What does the SERVICING of WIND TURBINE GEARBOXES look like?

Описание: [Sponsored by Famur Gearo]

In the latest episode, we take a closer look at the process of servicing WIND TURBINE GEARBOXES – a key component in the production of green energy. Wind farms, increasingly present both onshore and offshore, require ongoing technical support to operate without interruptions. A visit to the Katowice-based company Famur Gearo reveals the comprehensive process of gearbox repair and maintenance – from dismantling the unit in the field, through technical diagnostics, to reinstallation and testing. The company also collaborates with Total Wind PL, a specialist in turbine assembly and disassembly.

The overhaul process begins with a borescope inspection, which allows engineers to look inside the gearbox and identify any internal damage. This is followed by disassembly and detailed examination of individual components such as gears, shafts, yokes, and housings. Based on precise measurements and tests, the scope of the repair is determined. Many parts are refurbished, while others – especially the most worn ones – are completely remanufactured. Famur Gearo not only repairs gearboxes but also designs and manufactures new ones, including the first Polish-made GearoX gearbox for 2 MW turbines.

Regenerating mechanical components is a process that demands the highest level of precision. Cast housings are milled and turned, gears are hardened and ground, and shafts are machined to micrometer accuracy. The refurbished parts are then thoroughly measured in a laboratory and reassembled according to detailed technical documentation. The finished gearbox undergoes testing on a dynamometer to simulate real turbine operating conditions. Once it passes all tests, the gearbox is reinstalled at the top of the tower. Thanks to SCADA and CMS systems, customers also gain remote monitoring tools to track equipment health, prevent failures, and plan maintenance in advance.

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