Achieving speed, precision and high safety in wind turbine blade installation for global wind turbine manufacture
In the fast-evolving wind energy sector, efficiency, safety, and precision are key to maintaining a competitive edge. This case highlights how a close partnership and technical innovation enabled a global wind turbine manufacturer to significantly improve one of their core installation processes.
AS SCAN technician making adjustment to turner gear control box.
Customer challenge: outdated Turner Gear for single blade installation
A global leader in wind energy with turbines installed worldwide, faced a critical challenge in optimizing their blade installation process. The existing turner gear technology resulted in longer installation times, higher operational costs, and an increased risk of equipment strain. To maintain their global market leadership and meet rising demand, they needed a next-generation tool that could improve efficiency, safety, and reliability while minimizing downtime.
Solution: PLC-controlled high-speed turner gear blade installation tool
AS SCAN was selected as the preferred partner through a competitive bidding process due to our expertise in hydraulic and electronic systems and our flexible approach.
The HMI control interface used for managing and monitoring the Turner Gear.
In close collaboration with clients engineering team, we developed a PLC-controlled Turner Gear solution featuring an advanced high-speed blade installation tool. The solution significantly enhanced safety, efficiency, and precision control.
3 key features of the solution
1. Enhanced Turner Gear safety during single blade installation
Drawing on our extensive experience in green energy sectors such as Power-to-X and Wind, we ensure full compliance with our clients’ strict safety and documentation requirements.
A close-up of the robust Turner Gear for single blade installation
The Turner Gear unit incorporates multiple safety functions, all designed in accordance with ISO 13849, an international standard with stringent safety regulations. The AS SCAN Turner Gear system is engineered to meet Performance Level PLd, which signifies a high level of risk reduction. This ensures that the system not only enhances efficiency but also adheres to one of the highest safety standards in the industry.
A key safety feature of the Turner Gear system is the interlock mechanism, which plays a crucial role in reducing the risk of base frame cracking.
“The safety improvement that has to be highlighted has to be the interlock solution between the Turner Gear and the WTG rotor lock system, in a sense that the risk of cracking a base frame due to over torque when the rotor lock system is malfunctioning has lowered by 99%. We continuously collect real-site data on this and look forward to seeing whether these measurements confirm the theoretical numbers.”
- Lead Engineer, Powertrain, TCM
2. Turner Gear high-speed operation
A specially designed high-speed functionality significantly reduced blade mounting time, improving productivity while maintaining safety. The AS SCAN Turner Gear increased rotation speed by 50%, in balanced condition, when no blades were mounted or when all blades were fully installed. This optimization streamlined powertrain preparation and blade installation, reducing downtime and improving workflow efficiency.
Illustration of the significant reduction in installation time with new Turner Gear
“By implementing the new Turner Gear solution, the client saves about 50-66% of the powertrain preparation time (PRE-RUN) as well as during blade installation when the system is under load for several minutes without stopping due to overheating.”
– Lead Engineer, Powertrain, TCM
3. Remote Connectivity
Wind turbine installations often take place in remote locations where on-site technical support is costly and time-consuming. To address this challenge, we integrated remote connectivity into the Turner Gear, allowing clients field technicians to perform real-time troubleshooting and system adjustments via PC connectivity.
Remote assistance can be performed either directly by AS SCAN or by specially trained clients’ technicians. These technicians have completed a dedicated training program at AS SCAN, equipping them with the necessary expertise to handle such tasks independently.
The diagram illustrates AS SCAN / client remote assistance streamlines troubleshooting
A real-world example illustrates the impact of this solution:
Early one morning at a wind farm in USA, a wind turbine installation technician encountered an unexpected issue. With a tight schedule and limited on-site support options, he contacted AS SCAN via WhatsApp. Within an hour, an AS SCAN service technician connected remotely through Danfoss Plus+1, diagnosed the issue, and guided the technician through the necessary adjustments. The problem was resolved swiftly, ensuring installation continued without significant delays.
“This case highlights the importance of remote support in minimizing downtime and ensuring efficient turbine installation. Our ability to respond quickly, even in remote locations, demonstrates our commitment to supporting our customers in real time.”
– Michael Vejlgaard, CEO, AS SCAN
Turner Gear Testing and Quality Assurance
To guarantee reliability and performance under diverse conditions, the Turner Gear tool undergoes rigorous testing—both in-house and in the field.
The following video demonstrates a Factory Acceptance Test (FAT) conducted on the largest of our three Turner gear models:
AS SCAN also introduced a state-of-the-art test board, providing a comprehensive overview of all signals connected to the nacelle control unit. This allows technicians to verify full system functionality before deployment. A detailed test report is generated to document compliance with the highest industry standards.
Screens displaying AS SCAN's software for monitoring and testing Turner Gear components.
Key Project Outcomes
- Faster and safer installations: 50-66% reduction in preparation time, lower risk of errors.
- Minimized downtime: Remote support ensured quick troubleshooting, preventing long delays.
- Global reliability: Used by turbine installers worldwide, backed by comprehensive training and remote assistance.
- Improved working environment: Reduced manual handling, less physical strain on technicians.
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