Modernization of the FAMUR Gearo test station

The modernization of the test station at the FAMUR Gearo division, part of Grenevia SA, made it possible to increase its capacity from 1.8 to 5.4 MW and transform it into a universal gearbox testing facility capable of operating at a full load of 5.4 MW and temporary overloads of 8.1 MW, while minimizing energy consumption from the power grid. As a result, one of the largest installations of this type in Central and Eastern Europe was created, enabling both the development of service offerings and the building of production capabilities in the wind energy sector.

The project implementation was directly linked to Grenevia’s business transformation. As the company expanded its operations in the wind energy sector, it began building capabilities to support the entire value chain—from service and testing to the development of its own product solutions. In this context, FAMUR Gearo became a key competence center for the wind gearbox segment.

With growing technological ambitions, it became necessary to create infrastructure enabling advanced load testing of gearboxes. The existing test station, with a capacity of 1.8 MW, had not been designed for such a broad range of applications and limited further development possibilities.

“Expanding the test station is not only a technological leap forward, but also a clear signal that FAMUR Gearo is consistently strengthening its position in the renewable energy sector. Increasing testing capabilities makes it possible to develop service operations and prepare for the production of our own higher-capacity wind gearboxes,”
- emphasizes Paweł Majcherkiewicz, Vice President of the Management Board of FAMUR SA, responsible for the development of the FAMUR Gearo segment.

The scope of the modernization covered several areas simultaneously: drive systems, mechanics, automation, and an extensive technical infrastructure, including an expanded cooling system. Siemens was responsible for designing and integrating the entire solution, working closely with partners supplying key components.

The organization of work and the project execution approach were of crucial importance. Instead of a traditional, fragmented model, an integrated team was established, encompassing all necessary competencies—from mechanical design and electrical systems to automation and cooling. This approach made it possible to carry out work in parallel, significantly shorten decision-making paths, and reduce the number of design iterations, which under standard conditions can extend project timelines by many months.

Technology partners were also involved in the project execution. The motors were supplied by Innomotics, the cooling system was provided by Sigma, while in the area of mobility and flexibility of the station (a special cable carrier), cooperation with Igus played a key role.

The result of the project was not only an increase in the station’s capacity, but above all a change in its functionality. The installation was designed as a universal test environment, capable of operating with different types of gearboxes. The central element of the solution was the modular SINAMICS S120 drive system, which enables precise control of the system’s operation and the reproduction of real gearbox operating conditions.

An important innovation of the project was a special cable carrier for the 5.4 MW motor, developed jointly by Siemens and Igus, with the support of FAMUR Gearo. The station was equipped with a movable test motor weighing several tons, which could be repositioned within the test stand without the need to disconnect the installation.

This element—the combination of a movable mechanical system with a dedicated cable management solution—constitutes one of the most innovative aspects of the project and distinguishes it from other installations of this type.

As part of the modernization, the station achieved a rated capacity of 5.4 MW at 1470 rpm, with the ability to continuously adjust both rotational speed and load values to match the specific parameters of the tested gearboxes. An important feature of the facility is its ability to handle overloads of up to 150% of the rated torque, enabling testing of gearboxes with capacities of up to 8.1 MW. This, in turn, makes it possible not only to refurbish gearboxes from the secondary market, but also to manufacture new ones for use in modern wind turbines.

The project was completed in January 2026. The value of the contract between Siemens and Grenevia amounted to nearly EUR 3.5 million gross.

The modernization of the test station was part of a broader investment program by Grenevia, implemented with the support of EU funding. The project, valued at over PLN 68 million and co-financed with nearly PLN 21 million, included the development of technological facilities and competencies in the wind energy sector.

In this context, the test station became one of the key infrastructure elements enabling further business development. It made it possible to expand the scope of testing, shorten the execution time of service projects, and create a foundation for the development of in-house production.