PI 062-14 Lohr am Main, 2014-09-08

Reduce cost of energy, increase availability

Bosch Rexroth can offer turbine manufacturers over 30 years of experience in the design of wind turbine drive trains.

Bosch Rexroth at WindEnergy Hamburg

Bosch Rexroth supports manufacturers and operators throughout the lifecycle of their wind turbines. The company reduces the cost of energy (CoE) and increases system availability by designing and developing drive trains, products for new generations of wind turbines, condition monitoring solutions and a wide range of services.

The product and solution portfolio of Bosch Rexroth in the wind energy sector helps manufacturers and operators to reduce the CoE and thus increase the availability of their systems. "For us, WindEnergy 2014 in Hamburg is all about reducing the CoE," reports Christoph Kainzbauer, Vice President Sales Renewable Energies at Bosch Rexroth AG. He suggests that the reason for this is that manufacturers are increasingly facing pressure on prices, not only from conventional forms of energy generation, but also from within their own ranks. In Hamburg, Bosch Rexroth is presenting a new gearbox platform which is consistently oriented towards increasing reliability. An integrated Condition Monitoring System increases efficiency and cost-effectiveness, while the wide range of services improves the availability of wind turbines.

The right gearbox for every application

For wind turbines with high-speed drive systems and a power range of 3 MW to 4.5 MW, Rexroth is providing manufacturers with a new gearbox platform, the development of which focused on reducing CoE and increasing reliability. A test program developed by Bosch Rexroth for the market validation of the platform significantly reduces the subsequent testing costs and thus reduces costs for the manufacturer. Kainzbauer explains the benefits: "the modular structure enables rapid adaptation to customer-specific requirements and reduces the time-to-market." At the same time, the parts have been considerably standardized, which means, among other things, that they are available more quickly.

Rexroth offers the REDULUS GPC planetary gearboxfor wind turbines with medium-speed drive systems. Medium-speed drive systems are characterized by high levels of effectiveness at partial and full load, low investment costs and high levels of reliability, as no fast-moving components are used.

With multi-body simulations, robustness tests and validation of design and calculations, Bosch Rexroth further improves the reliability of gearboxes and increases component service life. Christoph Kainzbauer explains: "The latest calculation methods to increase reliability in the automotive industry are incorporated into development and production."

Condition Monitoring improves cost-effectiveness

Condition Monitoring solutions increase availability and thus also improve the cost-effectiveness of wind turbines. This means that damage to wind turbine components can be detected early and repair costs avoided. Bosch Rexroth offers manufacturers the rotor blade condition monitoring system BLADEcontrol. Early recognition of damage on the rotor blade itself means the solution is now increasing the availability of over 500 wind turbines. The BLADEcontrol ice detector takes measurements directly on the rotor blade and detects critical degrees of ice accumulation. It can also recognize when the risk has passed. The wind turbine can then be automatically restarted at any time of the day or night.

Both the BLADEcontrol ice detector and the entire BLADEcontrol system are the only solutions in the world to be certified by Germanischer Lloyd in accordance with the "Guidelines for the certification of condition monitoring systems for wind turbines".

ACoS, the Advanced Condition Monitoring System, is the first system in the world to monitors the complete drive train, starting from the rotor blades and covering the main shaft bearing, the gearbox and generator bearings. The software incorporates the continuous results of the measurement and analysis processes into an integrated monitoring strategy. A professional visualization gives a clear overview: the wind turbine is considered as a whole.

Service improves efficiency and system availability

With Bosch Rexroth, manufacturers and operators can rely on a global service network. With a service strategy tailored to the relevant requirements - starting with on-site support from experienced service technicians, going through inspection and maintenance to repairs, spare parts and the gearbox exchange pool - they can increase availability, reduce operating costs and thus improve the efficiency of wind turbines.

Bosch Rexroth at WindEnergy Hamburg: Hall A1, Stand 432

As part of an engineering forum, there will be expert interviews on the key issues on the Rexroth show stand. More information on the range:

Economical, precise, safe, and energy efficient: drive and control technology from Bosch Rexroth moves machines and systems of any size. The company bundles global application experience in the market segments of Mobile Applications, Machinery Applications and Engineering, Factory Automation, and Renewable Energies to develop innovative components as well as tailored system solutions and services. Bosch Rexroth offers its customers hydraulics, electric drives and controls, gear technology, and linear motion and assembly technology all from one source. With locations in over 80 countries, roughly 36,700 associates generated sales revenue of approximately 5.7 billion euros in 2013.

To learn more, please visit

The Bosch Group is a leading global supplier of technology and services. In 2013, its roughly 281,000 associates generated sales of 46.1 billion euros. (NB: Due to a change in accounting policies, the 2013 figures can only be compared to a limited extent with the 2012 figures). Its operations are divided into four business sectors: Automotive Technology, Industrial Technology, Consumer Goods, and Energy and Building Technology. The Bosch Group comprises Robert Bosch GmbH and its roughly 360 subsidiaries and regional companies in some 50 countries. If its sales and service partners are included, then Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further growth. In 2013, the Bosch Group invested some 4.5 billion euros in research and development and applied for some 5,000 patents. This is an average of 20 patents per day. The Bosch Group’s products and services are designed to fascinate, and to improve the quality of life by providing solutions which are both innovative and beneficial. In this way, the company offers technology worldwide that is “Invented for life.”

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Susanne Herzlieb
Maria-Theresien-Straße 23
97816 Lohr am Main
Phone: +49 9352 18-1573

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Produvt Information

Flexible advance planning

With a service concept tailored to their specific needs, manufacturers and operators increase the efficiency and availability of their systems. Flexible maintenance offerings from Rexroth safely ensure reliable operation of the wind turbine and reduce operating costs.

Product Information

Efficient wind energy

Modern Condition Monitoring Systems (CMS) from Rexroth can permanently reduce the cost of energy (CoE) of wind turbines. The BLADEcontrol from Rexroth, which is certified by Germanischer Lloyd, provides continuous rotor blade monitoring and ice detection. The Advanced Condition Monitoring System ACoS incorporates even the entire drive train and other subsystems into the condition monitoring. The result: holistic monitoring with a continuous control desk link.