Gallery: How to assemble a gearbox

FINLAND: Gearboxes are an important component of a wind turbine, but few people get to see inside.

by David Weston 24 July 2015

  • Moventas carburise their components to ensure a wear-free surface

    Moventas carburise their components to ensure a wear-free surface

  • Bearings are integrated into the planet gear

    Bearings are integrated into the planet gear

  • The planet stage transmits the power produced by the blades

    The planet stage transmits the power produced by the blades

  • Each component is measured before assembly to make sure it meets design requirements

    Each component is measured before assembly to make sure it meets design requirements

  • Gearboxes are then tested with a full load to check for vibration and noise behaviour

    Gearboxes are then tested with a full load to check for vibration and noise behaviour

  • Sensors, heaters and other electrical components are attached

    Sensors, heaters and other electrical components are attached

  • A complete 3MW gearbox

    A complete 3MW gearbox

  • To transport the gearbox is wrapped in film to protect against rust and dirt

    To transport the gearbox is wrapped in film to protect against rust and dirt

  • An exploded view of a Moventas gearbox

    An exploded view of a Moventas gearbox

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Moventas has unveiled some of its manufacturing process, giving a close up view of the components inside its 3MW gearbox. 

The company explained that the gearbox is made up of a number of segments, which are all carburised to ensure a wear-free surface. Carburising is a process whereby iron or steel is heated in order to absorb more carbon, making the metal especially hard wearing. 

Bearings are integrated into the planet gear to avoid common bearing failures and ensuring a precise fitting. The planet stage transmits power produced by the blades.

Before assembly takes place, each component is measured against design specifications. Each part is washed several times before it is put in place, Moventas said. 

Once assembled, the gearboxes are tested with a full load to check for vibration and noise behaviour. This is done by placing a second gearbox back to back with the first to put the load on.

Heaters, sensors and electrical systems are placed on the gearbox after it has been fully assembled and painted. 

To be delivered, Moventas placed the gearbox on a tailor-made stand and wraps it in Zerust film to prevent exposure to the elements.