The alternative energy industry continues to focus on wind power as a viable addition to address the ever-expanding global energy demand. With this in mind, Lincoln Electric has recently hosted more than 120 industry professionals interested in learning more about wind tower fabrication for several daylong seminars.

Seminar attendees traveled from across the United States and as far away as Brazil and Portugal to Lincoln’s Cleveland, Ohio, headquarters to learn more about wind tower fabrication. Each seminar featured an industry overview, technology sessions, and live welding demonstrations for companies already fabricating wind towers and those currently considering it.

“Governments in every corner of the globe, including the United States, continue to focus on alternative energy, especially wind,” says Patrick Wahlen, global segment business director, power generation. “Many of our customers want to add wind tower fabrication to their portfolio, and this seminar shares insight into the industry, guidance on capitalizing on this market and an overview of Lincoln’s product portfolio.”

Whalen added that the company has long offered a comprehensive welding solution for wind tower fabrication. “In 2008, there were 38 new wind tower manufacturing facilities constructed globally, and 33 of those facilities used Lincoln products,” he says.

Due to its Waveform Control Technology®, Lincoln Electric’s Power Wave® AC/DC 1000® SD is the leading power source for wind tower fabrication. When combined with Lincoln’s process knowledge, it can increase productivity by 30 percent or more. Lincoln also has a complete offering of consumables designed specifically for wind tower welding applications, including tacking, longitudinal can seam, circumferential can seam, circumferential ring and flange, base flange, entry hatch, and rotor shaft.

Steve Knapple, welding engineer for tower fabricator Katana-Summit, attended the May Lincoln seminar and says that “Lincoln did its homework when it got into this industry. They shared insight into areas of opportunity and demonstrated different levels of solutions, which was very helpful as the attendees represented established wind tower manufacturers as well as startups. I also had the opportunity to meet others who do what we do and share best practices. It was a valuable experience.”
For more information e-mail windtower@lincolnelectric.com or visit www.lincolnelectric.com.

In wind power plants, electrical circuit problems are known to cause short-term torque peaks. In this event, slip clutches protect the costly gearbox against overload by slipping at a defined maximum torque in order to temporarily interrupt the drive. The slip process takes place not on the generator shaft surface, but inside the CENTA Torque Hub, which is mounted on the generator shaft in the coupling’s clamping set.

CENTA’s latest development in slip systems, “CENTA Torque Set,” now positions the slip unit to the middle section of the shaft. By relocating the slip function, manufacturing tolerances at the generator shaft no longer cause variations in the slip torque, resulting in improved accuracy of the slip function. Another advantage of the new design is that the slip system is made to be pre-mounted as a complete unit. The maximum torque is set on a certified test bench according to the manufacturer’s requirements and documented in a test report, eliminating the need for on-site adjustments.

The low-maintenance slip system is also designed to allow for multiple slip processes (> 200) without having a major impact on the slip torque setting.

Depending on the size, a torque range of up to 120 kNm is covered. The new slip system can also be provided as a low-cost system component which does not include the coupling unit.

CENTA Corporation’s newly expanded Chicago facility includes a large in-house machine shop for domestic production of your wind turbine couplings from a trusted source. For more information contact Bob Lennon at (630) 236-3500 or bobl@centacorp.com. Also visit www.centa.info.

Emuge Corp. has introduced an extensive line up of tools optimized specifically for the production of wind turbine components. Continuous technology advancements in components and materials demand high quality tooling for the most efficient and cost-effective machining of parts used in today’s wind turbines. Emuge’s new Wind Power program offers a complete solution for precise, affordable machining of wind turbine parts.

For the production of top quality internal and external threads, Emuge’s new program provides taps up to 114 mm (4 ½”), roll form taps up to 51 mm (2”), and thread mills up to 102 mm (4”). These tools are designed for all thread sizes—with a special focus on large and deep threading—and every material used in the manufacture of wind turbines. Also included in the new line are the highest quality tap and workpiece holders, available from stock or custom engineered for wind turbine applications. Gaging tools are also available for quick and reliable process control.

The new Wind Power program also offers a wide range of both solid carbide and high-speed steel milling cutters, milling tools with indexable inserts, and other milling accessories. The program includes end mills, slot drills, die-sinking cutters, shell end mills, and gear cutters, in addition to the most complex profile milling tools.

“The wind power industry is currently undergoing a period of rapid growth,” says Peter Matysiak, president. “Constant improvements in component and material technology makes it challenging for suppliers to keep up. Emuge is committed to meet this challenge and to providing tools that are precision-manufactured for optimum performance, durability, and tool life for manufacturers in this growing market.”

Emuge Corp. is a subsidiary of the 1,000-plus employee German company Emuge-Werk Richard Glimpel KG that has been the product technology and performance leader in their field for more than 90 years. The company manufactures an extensive line of taps, end mills, thread mills, holders, and attachments, with 100,000 items sold through distributors worldwide. Emuge also offers end-user technical support through a network of field engineers with extensive tooling experience.

More than 10,000 types of cutting tools and accessories are stocked in the company’s new North American headquarters. The 21,000 square foot state of the art facility, custom-designed and built in 2005, also serves as a technology center, offered to the industry as a resource for machining process development. Milling, thread cutting, and workholding seminars will also be conducted at the technology center. For more seminar information visit www.emuge.com.

ESAB Welding & Cutting Products introduces the new Caddy™ Tig 1500i and 2200i single-phase DC/CC portable welding machines. The new machines have been designed to deliver quality gas tungsten arc (TIG) and shielded metal arc (Stick) welds in a variety of materials for the demanding professional. This fifth generation of Caddy machines features advanced inverter technology to deliver unparalleled welding quality and performance and offers a compact design with an impact-resistant polymer and aluminium casing that is light and easy to carry, yet stands up even in demanding environments.

The Caddy Tig 1500i and 2200i feature new control panels that present all welding parameters in an easy-to-understand layout. ESAB’s two-program function allows pre-programming and program changes during welding. Caddy Tig offers a pulse TIG feature for greater control of heat input and the weld pool, and a “micro pulse” feature that minimizes the heat-affected area, particularly with thin metals. Other features include “hot start” and “arc force” settings.

The new Caddy family is equipped with large cable connectors for high durability. Large heat sinks and an innovative design create a cooler running machine with a longer life expectancy when used in harsh working environments. This ensures that the small size of the machine does not compromise the cooling of vital internal components. The design also helps to keep all sensitive parts inside the machine clean and dust free.

Caddy machines are built in accordance with IP23 for outdoor use, even in the rain. They are also equipped with a power factor correction (PFC) circuit that allows the machine to perform a full range of functions on a 16A fuse, protects against fluctuating mains voltage, and makes the machine safer to use with a generator. A Caddy Tig 2200i AC/DC version is also available.

With more than 100 years of experience, ESAB Welding & Cutting Products is one of the world’s largest and most knowledgeable manufacturers of welding and cutting equipment and welding filler metals. To ensure customer satisfaction, many ESAB products carry a 100-percent satisfaction guarantee. Recognized as the technological leader in the industry, ESAB is committed to providing customized solutions for its customers. For more information call (800) ESAB-123 or visit www.esabna.com.

TRICO TCWIND, an IPS company, has certified the IPS Denver Regional Service Center for wind service. Denver joins four other TRICO TCWIND certified locations—Litchfield, Minnesota; Portland, Oregon; Shreveport, Louisiana; and Washington, Pennsylvania—in providing coast-to-coast maintenance service for the wind power industry.

IPS, the national leader in the service and repair of electric motors, generators, and mechanical power transmission components, acquired TRICO TCWIND in September 2008 to lead its wind power services. The family-owned independent power services company had played a key role in the industry for years, developing in-shop and up-tower service and repair standards for wind turbine generators while working closely with OEMs, operation and maintenance companies, and wind turbine owners.

“We’ve found that our counterparts at other IPS service centers have ready-made skill sets,” says Jason McDonald, IPS senior VP of wind power. “They look at wind power the way they look at every technology that involves rotating assets—their job is to make it more reliable and meet delivery commitments. Certifying the IPS Denver regional service center was the right thing to do in support of our customers and the growing wind power industry in the Rocky Mountain region.”

“Adding TRICO TCWIND to the IPS portfolio gave us instant recognition and an entrepreneurial approach to wind power services,” says Brian Brehmer, president and CEO of IPS. “Our plan is to continue on this path, certifying additional IPS regional service centers to expand our wind service capabilities. As one company with 16 regional service centers, we believe we have the best local, regional, and national footprint for wind power services in the United States.”

To learn more contact John Covington, IPS senior vice president of marketing, at (864) 451-5634. Go online to www.integratedps.com or www.tricotcwind.com.

Nordex USA, Inc., a leading manufacturer of wind turbines, has begun construction of its first U.S. manufacturing plant in Jonesboro, Arkansas. The announcement comes after a decision by the supervisory board of the parent company, Nordex AG. “After much careful planning, we are eager to break ground and make the plant a reality,” says Ralf Sigrist, president and CEO. “The plant is critical to our goal of generating 20 percent of global revenue in the U.S., and I must say I am extremely pleased that construction will begin on schedule.”

The United States is on track to be the world’s single largest wind market in 2010, with 8,500 megawatts of new capacity projected. Globally, that represents 23 percent of expected new capacity. The Arkansas plant will position Nordex to be a key competitor in the U.S., building on its growth of over 50 percent for four consecutive years. “The U.S. is hungry for wind power,” says Sigrist, “and Jonesboro will supply it with the highest-quality turbines in the world.”

Construction will take place in two phases, beginning with the nacelle assembly plant and followed by a rotor blade manufacturing facility at the same location. Nacelle assembly will begin ramping up in the second half of 2010, operating at full scale by 2012 with an annual production capacity of 300 turbines, or 750 megawatts. The entire facility, including rotor blade production, will be fully operational by 2014. The nacelle plant will be built on 187 acres in the Craighead Technology Park and will have 115,000 square feet of production space, 10,000 square feet for a training academy, and 35,000 square feet of office space. The plant represents a total investment of $100 million, with about $40 million allocated to the nacelle plant and the remainder to the rotor blade facility. It will directly employ up to 700 skilled workers and other staff by 2014.

The Jonesboro operation will be an original equipment manufacturer (OEM) producing one of the largest classes of wind turbines in the world, the 2.5 megawatt N90 and N100. In the U.S., each of these utility-scale turbines is capable of generating enough renewable energy to power about 700 homes. Nordex was the first manufacturer to build a turbine this large in 2000 and has the longest track record for reliability in the class. To learn more go to www.nordex-online.com.

In addition to Lapp’s full-line catalog, it has introduced a core product catalog for industrial and factory automation. At a time when other companies are implementing higher minimum order quantities and longer lead times, Lapp Group is committed to servicing product demand from stock on all core products. This 48-page catalog features a mixture of cables, connectors, and cable glands. Product cross references are included to make it easier to find the right SKINTOP® and EPIC® connector for each cable.

The Lapp Group offers a complete one-stop automation solution for cable and connector needs. Lapp has the broadest range of products, including OLFLEX® power and control cables, UNITRONIC® data cables, EPIC rectangular, circular, and pin and sleeve connectors, SKINTOP strain relief cable glands, cable management accessories, remote access ports, and custom harness assemblies. From its manufacturing facilities in Florham Park, New Jersey, Lapp manufactures custom cables for unique applications. For more information call (888) 456-3539 or visit www.lappusa.com.

Capital Safety announces the launch of the world’s next generation harness, the ExoFit NEX™. With first of its kind features and benefits, the harness provides the highest level of safety and the utmost comfort with technologically advanced hardware, soft yet extremely durable anti-absorbent webbing, strategically placed padding, and protective elements that prolong the service life of the harness.
“The original ExoFit, the industry’s first premium comfort harness, changed workers’ attitudes about fall protection. With the ExoFit NEX, we’re taking that to the next level,” says Nate Bohmbach, product manager for soft goods. “We’re turning the harness into a piece of equipment that workers will want to wear and that’s long-lasting. So we’re catering not only to the end user, but to the safety director and purchasing department as well.”

The technologically advanced hardware allows for a one-time adjustment that stays in place throughout the day and improves safety by ensuring a snug fit. The Duo-Lok™ quick-connect buckles now include a revolutionary locking mechanism to eliminate slippage and constant readjustment. Workers will no longer need to adjust their harnesses throughout the workday; the straps won’t budge, even with movement and the weight of tool belts that have traditionally caused adjustments to loosen. The Revolver™ ratcheting torso adjustor features a winding adjustment that spools the webbing as the user adjusts the harness for a proper fit. The adjustor locks into place and holds the adjustment, preventing slippage due to movement and added weight. It also eliminates excess webbing that can be hazardous near moving parts. Additional hardware includes breakaway molded lanyard keepers that allow easy connection of any size snap hook and breaks away to help prevent snagging and tripping. To learn more call (800) 328-6146 or go to www.capitalsafety.com.

NRG Systems has partnered with the Massachusetts Institute of Technology Wind Energy Group on a multi-phase project to advance the use of renewable energy at MIT’s campus and further the science of remote sensing with laser-based technologies. The MIT Wind Energy Group, an on-campus organization that addresses global wind energy challenges through fact-based research, analysis and education, initiated the partnership after meeting with NRG Systems’ employees last year at an energy career fair.

“NRG Systems is a name synonymous with wind resource assessment here in the U.S.,” says Katherine Dykes, vice president of the MIT Energy Club and founder of the group. “Their reputation, in addition to their role in developing new technology such as lidar, makes them an ideal partner for MIT.”

Along with Kathy Araujo, current group president, Dykes has been leading the project that should culminate in the installation of small-scale wind turbines on MIT’s campus. Last month NRG Systems’ employees Larry Jacobs and Emeric Rochford installed measurement equipment on an existing light tower at the MIT athletic fields to begin collecting wind resource data. This will be followed by deployment of a WINDCUBE™ lidar remote sensor, a laser-based sensor that provides 200-meter vertical wind profiles, and a 34-meter meteorological tower. Installations will support student research in the fields of wind measurement and renewable energy. “We’re thrilled to be partnering with the MIT Wind Group on this initiative,” says Jacobs, NRG Systems’ marketing manager. “Not only does it deepen scientific understanding of lidar, it also supports ongoing innovation and technological advancement in the field of wind resource assessment.”

NRG Systems is an independently owned company that has served the global wind energy industry for 27 years. Its wind measurement systems and turbine control sensors can be found on every continent in more than 130 countries. The Wind Group of the MIT Energy Club was founded in the summer of 2008 with the mission of bringing together people within MIT and the broader community who are interested in all aspects of wind energy. For more information go to www.nrgsystems.com or www.mit.edu.

Carbone of America, a leader in power and signal transfer solutions, has redesigned the phase and ground brush holders for Hitachi generators installed in the GE fleet of 1.5 MW wind turbines. The new brush rigging assembly is a totally reengineered system, designed to reduce wear, maintenance and downtime in the long term. The brush holders are plug-and-play, so that uptower installation is fast, simple, and requires no modifications to the generator. The mass produced holders, die-cast from bronze alloy, are sturdy and built to withstand rigorous field use and turbine maintenance without sustaining damage. The radial-mounted brush holders were engineered to eradicate the previous reaction and trailing configuration and improve load sharing and equal wear rates between brushes. The brush dimensions were changed to provide equal surface area for the same energy transmission. The ratios of brush coverage to slip-ring diameter, width, and helical groove, have been optimized for peak performance.

The constant-force style brush pressure systems—200g/cm2 applied to the well-known carbon brush grade CG626—provide extremely low wear rates and minimal ring wear over long-term operation. They exert consistent force to keep all brushes in constant contact with the high-speed rotating slip rings for the best possible distribution of current between the four-phase (power) brushes. Upgraded brush terminals carry continuous high loadings; bolted connections ensure continuous, even current distribution between brushes in a phase group. Carbone of America’s brush rigging also incorporates a reliable indication system to alert when brushes become worn. The micro switch system, already widely used in the field, has proven to be dependable. For more information contact Roy Douglas, technical manager, at (973) 299-4518 or roy.douglas@carbonelorraine.com. Visit online at www.carbonebrush.com.

New Schmidt 5D couplings from Zero-Max are the ideal choice for applications requiring large axial, angular, and parallel shaft misalignments. This “all in one” coupling design will handle all shaft displacements, providing low backlash for precision high torque applications such as roll forming and similar heavy duty fabricating equipment.

Designed to fill an important need in the Zero-Max family of torque-rigid couplings, 5D couplings allow for easy adjustment to any possible misaligned shaft position without imposing heavy side loads on shafts, bearings, or other machine equipment. The coupling can accommodate up to 5 degrees of angular misalignment and as high as 1.5” parallel misalignment while maintaining undisturbed power transmission at constant angular velocity. Acting forces within the coupling can be precisely calculated, assuring reliable, trouble-free system operation; especially important in heavy-duty applications. This unique design will tolerate high shock and reversing loads with minimal or no maintenance required.

Additional features include space-saving design and easy installation—couplings can be mounted to shaft hubs or directly to existing machine flanges (no need to reposition either shaft being coupled)—and they are available in standard and inverted hub configurations in bore sizes from 1.500 inch to 6.375 inches or 38mm to 160mm. Custom designs can take this coupling design beyond the catalog specifications. The 10 different model sizes handle speeds up to 1000 RPM and torque from 2800 to 500,000 in-lbs. Special design modifications are available.

“The 5D coupling has very robust design features for use in applications such as roll drive systems used in converting machinery,” says Robert Mainz, sales manager. “The unique and highly flexible design allows for a wide range of movement to improve the quality of the end product. They do a very good job of handling shaft misalignments and protecting drive train components in these high performance systems.”

To learn more call (800) 533-1731, e-mail zero-max@zero-max.com, or go online to

www.zero-max.com.

Gleason has introduced a new line of Titan® grinding machines designed to reduce finish grinding times by as much as 50 percent on cylindrical gears up to 1,500 mm in diameter. Titan machines are unique in their ability to offer users, on a single platform, both pure profile grinding for the greatest flexibility when producing single parts, and threaded wheel grinding and profile grinding working together for much faster fully-automated large-scale production. This new process, called Power Grind, enables users to reduce grinding production times by as much as 50 percent, by first using threaded wheel grinding to “rough” gears much faster and then profile grinding to achieve optimal gear quality, surface finish and complex gear modifications in the finishing operation.

The Power Grind process can optionally include an external setup table to allow the workpiece and workholding package to be set up in parallel with primary production, rather than sequentially. Workpieces then can be loaded automatically through use of an optional workpiece changer. These features, plus an innovative new high-speed tool changer that automates the exchange of threaded wheel for profile grinding wheel, greatly reduce non-productive time.

Titan 1200G and 1500G machines—for workpiece diameters of 1200 mm and 1500 mm respectively—are also equipped with a patent pending universal dresser. This enables the user to dress both threaded grinding wheels and profile grinding wheels right on the machine using a single dressing tool, thus eliminating the changeover time and expense of multiple dressing tools. These machines also greatly reduce the time required for the production of individual parts through pure profile grinding. A unique, patented dual-flank twist-free grinding option is available that can create highly desirable asymmetrical tooth trace modifications in half the time normally required when conventional single flank grinding is used. The machines come equipped with the latest Siemens 840D CNC and Gleason Windows-based Intelligent Dialogue software to greatly simplify setup and operation. For example, a grinding technology database recommends and optimizes the production methodology for the Power Grind process before machining starts, enabling even less experienced operators to produce high quality parts more productively. 

Titan machines are just the latest in a complete line of Gleason gear grinding machines that include profile grinders for workpiece diameters up to 6 meters. For more information visit www.gleason.com.

For the third consecutive year, Second Wind has made the Inc. 5000 list of fastest-growing private companies in the United States. “Second Wind is dedicated to making wind energy profitable through the use of innovative technology,” COO Larry Letteney says. “Our third year on this prestigious list speaks to the hard work of our dedicated employees and the continued growth of the renewable energy sector.”

Letteney credited the growing acceptance of Second Wind’s newest product, the Triton sonic wind profiler, as adding significantly to the company’s overall growth. The Triton is designed to give wind farm developers more accurate information about siting wind farms and turbines, thus streamlining wind farm development and increasing financial certainty. The Triton assesses wind speed and direction by sending sound pulses into the sky and measuring the returning echoes. Triton sales are increasing each quarter, with over 80 units currently operating in the field including sites in the United States, Canada, Europe, and Australia.

“With this accomplishment, Second Wind, Inc., joins the rarified company of enterprises that have appeared on the list multiple times,” says Inc. 5000 Editor Jane Berentson. “Since debuting in 1991, the list has served as evidence of the significant accomplishments of entrepreneurial companies.”

Founded in 1980, Second Wind advances the use of wind data to make wind energy more profitable for owners, painless for operators, and practical for consumers. More information is available at www.secondwind.com.

Featuring more helpful tips and installation advice than before, Dr. Shrink’s new Web site is a single source for all necessary shrink-wrap knowledge, allowing visitors to browse the company’s complete line of shrink wrap and accessories.

Serving seasoned business owners to novice do-it-yourselfers, a convenient “How-To/Training” tab offers free, step-by-step directions on how to shrink wrap a wide variety of objects. A helpful chart enables users to find the right size shrink wrap for their asset. Visitors can sign up for the company’s e-newsletter to learn more details about upcoming shows, new products, tips, and other special offers. The site offers a full-color photo gallery, providing ideas on all the different types of objects that can be shrink wrapped.

Based in Manistee, Michigan, Dr. Shrink is an international premium shrink-wrap supplier. With a reputation for great customer service, the company provides prompt service, competitive pricing, and experienced application advice. Call (800) 968-5147, e-mail drshrink@dr-shrink.com, or go to www.dr-shrink.com.

RBC Bearings is pleased to announce that it has received a letter of conformance from Germanischer Lloyd (GL) for pitch and yaw bearings for the ACCIONA Windpower wind turbine generator. ACCIONA Windpower North America is owned by the ACCIONA group, a Spain-based global leader in the renewable energies field. The company has installed 252 wind farms in 14 countries and manufactures wind turbine generators with proprietary technology.

The GL type certification was issued to RBC Bearings in April, 2009, for RBC slewing ring bearings being built for 1.5 MW ACCIONA wind turbines. The bearings are being manufactured in RBC’s new custom-built 80,000 square-foot facility in Houston, which became operational in late summer of 2009. This is another important milestone for RBC in the company’s initiative to supply pitch and yaw bearings to the wind turbine generator industry.

“We are pleased with the progress our team is making to serve this industry. Our state-of-the-art manufacturing facility is now ready. Our advanced engineering team, equipped with the most up-to-date analytical design tools, now provides custom-engineered solutions to some of the largest producers of wind turbine generators in the world,” says Dr. Michael J. Hartnett, RBC president and CEO. “This certification is another significant step for RBC Bearings. We are at the beginning of what I am sure will be a very successful new business segment for us as we provide critical components necessary to the growth of the U.S. wind turbine generator industry.”

RBC Bearings is a leading manufacturer of precision bearings for industrial, aerospace, and defense applications. The company has 22 manufacturing facilities throughout North America and Europe and is supported by a global network of sales engineers, authorized distributors, and agents. For additional information call (800) 390-3300 or go to www.rbcbearings.com.

The City of Iowa City, Iowa, continues its work to develop what is believed to be the first Wind Energy Supply Chain Campus in the United States. Since November 2008 the city has taken steps to acquire, annex, and zone 173 acres of land located on the city’s east side and begin infrastructure work. Sewer service projects and road improvements are underway or scheduled for development. To date over three-dozen companies have visited or requested information about the campus.

“We are able to meet power and transportation needs because this campus is being developed from the ground up,” says Joe Raso, Iowa City Area Development (ICAD) Group president. “Unlike other industrial sites which may have to be retrofitted, this campus is being designed specifically to the needs of the wind energy sector.”

This development puts OEM suppliers in close proximity to Acciona North America’s operations in West Branch and Clipper’s North American nacelle manufacturing plant in Cedar Rapids. The campus is rail served and will allow companies easy access via Interstate 80 to their customers and the growing number of wind projects not only in Iowa, but in the upper Midwest. Additionally, it will soon be certified as one of only three “shovel-ready sites” in the region.

In response to continuous inquiries, ICAD Group has launched a special Web site featuring a snapshot overview of the campus and important facts about the benefits of doing business in Iowa City. Users can link to laborshed reports, detailed property information about the campus, and obtain a free transportation quote to estimate costs of shipping products to and from our area. “At this stage companies are planning for projects in 2010 and 2011 and need data to determine which locations make sense for their needs,” Raso says. “Our supply chain campus Web site will help national and international companies with their research and make it easy for them to contact us with specific questions or to arrange site tours.”

To learn more contact Raso at (319) 354-3939 or jraso@iowacityarea.com. Also visit www.iowacitywind.com.

Hyosung has again selected Romax Technology as a leading partner in their wind energy activities. Following the success of their first collaborations on 750kW and 2MW wind turbine gearboxes, Hyosung and Romax will cooperate on future wind turbine projects.

Romax and Hyosung first worked together when the UK based consultancy supported Hyosung in the design and optimization of a 750kW and 2MW gearbox. Romax assisted in the collation of commercial and engineering market research and the concept design, detailed design, and manufacturing drawings. In addition, Romax has provided continuous testing and certification support. Both projects proved successful with the 750kW and 2MW gearboxes recently achieving type certification through DEWI-OCC (Offshore and Certification Centre GmbH) following successful field trials.

The success of these previous ventures and the standard of the technical and commercial support they received led Hyosung to select Romax as a key partner in their new venture. “Romax’s expertise in wind turbine engineering is an important factor in our success,” according to K.H. (Kevin) Ho, senior vice president of industrial machinery PU from Hyosung. “We have no doubt that this will continue well into our future collaborations, and we had no hesitation in choosing to work with Romax again.”

“We are delighted that Hyosung have asked us to partner with them again and we are confident that the partnership will yield more success for both Romax and Hyosung,” says Andy Poon, director of renewable energy at Romax. For more information go to www.romaxtech.com.

A new collaboration between MAG Industrial Automation Systems and Dowding Machining LLC is poised to revolutionize manufacturing of wind turbine components with specially-designed CNC modules for the production of hubs and new automated technology for composite wind blade production. The Michigan-based venture—dubbed Astraeus from the Greek mythological “father of the four winds”—will use a unique new machine design to dramatically reduce the production times of turbine hubs, the large castings to which the blades are attached, to about four hours—a process that now typically takes 20 to 24 hours on the best production lines. In what will be the first implementation of MAG’s Rapid Material Placement System (RMPS), the new company will bring integrated manufacturing with automation and repeatable process control to wind blade fabrication—a process that has historically been manual, making blades prone to imperfections and weight variations, and exposing wind turbine manufacturers to warranty and replacement costs.

The new business unites MAG, a world leader in machine tools and aerospace composites, and Dowding Machining, a large-component precision machining operation, in an effort to make wind energy more cost-competitive as an alternative energy solution. “We’ve already seen significant interest in our capabilities from Asian and European companies,” says Jeff Metts, president of Dowding Machining. Plans for Astraeus include opening global facilities to supply worldwide demand.

 The management and organization of Astraeus will be announced by the end of the year, with production expected to ramp up very quickly. “We plan on producing some of the components by the middle of next year,” according to Roger Cope, president of the Strategic Business Development Group of MAG.

MAG is a leading machine tool and systems company serving the durable-goods industry worldwide with complete manufacturing solutions. The company offers a comprehensive line of equipment and technologies including process development, automated assembly, turning, milling, automotive powertrain production, composites processing, maintenance, automation and controls, and core components. Key industrial markets served by these technologies include aerospace, automotive and truck, heavy equipment, oil and gas, rail, solar energy, wind turbine production and general machining. More information is available at www.mag-ias.com.

Dowding Machining LLC is a precision machine solutions provider for large components and is an affiliate of Dowding Industries, Inc., a woman-owned manufacturer of progressive die stampings, metal fabrications, and welded assemblies. Learn more by visiting www.dowdingindustries.com.

The world leader in environmental measurement Vaisala, together with electricity and natural gas energy company Xcel Energy and the National Center for Atmospheric Research (NCAR), have joined forces on a pioneering pilot project in the United States that will take observing and forecasting for wind energy production to the next level.

The goal of the pilot is to explore the use of a new wind observing and forecasting system in Xcel Energy’s wind power generation. The system will provide critical decision-making support for balancing wind power with traditional fossil fuel generation while minimizing costs and improving reliability. A primary focus of the effort is to develop technologies that will better anticipate changes in wind energy output from wind farms. “This is a great opportunity for Vaisala to again demonstrate how we can provide observation systems for weather critical applications,” says Richard Pyle, head of the company’s wind energy market segment.

“We are extremely pleased to enter this pilot project with Vaisala and NCAR, who both are leading players in their fields and can significantly contribute to the development of wind forecasting in energy production,” says Mary Fisher, vice president of strategic technology for Xcel Energy. “Once completed the pilot, if successful, will inform wind farms operators on the means to increase reliability and minimize integration cost.”

Vaisala is providing Xcel Energy with surface weather stations, radar wind profiling capability, and National Lightning Detection Network® data, as well as installation and operating services for a 12-month pilot program. The wind observation network will be located around wind farms in Colorado that total 400 megawatts of installed capacity. The network became operational in November 2009.

NCAR has been contracted to refine a wind forecasting system that focuses on wind ramp detection for the project. Vaisala’s observation data will be integrated with the forecast information in a decision support tool developed by Vaisala in close cooperation with the three parties. To learn more contact Richard Pyle at (303) 589 8772 or richard.pyle@vaisala.com. Visit online at www.vaisala.com.

Ohio Gov. Ted Strickland recently announced that 25 state solar and wind projects will receive more than $13 million in grants funded through the American Recovery and Reinvestment Act’s State Energy Program. The announcement was made last November at Lincoln Electric’s Automation Center of Excellence in Cleveland, highlighting the company’s welding solutions for wind tower fabricators.

Among those projects was $1 million awarded to Lincoln Electric to help install a wind turbine at its Cleveland manufacturing facilities. The plans call for a 2.5-megawatt turbine that will generate approximately 10 percent of the electrical needs for Lincoln’s Cleveland manufacturing operations.

“We are excited to have this opportunity under Ohio’s energy program to demonstrate the value of wind energy by investing in our own installation,” says John Stropki, chairman and CEO. “This project is a continuation of other Lincoln environmental, health, and safety (EHS) programs and green initiatives currently under way in our manufacturing operations to improve our costs and protect our environment. Not only will the wind project provide long-term benefits by reducing our energy costs, it will also showcase the unique benefits that Lincoln products and welding solutions provide to wind tower manufacturers to improve their quality and lower their costs.” Learn more at www.lincolnelectric.com.