Quality Assurance for
the Wind Sector

Precise manufacturing of blades and fiber parts is essential for operation and longevity. ZEISS 3D scanning tools visualize deviations in size, shape and position, enabling detailed and accurate mold inspection of blades and other components.

Molded and pre-machined parts require inspection at every step of production, from incoming inspection to pre- and final machining. At each step, ZEISS Metrology Solutions provide the right data according to the level of accuracy, whether it is optical 3D or CMM data.

Bearings for the drive train and pitch control are vital to the operation of the turbine and are subject to high loads. The accuracy of all bearing components is the determining factor for longevity, low lifetime maintenance, and the elimination of noise and vibration. The bearings have an impact on the efficiency of the drive train and must be fully functional at all times.

The drive train converts the rotation of the hub to the generator for power generation. For the direct drive technology, the shaft is part of the rotor of the ring generator. For the wind turbine equipped with an acceleration gearbox, there are usually different shafts such as the low speed and the high-speed shaft connecting the hub through the gearbox to the compact generator. Accurate measurements regarding size and form are essential to ensure a smooth-running system and to prevent imbalances from causing damage to the system.

The gearbox accelerates the rotational speed coming from the low-speed shaft through two or three stages by a predefined ratio. The low-speed stage, intermediate speed and high-speed stage accelerate the speed and as a result the high-speed shaft runs the generator at ideal operation. All gearbox components must be manufactured very precisely to ensure a perfect fit and interaction. This is mandatory to achieve the highest power, to transfer the torque and to minimize the energy loss.

The direct drive technology describes a design where the generator is directly built into or next to the hub and rotates with the same speed as the hub. As there is no gearbox and the generator is part of the drive, it is so called direct drive. Dimensions and tolerances of the components are crucial for to high energy output by providing enough flexibility under stress. Accurate measurements and analyses are essential to identify potential issues early on and prevent costly breakdowns while improving overall efficiency.

This more "compact" generator type is located inside of the nacelle at the end of the high-speed shaft coming from the acceleration gearbox. This generator type requires high accuracy based on the higher speed and sometimes the more complex double feed design. Precision of the components is crucial for the overall efficiency of the generator and is preventing costly failures