Vejle-based CNC Onsite, a mobile machining company, has expanded its on-site repair service for broken rotor teeth. The service now covers a range of common wind turbine platforms. As nacelle layouts and the workspace around the rotor vary, each turbine type requires a tailor-made machine setup. With the expanded service, CNC Onsite is meeting the company's growing demand for cost-effective repairs rather than replacing the entire rotor, CNC Onsite said in a press release.
– The number of turbines approaching the end of their design life is increasing. This means that although the percentage of turbines with rotor problems is relatively low, the total number of turbines that can benefit from this solution is growing. This, together with the increasing interest in life extension, has led to us now offering repairs on more wind turbine platforms, says Søren Kellenberger, Sales Director and Partner at CNC Onsite.
In order to serve the most common wind turbine manufacturers, CNC Onsite has invested in additional engineering and technical resources to further develop its rotor repair service. Two years ago, the company established a technical center in Vejle, which includes mechanical and electrical competencies, as well as a 2,000 square meter workshop to test and validate repair methods.
Already in use on three continents, CNC Onsite’s mobile machines have been used to install more than 100 new rotor segments, equivalent to 600 teeth, on both offshore and onshore turbines. The toothed rotor keeps the blades aligned with the wind direction for maximum energy production, but over time the teeth can wear down or break. Possible causes include sustained loads or unpredictable wind conditions. If the problem is ignored, not only does energy production decrease – it can also lead to more extensive wear on the blades and driveline, potentially leading to costly failures.
CNC Onsite repair service is now available for rotors on a range of wind turbine types and costs a fraction of the cost of replacing the entire rotor, which is the conventional solution. The patented repair method restores the rotor in a matter of days, whereas a full replacement can take weeks.
The specially designed machine mills the damaged rotor teeth with extreme precision, creating a pocket that fits the new replacement segment precisely.
As the repairs are carried out inside the tower, the work is not dependent on favourable weather conditions. The nacelle remains intact and does not need to be dismantled, reducing costs while improving safety – handling large turbine components poses a safety risk for technicians. In addition, potential damage to the blades that could otherwise occur during dismantling is eliminated.
Repairing the rotor with the necessary precision up in the tower is complex due to the location of the rotor. The working space for both the machine and the technician is often limited. CNC Onsite has therefore designed its machine in several modules, which makes transport and assembly up in the tower easier.
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