Quality Assurance For
The Wind Sector

ZEISS Power & Energy Solutions
Longevity assurance for wind turbines

Ensuring excellence in wind energy

Longevity assurance for wind turbines

Wind energy is crucial to meeting the world’s future power supply and net zero goals. Therefore, it is essential to have reliable quality assurance processes during the manufacturing process of wind turbines, to ensure longevity and stable operation as well as low maintenance effort during the whole lifetime of a turbine. With ZEISS metrology solutions, it is possible to perform measurement and inspection on small and big dimensional components on the highest level of accuracy.

Quality assurance for a prolonged lifespan

Precise manufacturing of blades and other carbon fiber parts is essential for operation and longevity.

Blades and molds

At each step, ZEISS Metrology Solutions provide the right data according to the level of accuracy, whether it is optical 3D or CMM data.

Inspection of casted parts
Hub, torque arm, housing

Bearings for the drive train and pitch control are vital to the operation of the turbine and are subject to high loads.

Bearings inspection
Main shaft, pitch control and more

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.

Drivetrain components

The drive train converts the rotation of the hub to the generator for power generation.

Drivetrain shafts

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, form and are essential to ensure a smooth-running system and to prevent imbalances from causing damage to the system.

Components such as rotor shafts, stators, stator frames and even the towers of wind turbines are subject to strict quality standards.

Gearbox (acceleration)

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.

Generator

Direct drive technology describes a generator where the gearbox is built directly into or next to the hub.

Generator for direct drive technology

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 generator type requires high accuracy based on the higher speed and sometimes the more complex double feed design.

Compact generator combined with acceleration gearbox

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

Powerful software for efficient analysis

All-purpose software for dimensional metrology​

ZEISS CALYPSO​

Coordinate measuring machine software: ZEISS CALYPSO measures geometric elements - accurately, fast and efficiently. Select the required measurement features to configure your inspection plans. When used in connection with ZEISS measuring systems and sensors, ZEISS CALYPSO provides you with a powerful system from a single source. The software also adapts to your needs: With numerous optional add-ons, ZEISS CALYPSO also provides the perfect solution for demanding applications.​

One software for advanced metrology​

ZEISS INSPECT​

Discover the strength of ZEISS INSPECT, a software solution that allows you to analyze a variety of data types, including optical 3D data, volume data, blades and airfoils, and moving image data. The software's powerful features ensure your specific needs can be met, regardless of the system you use. Easy drag-and-drop data import and user-friendly templates ensure efficient workflows and accurate results.​

Intelligent inspection software for high demands​

ZEISS PiWeb​

ZEISS PiWeb supports decision making on the shopfloor with measurement results, values for temperature and other input data from various sources and equipment. This allows you to efficiently track your production quality across all machines along the production. ZEISS PiWeb can capture and analyze results from tactile, optical, manual or CT measurements from other parties as well as other machines such as CNC milling and more.​

ZEISS Solutions for Power & Energy​

From blades and injectors to metallurgical and other inspections, ZEISS provides the appropriate solution for your application.​

ZEISS Solutions for Power & Energy​
ZEISS ATOS LRX​

ZEISS ATOS LRX is the specialist for large-volume parts as molds, blades or casting parts.​

ZEISS MMZ​

ZEISS MMZ delivers the highest level in accuracy for big dimensional parts, such as e.g., for bearings, rings, retainer, drivetrains, gearboxes, gearbox housings, gears, and planetary carriers.​

ZEISS AXIO, EVO and SIGMA​

The microscopy solutions from ZEISS support you with deep insights of metallurgy.​

ZEISS ATOS 5​

ZEISS ATOS 5 is perfectly suited for the optical 3D measurement, e.g., in mold and blade inspection, and for casted parts.​

ZEISS T-Scan Hawk 2​

ZEISS T-Scan Hawk 2 for castings that may be unmachined or pre-machined.​

ZEISS PRISMO​

ZEISS PRISMO – High-precision tactile measurement of bearings, rings, rollers, gearbox housings, gears, and planetary carriers. ​

ZEISS CONTURA​

ZEISS CONTURA is designed to provide versatile inspection for gearbox housings, gears, and planetary carriers etc. ​

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