Siemens has produced the world's longest rotor blades. Measuring 75 meters in length, the blades are almost as big as the wingspan of an Airbus A380. The B75 rotor blades have been installed in a prototype six-megawatt offshore wind power plant at Denmark's Østerild test station. Another innovation is a gearless wind generator permitting implementation of wind turbines with an output of up to 10 MW. The generator is particularly reliable and is therefore suitable for operation under rough conditions and in isolated locations. A prototype of the Direct Drive Wind turbine has been installed at Valsneset, Norway.
To produce the world’s biggest rotor blades, Siemens uses the patented IntegralBlade process, in which the entire blade is poured as a single piece made of glass fiber-reinforced epoxy resin and balsa wood. As a result, the blade has neither seams nor bonded joints and is extremely robust. The gigantic rotor, which measures 154 meters, has to withstand huge air masses as it is hit by the energy of 200 tons of air per second when the wind blows at 10 meters per second. The tips of the blades rotate at up to 290 kilometers per hour. Thanks to another patented technology, QuantumBlade, the rotor blade weighs 20 percent less than conventionally produced blades. As a result, the nacelles, towers and foundations can be made lighter as well, which reduces the facility's cost. This weight reduction is achieved by using specially designed blade profiles that are also shaped in a way that delivers maximum rotor performance at a range of different wind speeds.
Based on a modular technology platform, the gearless wind generator is not manufactured as a single unit but is instead put together from preassembled segments. This makes it possible to implement the most varied plant designs in a very flexible manner with a selection of different bearing concepts, voltage levels and cooling methods from a modular component range. Since the generator does not have to be transported as a whole, the organization of logistics operations is very simple. The Direct Drive Wind achieves a high level of efficiency due to its integrated design, which obviates the need for a dedicated generator bearing and thus contributes to reducing losses generated by bearing frictions, and to the elimination of excitation and gear losses. This reduction of complexity and the lack of excitation equipment, such as slip rings, also ensure excellent reliability with minimal maintenance requirements. This is a considerable advantage, particularly with regard to the extensive repair logistics for offshore wind farms.