rothe erde® slewing bearings - empowering a sustainable future
Information about our booth Product highlights at the fair Wind energy plant expertise - from top to bottom Floating wind turbine We are the reliable partner at your side Complaint rate below 1% The future of steel is green Sustainable manufacturing and procurement Our commitment to climate protection until 2050 Our solutions in the wind energy sector Useful links
thyssenkrupp rothe erde: The technology and quality leader for slewing bearings with a unique global production and sales network!
Welcome to the WindEnergy Hamburg 2022!
Moin Moin! We look forward to welcoming you at WindEnergy Hamburg 2022 from September 27th to 30th .
Visit us in person at at the largest and most important meeting of the onshore and offshore wind industry in hall B6 at our booth B6.232.
Pay us a visit in Hamburg to get an impression of our innovations and solutions and allow our experts to comprehensively inform and advise you. We are looking forward to exchanging with you!
An insight into our booth
Our product highlights at the fair - key components for the global energy transition
TRB-TRBs are particularly suitable for the use in offshore wind turbines. They have the following characteristics:
high service life
high system stiffness
low friction
A TRB-TRB arrangement is an adjusted bearing arrangement consisting of two single tapered roller bearings (TRB). Each of the two bearings consists of:
an inner ring
an outer ring,
a set of rolling elements and
a cage.
In conjunction with the shaft and housing, the two bearings form a preloaded bearing unit that enables the transmission of high moments with a simultaneously small bearing size. The tapered rolling elements allow a pure rolling contact between rollers and raceways. The correct adjustment of the system preload on the one hand ensures a sufficient load zone in the bearing and on the other hand ensures a high system stiffness. The different and individual contact angles of the two bearings allow an optimized distribution of the external loads as well as the absorption of high radial and axial forces.
The bearing rings are induction hardened by default using a process patented by thyssenkrupp rothe erde. We also offer bainitic or case-carburized variants. Production is possible at many international thyssenkrupp rothe erde locations.
TRB-TRB arrangements have a high span width and are therefore particularly suitable for supporting high moments. Compared to a single main bearing, the size of the individual bearing rows can be significantly reduced, making the TRB-TRB arrangement a cost-efficient alternative.
Particularly advantageous: As the bearing set is clamped, it can be mounted easily and safely.
TRB’s are tailor-made by thyssenkrupp rothe erde. We always take into account that on- and offshore wind turbines have different requirements. Characteristics of the specific turbine are already considered in the early design phase, while also a support in the design of the assembly process can be provided.
A long service life and a high resistance to common damage mechanisms are achieved through the design, material selection and hardening process.
We build on many years of experience in the field of main bearings. The continuous development of our products and technologies is ensured by one of the largest research facilities for slewing and large-diameter bearings with our own test field and in-house calculation and simulation tools, as well as with cooperations with national and international research institutes.
Bearings for Wind Gearboxes have to withstand various loads resulting from the intended operation:
constantly changing loads,
strong vibrations and
temperature fluctuations.
Gearbox bearings in the form of radial cylindrical roller bearings or radial tapered roller bearings are mainly used in planetary gearboxes of wind turbines.
The exact design of the selected bearings depends on several operational factors:
Load size
Load direction
Operational speeds
Build-up inner gearbox space
Generally, single row or double row bearings are used for these applications. Cylindrical roller bearings without cages are preferred for slow-running shafts and high operational loads.
Gearbox bearings are critical-to-quality components. They are used for the support of different gearbox components like high, intermediate or low speed shaft, but also for components as planet carriers and planet gears. Bearings for wind gearboxes made by psl® are able to withstand the demanding operating conditions, even for gearboxes with for increasingly higher power densities.
psl® cylindrical and tapered roller bearings are types mostly used in wind turbine planetary gearboxes. The tailored bearing design depends on several operational factors such as the load level, the operational speeds and the available space.
Generally, bearings with one row two rows are used for these applications. For low-speed shafts and high operational loads, cylindrical roller bearings without cage are preferred. Due to very limited inner space, special bearing solutions involving outer rings with integrated gearing can also be considered.
Bearing rings made out of through, case or induction hardened steels provide sufficient hardness of the raceways. Our hardening processes ensure an appropriate resistance against common failure modes due to dynamic loads, which frequently occur in wind turbine gearboxes.
A special surface coating (black oxide) improves sliding resistance and reduces the likelihood of white etching cracks (WEC), especially during the initial stages of operation.
The gearbox bearings must fulfill various requirements resulting from the intended operation: constantly changing loads, strong vibrations and temperature fluctuation. All these operational requirements must be thoroughly analyzed and considered during the design phase.
In the field of wind energy, an extender bearing is a pitch or yaw bearing with the following special features:
Integrated extender
Inwardly tapered or outwardly extended flange
Adaptation of different connection diameters (modular principle)
Reduced mounting effort
To get a better understanding, the operating principle of the extender bearing is shown by the example of a pitch bearing:
In this example, the extender bearing is a slewing bearing in the wind turbine, which combines the pitch bearing and a separate extender ring into one component.
The inner ring of the extender bearing is designed with an inwardly tapered flange to which the rotor blade of a wind turbine is mounted. By changing the flange taper, different blade root diameters can be adapted without changing the raceway system, the outer ring, etc. in terms of design.
The manufacturing of the extender bearing presents a particular challenge. Not only is achieving the material properties in the highly stressed areas difficult but also the quenching and tempering. The reason for this is its shape and the dimensions of the special inner ring.
Extender bearings can be used if a unit hub is supposed to be used for different blade root diameters. The functional principle can also be reversed by mounting different hubs on a constant blade root diameter.
This enables the standardization of components and the minimization of variants. In addition, an enormous cost optimization is achieved.
Extender bearings offer various advantages for wind turbine manufacturers. This is also proven by the manufacturing figures: a large number of these bearings leave our plant in Lippstadt every day after comprehensive quality checks.
Wind turbine manufacturers particularly appreciate:
the exceptionally long service life
the robust design
the reduced risk of corrugation during downtime
the small size of the components
The extender bearing enables a modular design and reduces the assembly effort by making a separate extender ring obsolete.
The power rating of wind turbines are more and more increasing - and so do the hub and tower heights as well as the rotor diameters. The size of the individual components connected to the pitch or yaw bearing, such as the hub and the blade, are growing in consequence of this size trend.
At the same time, the operating conditions of the pitch bearings are getting purposefully optimized on a turbine- and customer-specific basis to maximize power yield and to reduce dynamic structural loads. For pitch bearings that are used for a targeted, continuous adjustment of the pitch angle, this leads to an increase in pitch travel. Both development trends pose increasing technical challenges towards an efficient and reliable operation of pitch bearings of future multi-MW wind turbines in the on- and offshore sector.
In order to optimize the hubside system stiffness, particularly for large multi-MW and thus potentially low-stiffness hub structures, thyssenkrupp rothe erde has developed the Pitch Bearing Unit (PBU) for the requirements of next-generation pitch bearings.
The Pitch Bearing Unit is an extender bearing unit to be bolted between the hub and the blade. Both the integration of the pitch bearing functionality (ball or roller bearing) and that of the pitch drive (electric or hydraulic) are enabled based on this compact unit.
The optimized system stiffness offers significant mechanical advantages for the operation of the pitch bearing. At the same time, the integration of the pitch drive facilitates a targeted modularization of the complete pitch unit as well as a standardization of the hub across different product families, while at the same time simplifying the hub design in terms of the sourcing, machining and shipping processes.
Together with HAWE Energy Solutions and ITH bolting solutions, a hydraulic pitch drive has been developed for a 10MW offshore project and integrated into the PBU, as shown schematically in the following figure.
Learn more about these and other possible applications of the Pitch Bearing Unit also in the onshore area, e.g. for the targeted reduction of the hub size to solve hubside supply chain and / or transport restrictions as well as for the increase of the blade root diameter. Discuss with our team the advantages of the plug-and-play feature of the Pitch Bearing Unit and your requirements for a simplified component management, cost-optimized manufacturing and assembly processes.
Features
Integration of pitch bearing functionality
Integration of hydraulic or electrical pitching system
Plug-and-play feature
Structural design of PBU tailored to OEM-specific turbine design
Advantages
Superior blade bearing performance - derisiking strategy for 3RR bearing applications
Enabler for modularization and standardization of pitch system
Improved transportation (less hub size, in particular onshore)
Bigger blade root diameter feasible for given hub dimension
Less complex hub design and less hub machining costs
Easy OEM supply chain due to plug-and-play
Easy installation on site due to plug-and-play
Proven technology from a leading bearing manufacturer and pitch drive supplier
Wind energy plant expertise - from top to buttom
Along with innovative solutions for pitch bearings, yaw bearings and bearings for wind gearboxes, the main focus lies on developing main bearings. thyssenkrupp rothe erde has been crcially involved in its role as the global market leader for slewing bearings.
Intensive research and development has resulted in the successful deployment of thyssenkrupp rothe erde products in wind energy plants (both onshore and offshore) throughout the world. In order to test our products as realistically as possible, they are subjected to various tests on the rotor bearing and pitch bearing test benches in our 10,700 m² research and development center. Additionally, we investigate and improve the reliability and structural behavior of our products on site. With more than 60 years of experience in research, we are able to solve the biggest challenges in the development of slewing bearings for the wind industry.
With the aim of achieving advances in providing environmentally friendly energy, we are installing increasingly efficient wind energy plants around the world, which are now able to compete against fossil energy resources.
We at thyssenkrupp rothe erde are a strong, progressive partner in the field of onshore and off-shore systems. Our constant search for innovative breakthroughs enables our customers not just to be part of the new energy era but to advance it, and to make crucial contribution to securing a more environmentally friendly future. Together we master every challenge!
We are the reliable partner at your side
Global strength – local presence
You can find us where we are needed
- Production plants in 10 countries
- Global distribution network
- Local and decentralized sales
Full Service
A strong partner from A to Z
- Full implementation
- Extensive consulting & training
- Full after-sales services
Highest quality standards
We meet your requirements
- Modern calculation methods
- World's largest R&D center
- Complaint rate below 1%
The future of steel is green - thyssenkrupp will be completely climate neutral by 2045
Sustainability is a core element of our company strategy: As part of a global industrial group, thyssenkrupp rothe erde develops innovative product solutions, which not only secure long-term successes for our customers, but also make a positive contribution to global development.
We are convinced that we can substantially advance the CO2 neutrality of the industry with our engineering expertise. We achieve this not only by developing and manufacturing products that enable, for example, the sustainable transformation of energy generation and decarbonization, but also in our production processes. Resources are reused and recycled, processes become more energy efficient and, wherever possible, we use electricity from renewable sources. This project has already been implemented in Germany and France, and other plants will follow successively. We also, where it makes sense, install more and more photovoltaic systems at our plants, most recently for example on a newly built production hall in Lippstadt.
A thyssenkrupp rothe erde energy management system, certified to ISO 50001, has already been implemented at the major plants, the smaller plants will follow soon. We develop products, which by virtue of their shape and nature, already reduce resource consumption in production. thyssenkrupp is actively participating in the climate targets of the Paris Agreement and has set itself the goal of being completely climate neutral worldwide by 2045.
Sustainable manufacturing and procurement
Sustainable manufacturing and procurement
We use raw materials with a high percentage of recycled content to manufacture our products in a way that conserves resources as much as possible. We also rely on recyclable materials in production.
In addition to our product design and manufacturing technology, which enables the energy-saving production, we reduce our CO2 emissions by shortening our transportation routes. This includes:
the local procurement of raw materials,
our own production of components, and
local production.
All our plants are certified to OHSAS 18001 and ISO 14001 standards and follow the ISO 50001 energy management system. The plants with high energy relevance are certified to standard ISO 50001.
Sustainability also plays an equally important role in our supplier management at thyssenkrupp rothe erde. We are continuously developing our processes. In this way, we aim to increase transparency on the origin of raw materials and conflict minerals in order to identify risks at an early stage.