ZF Wind Power has officially launched a 30 MW test rig at its Test and Prototype Center, marking a significant step in addressing the evolving challenges of the wind energy sector. The newly commissioned rig is designed to test and validate powertrains and components, ensuring they meet the rigorous demands of modern wind turbines and supporting ZF’s commitment to a sustainable energy future.
The 30 MW test rig, part of ZF’s state-of-the-art facility, is engineered to simulate real-world conditions, enabling dynamic testing of key components such as the gearbox, generator, and main bearings. This investment in advanced testing infrastructure bolsters ZF Wind Power’s ability to enhance the efficiency, durability, and performance of wind energy systems.
As a pioneer in the wind energy industry, ZF Wind Power continues to push the boundaries of innovation by increasing torque levels in its gearboxes and powertrains. The company places a strong emphasis on extensive validation to reduce risks and ensure product quality. “Validation is the cornerstone of ZF’s innovations,” says Bert Verdyck, Head of Product Portfolio Management at ZF Wind Power. “It is critical for gaining approval from customers, insurers, and certification agencies.”
The test rig, which spans an impressive 60 meters in length, tests powertrain systems under real operational conditions, pushing the limits of torque (45 MNm), bending moment (64 MNm), and axial force (7,500 kN). This cutting-edge technology plays a crucial role in developing next-generation powertrains for the wind energy sector.
The 30 MW test rig is housed within ZF Wind Power’s advanced Test and Prototype Center in Lommel, Belgium. This facility serves as a focal point for the company’s research, development, and validation efforts, offering various test rigs for components, assembly, climate testing, and more. The center also boasts a new lubrication test rig, further enhancing ZF’s testing capabilities.
Through the Test & Prototype Center, ZF collaborates closely with partners to accelerate product development. “By integrating all aspects of testing and assembly in one location, we can significantly improve efficiency and reduce testing time and costs,” says Felix Henseler, CEO of ZF Wind Power. The approach shortens the testing cycle by up to four months, reducing the need for duplicate tests at partner sites and improving time-to-market for new products.
The introduction of the 30 MW test rig represents a major milestone for both the wind energy industry and the Flemish economy. Matthias Diependaele, Flemish Minister-President, highlights the project’s importance, noting that the Test & Prototype Center in Lommel positions Flanders as a leader in wind technology innovation and strengthens its appeal to investment in cutting-edge industries.
This investment in sustainable energy aligns with ZF’s broader strategy to achieve climate neutrality by 2040. By enhancing the reliability and efficiency of wind turbines, ZF Wind Power is contributing to global efforts to transition to renewable energy sources. “Our commitment to sustainability is integral to our future vision,” says Felix Henseler. “The 30 MW test rig is a key element in our mission to drive the future of renewable energy.”
