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Raising the Bar: How Innovative Yoke Technology is Accelerating Wind Turbine Blade Assembly

Published in: Wind, Digital Blog

Raising the Bar: How Innovative Yoke Technology is Accelerating Wind Turbine Blade Assembly image

As Germany pushes forward with its energy transition, installing next-generation wind turbines efficiently and safely is paramount. Recent projects in Saxony and the Black Forest showcase how advanced rotor blade handling systems, like the RBC-D yokes from ematec, are playing a pivotal role in streamlining assembly, overcoming site challenges, and supporting the expansion of renewable energy infrastructure.

Indispensable Support in Challenging Conditions

For recent builds featuring large ENERCON EP5 turbines (5.6 MW E-160 models), project teams relied on ematec's technology for dependable blade handling.

"The RBC-D has become an essential part of our workflow. It gives us full reliability and significantly reduces installation time," confirms Matthias Jöde, project manager at ENERCON.

The system's practical benefits are clear:

  • Blades can be mounted at various angles.
  • Integrated sensors provide full control, allowing real-time correction of deviations.
  • Automatic halts occur if set thresholds are exceeded, enhancing safety.

A Smart Match: Yoke + Autonomous Positioning System (APS)

A significant innovation highlighted in the Königshain-Wiederau project was the combination of the ematec yoke with the Autonomous Positioning System (APS) from Seasight Solutions. This system uses propellers attached directly to the yoke, completely eliminating the need for traditional guide ropes.

"That changes everything. We no longer need winches and require far less space," says Jöde. This compact footprint proved crucial not only in Saxony but also during the Taubenkopf build in the Black Forest's steep terrain. "Given the steep terrain, this was the only realistic approach," notes Lukas Schuwald, managing partner of Ökostromgruppe Freiburg.

Faster Progress, Fewer Weather Delays

The synergy between the APS and the ematec yoke significantly improves the installation workflow and expands the weather window for operations.

  • Traditional guide ropes typically limit blade lifts to wind speeds below 8 m/s.
  • The combined ematec yoke and APS allows work to continue safely in winds up to 10 m/s.

"On average, we save 2.3 working days per site just by reducing weather-related delays," reports Klaas Schumann of ENERCON's site engineering team. He adds that under the right conditions, this efficiency boost makes it possible to install all three blades in a single day.

Furthermore, the system eliminates the need for a ballast arm when lifting blades, saving at least two crane operations per turbine and further accelerating the assembly process.

Proven Performance in the Field

The technology consistently delivered on its promise during the projects. "The single-blade installation went off without a hitch, even in heavy fog. There were no interruptions," says Lara Forsans, project manager at Leipziger Stadtwerke, commending the ENERCON crew for completing blade assembly in just one and a half days on one site.

"As a family-run business... it's incredibly rewarding to be directly contributing to Germany's energy transition and helping streamline turbine setup," adds Julian Eberhard, CTO at ematec. The successful deployments are leading to continued use in ongoing projects in both regions.

Technical Highlights: The RBC-D Yoke System

What makes the ematec RBC product line stand out?

  • Self-Balancing: The first single-blade yokes globally that automatically adapt to each blade and find its center of gravity using counterweights.
  • Versatility: Handles blades from 45 to 110 meters.
  • Stability: Stabilizes blades at angles up to ±30 degrees, preventing uncontrolled movement.
  • Secure Grip: The RBC-D features upper and lower grippers with hydraulically moved, cardanically suspended pads. Integrated safety valves prevent blade slippage, even if operated incorrectly.
  • Crane Friendly: Low hang height (approx. 3.5 meters) simplifies crane management, crucial with increasing hub heights.
  • Rapid Deployment: Ready for use quickly on site (<30 minutes for positioning and attachment).
  • Green Line Option: Battery-powered versions designed for cold temperatures (-20°C) with double redundancy, circumventing stricter engine emission standards (Euro 5 / EPA Tier 4). The electric motor stays below 48 volts, meeting UL requirements for US use.
  • Transport Ready: Designed for straightforward transport in Germany with a permanent permit.

As wind farms continue to grow in scale and turbines reach new heights, innovations in installation technology like ematec's RBC-D system, especially when paired with advancements like the APS, are crucial for maintaining safety, improving efficiency, and ultimately, accelerating the deployment of clean energy.

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