Solutions for Wind Turbine Gearboxes
Smart design, production and manufacturing of gearboxes focused on right-sizing, high efficiency and resilience.
Optimized designing and robust manufacturing of next-generation wind gearboxes
Wind turbine gearboxes are large and heavy, being one of the biggest contributors to turbine downtime in the field. Hexagon helps design and manufacture durable, fit-for-purpose, highly efficient gearboxes with a portfolio of simulation, CAM and inspection software and metrology hardware.
Design analysis and optimization of gearboxes
Design a gearbox and optimise it against a range of targets (cost, weight, durability, vibration, efficiency) in the minimum time and with minimized resources and project risk. Create a virtual model of a gearbox for design analysis, allowing the best design to be selected and the design fidelity to be gradually increased as the project progresses to virtual sign off.
System Dynamics
Structural Analysis
Products used
Virtual testing of designed and manufactured gearboxes
Reduce time and cost through virtual testing of wind turbine gearboxes during design and manufacturing. Verify the design before prototype manufacture and import measured data into a design simulation model to improve confidence that the design works as intended.
System Dynamics
Structural Analysis
Acoustic Simulation
Dimensional Analysis
Process Control & Analytics
First-time-right forging and welding of gear wheels
Save time and cost caused by multiple physical try-outs through virtual optimization of forging and welding sequences for a robust manufacturing process layout and extended service life. Simulate the forging of gear wheels. The resulting shape deviations and properties are then fed into a simulation of the welding sequence to determine possible thermally-induced distortions and residual stresses.
Virtual Manufacturing and Costing
First-time-right forging and rolling of bearings and shafts
Save time and cost caused by multiple physical try-outs through virtual optimization of processing steps and machine parameters for first-time-right production. Simulate the forging and rolling of bearings and shafts to predict part distortions and manufacturing issues like flow defects, machine overload or premature die failure.
Virtual Manufacturing and Costing
Efficient machining of gears
Substantially reduce the machining cycle time of gears through efficient machining strategies, ensuring smooth execution by building a Digital Twin that simulates the entire process. Prepare models for manufacturing, generate a toolpath NC program, then verify and optimize the toolpath through the creation of a Digital Twin and a simulation of the machining process.
CAD for CAM
Production Machining
CNC Simulation
Products used
Efficient gear measurement
Avoid costly reworks and cost-intensive downtimes by inspecting even very large gears with a highly accurate and standard-compliant inspection system. Nearline/inline inspection of standard geometries and gears with stationary CMMs, standard-compliant evaluation and data transfer for statistical evaluation and/or monitoring of the manufacturing process, reverse engineering of unknown gears during maintenance.
Dimensional Analysis
Process Control & Analytics
Products used
© 2024 Hexagon AB and/or its subsidiaries