For suppliers entering the wind energy market we can provide constructive support on the industry demands for turbine component manufacture, particularly drivetrain elements such as gearboxes and bearings. For those companies already supplying the wind energy industry we can offer an extensive audit of your facilities to develop your capabilities and improve results.
Our manufacturing experts advise and support component suppliers in developing manufacturing capabilities to serve the demands of the wind energy industry.
With extensive experience across a wide range of methods, processes and components we can work with established or new suppliers to provide expert guidance that can improve manufacturing capabilities and results.
New or existing manufacturers
To fully understand your existing capacity Romax will audit your manufacturing plant, or those of your suppliers, and offer constructive advice on improvements that could be made to methods, processes and equipment. Our experienced team provides guidance on:
- Wind turbine Gearbox component manufacturing methods
- Gearbox component manufacturing machines/equipment
- Bearing manufacture
- Inspection and measurement methodology
- Metallurgical and Heat Treatment issues/processes
- Process Control methods and documentation
Credentials
- Experts in the design, development and manufacture of wind turbine components
- Understanding of plant and equipment used in gearbox and bearing manufacture and assembly
- Expertise on mechanical property checks, chemical analysis and metallurgical structure assessment
- Proven knowledge of process specification, introduction and tuning
- Extensive experience of heat treatment processes
- Chartered engineers - extensive experience of manufacturing techniques, equipment & optimisation
- Qualified Metallurgists – extensive experience in primary metal production and component manufacture
- Experience of metrology techniques
Manufacturing and the design process
During your design phase, our manufacturing experts can advise on a
number of different areas and ensure that the most efficient
manufacturing outcome is chosen from the outset. Our manufacturing
experts can assist in the following ways:
- Material selection & suitability
- Manufacturing processes e.g. casting, forging, machining
- Heat treatment methods & specification
- Part inspection methods & specification
- Plant equipment suitability
- Assembly documentation & tooling design
Our range of experience
During your design phase, our manufacturing experts can advise on a number of different areas and ensure that the most efficient manufacturing outcome is chosen from the outset. Our manufacturing experts can assist in the following ways:
Casting
- Iron specifications and properties
- Mould box preparation
- Runner / riser technology
- Melt technique – cupola & induction furnaces
- Metal pouring techniques
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Forging
- Specification & properties of engineering steels
- Forging technique – hammer & press methods
- Ring rolling process & plant capabilities
- Process specification including dimensional control & tolerances
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Soft Machining
- Specification, purchasing and commissioning
- Turning / Boring
- Milling / Planing / Drilling
- Gear Cutting
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Heat Treatment
- Continuous, batch, salt bath & vacuum furnaces
- Normalising
- Stress relieving
- Carburising
- Nitriding
- Induction Hardening
- Tempering
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Hard Machining
- Specification, purchasing & commissioning
- Hard turning
- Surface grinding
- Cylindrical grinding
- Gear grinding
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Assembly
- Specification, purchasing & commissioning of relevant equipment and fixtures
- Part preparation & cleaning
- Production of sequence & instruction documents
- Experience of handling & pre-loading of rolling element bearings
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Measurement
- Metrology techniques:
- Dimensional & geometric
- Surface finish & roundness
- Gear measurement
- Knowledge of relevant measurement equipment including:
- CMM, Talysurf, Talyrond, Gear measuring machines, etc.
- Specification of control techniques:
- Control to international standards
- Calibration procedures
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Inspection
- Knowledge of wide range of NDT techniques:
- Magnetic Particle Inspection
- Dye penetrant
- Ultrasonic
- Eddy current
- Assessment of grinding damage:
- Etch inspection
- Barkhausen noise techniques
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