Our world faces major challenges. Global demand for resources is growing. Energy is expensive and is becoming scarcer. How can we use energy as responsibly as possible? How can we tap unlimited energy sources? ThyssenKrupp with its engineering expertise offers a wide variety of solutions for these global challenges and is constantly seeking further innovative responses. We regard it as our duty to help shape a sustainable future for present and future generations. Our strategy is based on the global drivers of demographics, advancing urbanization and globalization as well as the constraints imposed by climate change, finite resources and political conditions. New eco-friendly technologies are taking us further down this path, meeting needs for both “more” and “better”.

Demand for electricity from renewable energies is rising rapidly. Wind power is already playing an important role in this today and will gain further importance in the future. Offshore wind turbines are the current trend. Strong and steady winds make for much higher power yields. Repowering is another important area – replacing old wind turbines with new, more powerful and more efficient units. We strive to develop products that protect environment and climate. As a solution provider for our customers we develop innovative technologies and materials that open up new roads and help shape a sustainable future. Our outstanding engineering expertise also benefits our wind turbine customers in both the offshore and onshore sectors. Our research and development centers work to continuously improve our products and secure the highest quality standards. We focus systematically on innovation.

Research, innovation and knowledge-sharing: the best basis for first-class steel technology. ThyssenKrupp Steel Europe offers customized solutions in the field of research and development. In particular our two departments “Development and Optimization” and “Applications Technology” offer unique expertise that can be used for wind energy plants. Development and Optimization” is engaged in the further development of existing steels, coatings and technologies, and in the development of new steels and lightweight materials. Our surface engineering and pilot manufacturing facility in Dortmund is one of the world’s leading development centers for flat steel coatings. “Applications Technology” advises and supports customers on all issues along the value chain.

In offshore applications in particular, customers benefit from our unique materials expertise. Many of our materials are specifically designed to cope with extreme conditions. Our heavy plate is particularly suitable for tower and foundation structures, while grain oriented or non grain oriented electrical steel PowerCore® from ThyssenKrupp Electrical Steel is ideal for electrical equipment. Heavy plate products are the basis for highly stressed steel structures. Produced on state-of-the-art manufacturing facilities, they guarantee maximum robustness and strength with significantly reduced weight. They are used wherever extreme toughness is essential. Electrical steel is used as a core material in the electrical components industry throughout the energy value chain: from electricity production (generators) to transmission and distribution (transformers) to consumption (electric motors, appliances).

With our leading materials distribution companies, we can provide expert advice on materials and processing, ensuring outstanding quality as well as service and production from a single source. A tight-knit global distribution network keeps us close to our customers and allows us to respond quickly and flexibly. Our services are tailored to our customers’ requirements. Flexible material availability and extensive stocks provide additional dependability. The range is rounded out by sophisticated logistics solutions such as just-in-time delivery and complete supply chain management, which we continuously improve in collaboration with our customers. Our products include carbon steel, stainless steel and nonferrous metals in the form of flat, tubular and long products – many of them also as specialties and in custom sizes.

Rothe Erde® is world market leader in slewing bearings. We were involved in the design of the first research facilities and can look back on decades of experience. Our pre-sales service ensures we find the ideal technical solution: from technical advice to design, engineering, preparation of drawings, integration of finite element analysis including connecting parts, through to provision of all necessary certifications. Our after-sales service provides for continuous, trouble-free operation: from installation to maintenance and repairs to training.

In the world’s biggest research and development center, state-of-the-art technology is used to test and constantly improve forward-looking bearing solutions under the toughest of conditions. As a result of this intensive research work, Rothe Erde® slewing bearings are used successfully in wind turbines across the world. We also hold a leading position in seamless rolled rings of steel and nonferrous metals. As important structural and connecting elements in wind turbines, slewing bearings and rings make a major and sustainable contribution to conserving resources through the use of renewable energies. Rothe Erde® slewing bearings are used as rotor, yaw and pitch bearings. We supply seamless rolled rings to customer specifications, from simple as-rolled parts to ready-machined components. Rothe Erde® rings are suitable for all offshore and onshore applications, e.g. ready-to-install as yaw tops, tower flanges, foundation rings, gear rings and shaft-hub connections.

ThyssenKrupp is one of the world’s leading elevator companies. We have developed a new range of service lifts specifically for the maintenance and repair of wind turbines. Our service lifts are designed with the needs of service technicians in mind and offer space for two people including tools. Special cable tensioning devices reduce cab movements to a minimum. The support and safety cables are guided through the inside of the cab over a length of around 3 meters to enhance safety. The units are driven by an electric cable hoist, which positions the service lift on a support cable. The parallel safety cable passes through an integrated overspeed safety device. The modular design can be adapted to individual customer requirements.

Automated rotor blade production reduces costs, shortens production times and improves quality. ThyssenKrupp System Engineering has unique expertise in this area and carries out extensive research work in conjunction with various research institutes. In the simultaneous engineering phase we work together with the customer to jointly define specific requirements, which we then implement in full – from concept to production. The entire production facility for the rotor blades is designed, manufactured, installed and put into operation in accordance with customer specifications. The degree of automation can be varied in line with individual customer requirements. Once the rotor blade manufacturing facility has been set up, we offer integrated production support services.

Offshore wind turbines require safe foundations, which have to be installed under extreme weather conditions – a very difficult job. We have advanced technology and first-class expertise in this area. ThyssenKrupp GfT Bautechnik and ThyssenKrupp GfT Tiefbautechnik hire out and sell special equipment for foundation work, such as for tripod or jacket structures for offshore installations. Services include detailed advice on the choice of equipment and accessories. Maximum equipment availability on site is guaranteed by personnel who have been specially trained and certified for offshore work. To keep piles firmly embedded in the seabed, ThyssenKrupp GfT Bautechnik supplies anchors, so-called grouted piles, which are drilled down to the bedrock. Anchor drilling equipment rounds out the product range.

(Source: alpha ventus, photographers: Jan Oelker/Matthias Ibeler)

As a world leader in innovative testing equipment, ThyssenKrupp System Engineering has developed an online condition monitoring system – MDI Wind – especially for wind turbines. The system remotely monitors all wind turbine components as the basis for condition-based maintenance. The system – both software and hardware – is of modular, open design. It records the structure-borne sound signatures of drivetrain elements, rotor blades and tower, collecting operating data from the turbine control system and condition monitoring data in a single system. The intelligent evaluation and linking of the recorded signals permits adaptive monitoring strategies and when limits are exceeded automatically triggers an alarm via a diagnostics center – around the clock, 365 days a year.