed the basis of many successful collaborations
with our customers over the past decades.
Our experience and expertise in mechanical and electrical engineering have
evolved a set of sophisticated drive-train products and service offerings
specialized for the wind power industry.
Winergy - a pioneer in the wind power industry
- In 1981 Winergy started as one of the first suppliers the
industrial production of gearboxes especially designed for the wind
industry. At that point Winergy still belonged to Flender - the renowned
gearbox manufacturer with nearly 100 years of experience. The product
portfolio was expanded to include couplings even prior to the foundation of
Winergy AG in 2001.
Market leader with 30 years of experience
Thirty years of experience has resulted in a gearbox track record of more
than 70,000 installed gearboxes - a number that is growing every year. Every
second wind turbine worldwide is equipped with at least one Winergy
component. This experience has helped us to become what we are today: the
global market leader for drive train components.
Winergy globalized presence
- Moving together with our customers into new markets was a
logical step for Winergy, enabling us to make high-quality products
available under local conditions.
After Winergy AG was founded 2001 in Germany, Winergy Drive Systems
Corporation was established in the same year in Elgin, IL, USA. The market
entry into the Asian markets took place in 2005 with an opening of a plant
in Chennai, India and 2006 in Tianjin, China (Winergy Drive Systems Ltd.).
Our global production capacities allow us to provide excellent supply
flexibility around the world. This allows our customers to remain
competitive in global markets and also to respond to shifting regional
Highest quality for our customer
- In the late 1980s, the wind turbine market faced quality
issues arising from the young industry's lack of experience. In response,
Winergy developed rigorous test programs for all gearboxes and the other
drive train components. Each and every drive train component - whether new
or serviced - must pass our challenging test runs. With 65 megawatts of
test-bench capacity, Winergy is the current world champion in this area.
Our test programs include: Power rating, Sound intensity, Vibration, Temperatures on bearings, Torque, Speed, Oil sump, oil supply, oil return temperatures,
and Oil purity
In our climate chamber, we thoroughly test our prototypes' global
applicability in all weather conditions. Potential faults are spotted prior
to delivery, thereby saving our customers' money by keeping their turbines
turning! For Winergy, quality is not a local issue - it is a global topic.
Winergy has integrated the same strict quality standards into all of its
production and service facilities - with no exceptions.
Integrated process management with optimized workflows
- High-quality products and rapid delivery times are the
most basic requirements for every customer. This is why we strive for
holistic process management, lean operations, and zero failures. By
pinpointing and minimizing potential defect sources throughout the value
chain, we achieve the highest product quality and organizational
Zero defect tolerance
Winergy has made significant strides in identifying and eliminating
potential defects in all process steps. This has also entailed significant
If errors do occur, we consistently track them down. Error prevention and
solution measures are defined and implemented through a structured set of
procedures. Our suppliers share our commitment to a zero defect tolerance,
which ensures that the Winergy value chain has no weak links.
Short lead times and optimized processes
By introducing a comprehensive production system into our manufacturing
process, we have significantly reduced lead times as well as waste and
errors. And we have made an agreement with our suppliers to implement frozen
processes, which means that our optimized process steps - including
materials and alloys - remain unchanged. The result? The highest product and
process quality for our customers.
Individual customer support in every phase of the
- Winergy views itself as a technical advisor and partner
for our customers. This accounts for all of our products and services - with
We are experts in identifying the best possible solution for each wind
turbine development project. Starting from a very basic requirement
specification, our team supports customers in finding the optimal drive
train, taking both technological and business elements into account. Our
focus is on bringing the total lifecycle costs down to the most competitive
levels and therefore increasing your return on investment.
Customer support - important for us since we started
Our service team looks back on a successful track record in customer
support. We develop customized solutions to match your needs, including
service contracts, exchange concepts, and tools that enable up-tower
Highest reliability through innovation
- Winergy has been the leading supplier of innovative drive
train component concepts since the early years of the global wind power
industry. Many product designs, processes, and procedures have become
industry standards after their introduction by Winergy. Every production
step is carefully observed - from the design phase to the final product - to
ensure that the customer receives the most highly developed and efficient
product. This applies not only to our new-product business but also to our
Analyzing the current needs and future trends of the market, Winergy is
constantly developing new concepts, designs, materials, gear geometries, and
All of our innovation efforts have two objectives in common: improving drive
train reliability and decreasing product lifecycle costs.
Your partner for wind turbine service
- Winergy supplies a wide range of service solutions for
its customers. Our customers' requirements are highly individual, and our
wind turbine service concepts are tailored to fit.
Our prime goals are to ensure that your systems are fully available and that
your operating costs are kept low.
Technical support: First-class service
- Our customers' requirements and plans are highly
individual. Winergy's customer service teams work closely with each company
to develop a service concept to meet every need. Our common goals are high
system availability and low operating costs. All the necessary procedures
are professionally coordinated, drawing on the deep knowledge of Winergy
components from our 30 years of manufacturing experience.
Your advantages at a glance
- 24/7 hotline
- Global network of local partners authorized by Winergy
- Competent and friendly service team
- 30 years of experience servicing wind drive-train components
- Original documentation for all serviced products
Drive train components spare-parts
- Highest part quality and 100 percent traceability
We start with top-quality raw materials and original drawings, realize our
designs using state-of-the-art production processes and technologies, and
finally we subject all components to stringent quality control.
A huge inventory allows for fast deliveries. Thousands of spare parts for
all standard gears are kept in stock. Immediate availability ensures
efficient service and shorter downtimes.
Winergy optimizes tooth geometry on the micron level. Spare parts that are
not manufactured according to the original specifications can sustain
significantly higher wear. Being able to rely on original spare parts means
an increased lifespan for your wind turbines.
Field service: specialist for challenging projects
- Local specialists minimize response times
A rapid response from specialists is a key element of Winergy's service,
with local specialists to minimize response times.
Special tools optimized for Winergy products
Special tools designed by Winergy can lower or even eliminate the cost of
crane equipment and reduce maintenance costs overall.
Many years of experience in conjunction with continuous in-house development
of drive components have provided Winergy's customer-service teams with the
expertise required for on-site turbine repairs.
Worksjop service: repairs and updgrades
- Winergy service performs gearbox refurbishment
(disassembly and assembly) according to the specific failure mode,
condition, design status, and original scope of delivery.
Product upgrades to the latest version
Our service strategy is to implement technological improvements that have
occurred during the lifetime of every component. These upgrades ensure that
the most reliable products are integrated during repairs of the original
Sophisticated inspections and evaluations
The key element of our gearbox refurbishment process is the Winergy service
team's extensive experience in all phases - particularly in inspecting parts
and evaluating them in terms of their potential for reuse and reworking. A
final test run ensures that the highest repair standards are met.
Strictly defined repair processes
Based on the zero-defect culture implemented in our new-product assembly
processes, our service procedures also follow clearly defined repair
processes. In this way, every product is in step with the highest turbine
quality specifications to ensure safe operation.
Spare components pool: available for every turbine
- Winergy service handles all Winergy components
both in and out of serial production. Due to our long history, Winergy
manages a large installed base and is able to provide complete spare
components for nearly every wind turbine type and power range from 150
kilowatts to 6.5 megawatts.
Winergy has manufactured more than 175 different gearbox types for all known
wind turbine manufacturers. Winergy branched off from Flender in 2001, and
is still able to service all Flender wind gearboxes.