As global demand for renewable energy continues to rise, the wind power industry faces the dual challenge of increasing turbine capacity while reducing costs and material usage. Addressing this demand, German drive technology leader Flender has announced the launch of REVO, a groundbreaking new drive concept developed under its wind energy brand Winergy. REVO marks a significant milestone in turbine innovation, achieving for the first time a torque density of 300 Newton meters per kilogram (Nm/kg). This breakthrough represents a new benchmark in the design and efficiency of wind turbine drive systems.
“With REVO, we are setting a new standard in wind power technology,” said Andreas Evertz, CEO of the Flender Group. “By significantly increasing torque density, we are enhancing the efficiency of wind turbines while reducing material requirements, making the industry more competitive, sustainable, and cost-efficient.”
The new drive concept delivers a torque density of 300 Nm/kg for next-generation turbine developments, resulting in a far more compact and lightweight system. For the same power output, REVO enables a reduction in outer diameter of up to 25 percent compared to conventional designs.
Andreas Klein, Vice President of Drive Systems and Gear Engineering at Winergy, explained that torque density, often referred to as power density, is a crucial factor influencing the capital cost of a wind farm, as it defines the torque transmitted per kilogram of material.
The advantages of REVO extend across the entire turbine lifecycle. Its compactness reduces transportation costs, ensuring drive systems remain road-transportable even for turbines exceeding eight megawatts. The smaller size also opens access to new installation sites, supporting faster wind energy deployment.
Reduced material use leads to lighter nacelles and lower mass at the tower top, which translates into significant savings in tower and foundation construction. Compared to gearboxes of equivalent power class from 2010, REVO achieves up to a 70 percent reduction in CO₂ emissions due to its efficient use of materials. The system also incorporates low-noise journal bearings that comply with European sound regulations and improve long-term reliability.
REVO is the result of close collaboration within Flender’s global engineering network, combining advanced gear materials, optimized planetary stage configurations, and innovative second-generation journal bearings. These technologies collectively deliver exceptional torque density and operational durability. Following extensive validation and testing, the REVO prototype is now showcased at Winergy’s facility in Voerde, Germany.
“The compactness and performance of REVO reflect our commitment to innovation,” said Tommy Rahbek Nielsen, President of Winergy. “This development allows our customers to achieve higher output without increasing size or compromising reliability.” CEO Andreas Evertz concluded, “REVO represents a decisive step forward for the future of wind energy and reinforces our mission to make sustainable power generation more efficient and accessible worldwide.”
Flender is a global provider of mechanical and electrical drive systems, delivering innovative and high-performance solutions for over 125 years. Its product brands “Flender” and “Winergy” cover gear units, couplings, generators, and comprehensive services across industries including wind energy, cement, mining, power generation, marine, water treatment, and conveyor systems. Recognized for sustainability, Flender ranks among the top 1% of companies assessed by EcoVadis. The company employs around 8,500 people worldwide and is headquartered in Bocholt, Germany.
