Engineering

Benefit from our comprehensive engineering know-how: With the help of digital twins, we simulate your machines to test new components or performance improvements during operation and then implement them. Our services include testing, design, calculation, and simulation of your generators and drives to detect problems such as cracking, insulation wear, and vibrations – and of course, fix them. Notably, our engineers provide all these solutions independent of the manufacturer, without you having to deal with other service providers. And: We keep you informed about the project progress regularly, proactively, and reliably.

Design modifications to increase generator performance

Demand for a power increase or improved turbine efficiencies usually require an increase in generator output. We have the know-how and the necessary calculation tools to determine the performance limits of existing generators and to propose design options for possible performance increases. This gives you the opportunity to weigh up the time and financial implications of purchasing a new generator against optimized continued operation of the existing generator and thus select the optimum solution.

Vibration diagnostics and modeling on rotating machinery

We offer a range of vibration diagnostic services for large rotating machinery. These include modal analysis, operational vibration measurements, vibration analysis, rotor balancing, and FEM-based rotor dynamics simulations. To solve vibration problems, we combine the results of natural frequency tests and vibration measurements with our simulations, determine the root cause, and then develop solutions for design improvements.

Comprehensive diagnosis on generators

Our on-site inspection of turbo generators does not require the generator rotor to be removed. The Robotic Inspection System developed in-house provides comprehensive diagnostics for air-cooled and hydrogen-cooled generators. Our diagnostic tools include robotic crawlers, which are suitable even for tight clearances on air-cooled generators, and three modern, high-resolution cameras that allow thorough visual inspection. In addition, we use a Chattock coil in combination with ELCID data acquisition hardware and software, as well as a Wedge Tapping System for groove depths up to 35 mm to inspect your machines. All diagnostic tools are integrated in a single robotic configuration to ensure a time and cost-efficient assessment of the generator.

Manufacturing optimization for gear production

We already support you in the development phase of your products to realize a resilient and cost-efficient manufacturing. For example: Often there is potential for cost optimization with regards to material selection, surface hardening or heat treatment, finishing and testing methods. Depending on the challenge, we can work with you to reduce the manufacturing effort through simple design changes and thus, for example, optimize manufacturing steps, setup time or assembly structure.

Special solutions in construction of large gear units

Our extensive technical know-how enables us to reengineer large gear units to improve performance or extend availability. For example, we can manufacture new gear sets up to a diameter of 2000 mm for any application according to ISO standards in our production facility. In the event of a gearbox replacement after damage or during maintenance, we can repair the defective gearbox and thus ensure a high level of efficiency and availability. Ask us for a customized solution for you!

Focus

The production of large gears requires high investments in CNC machines. At the same time, it is technically very demanding and involves a high risk of rejects even in the case of minor processing errors. Producing these gears is one of our core expertise. More focus topics

Focus

Today’s energy mix with solar and wind, which are highly dependent on the weather, leads to a high alternating load on turbo generators. We have developed a new repair process. More focus topics