The Black Forest plays a crucial role in Germany’s energy transition. For more than 20 years, numerous wind turbines have stood there, and are now receiving a performance boost through repowering projects. For all projects, ematec’s special yoke handles all types of rotor blades thanks to its adaptive blade mount.
New Enercon turbines
There is plenty of work for Enercon, Germany’s largest wind turbine manufacturer. The company supplies its E-138-EP3 turbines for replacing older units in repowering projects and its E-160 EP5 E3 and E-175 EP5 E3 models for both repowering and new installations. The installation teams don’t have to worry about the lifting equipment for rotor blade assembly. For all projects, they can rely on the RBC-D 50 high-end yoke from the Allgäu-based specialist, ematec. Thanks to its adaptive blade mount, ematec’s special yoke handles all types of rotor blades, regardless of size or weight.
Combination of RBC-D and APS
Maximum process reliability is provided by ematec’s RBC-D technology in combination with the autonomous positioning system (APS) from Seasight Solutions. Two propellers are mounted to the ematec yoke, allowing installation of rotor blades without the need for guide ropes or winches.
Especially in forested or steep terrain, that’s a huge advantage, and often the deciding factor in whether a project can be realised at all. During the recent installation at Taubenkopf near Freiburg, using the RBC-D and APS was the only feasible solution due to the topography. Any other assembly method would have been impossible.
Installation at ±30 degrees
Enercon and its installation partners also benefit from significant time savings onsite. With ematec’s RBC-D, rotor blades can be installed at any angle within ±30 degrees, eliminating the need for additional tools to rotate the hub after each blade is mounted. The installation teams no longer need to install a ballast arm as a buffer during installation, saving at least two crane lifts per turbine.
Less downtime on construction sites
Another advantage of the RBC-D and APS combination is that rotor blades can be installed in wind speeds of up to 10 m/s. “This allows much greater flexibility in the installation process and significantly fewer weather-related delays,” says Norman Huske, who trains Enercon installation teams worldwide on using the ematec RBC-D and Seasight Solutions APS. “Using the new technology, all three blades of a turbine can be installed within a single day if needed. The limiting factor here is usually the crane operator’s shift schedule, not the equipment.”
Smooth installation
At the latest wind farm project in the Black Forest, the RBC-D from ematec and APS from Seasight Solutions once again ensured process and work safety. The rotor blades of the Enercon E-160 EP5 E3 turbines were installed in just 1,5 days. “Even in rain and fog, everything went smoothly,” Huske reports. “In total, six old turbines are being replaced by three new Enercon units in this major repowering project. We’re cutting the number of turbines in half while quadrupling the output, and doubling the distance from residential areas. It’s a win-win for everyone involved.”
The RBC generation rotor blade yokes from ematec are the world’s first and only single-blade yokes that automatically and individually adapt to each specific rotor blade, consistently balancing themselves. They can handle blades ranging from 45 to 110 metres in length and stabilise them at inclination angles of up to ±30 degrees, ensuring uncontrolled movements are entirely avoided. The RBC system always identifies the precise centre of gravity for safe blade handling. Two counterweights at each wing of the yoke automatically adjust to the centre of gravity, with or without the blade.
In addition to the lower gripper, the upper telescopic gripper is also equipped with fourteen hydraulically actuated and gimbal-mounted grip pads. The gripper hydraulic cylinders feature integrated safety valves that prevent blades from slipping out, even if improperly handled. With a hang height of only 3,5 metres, the RBC series greatly simplifies crane management, particularly considering the increasing hub heights of wind turbines.
Ready for action in record time
The Green-Line variants of the RBC yokes are powered by high-performance batteries, suitable for mounting three rotor blades at temperatures as low as -20 degrees Celsius. Battery operation is double-redundant. Thanks to ematec’s Green-Line technology, wind turbine manufacturers can bypass stringent emissions standards such as the Euro-5 and USA EPA Tier 4 final regulations. Additionally, ematec intentionally maintains the electric motor at a voltage below 48 volts, making it fully compliant and easy to deploy in the USA according to Underwriters Laboratories (UL) requirements.
For more information contact Enercon,
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