LORC inaugurates one of the world’s most powerful main bearing test facilities, enabling full-scale validation up to 25 MW.
As wind turbines continue to grow in size and power rating, the demands on critical components increase dramatically. Main bearings, which support the rotor and transfer loads into the turbine structure, are exposed to extreme forces over long lifetimes. Ensuring their
reliability at the multi-megawatt scale requires test facilities capable of replicating real operational conditions with exceptional accuracy and power.
Lindø Offshore Renewables Center (LORC) set out to address this challenge by establishing a new main bearing test facility capable of testing bearings for wind turbines up to 25 MW. From the outset, the ambition was clear: to build one of the most powerful and advanced main bearing test benches in the world.
R&D Test Systems was appointed to design, engineer, and deliver the complete facility, while Schaeffler provided extensive application knowledge, which formed the foundation for the test rig.
Project Scope and Objectives
The main bearing test facility was developed to support both LORC’s role as an independent testing center and Schaeffler’s need, as a market-leading bearing manufacturer, for advanced development and validation of next-generation main bearings. R&D Test Systems was responsible for delivering the complete test system. This included the mechanical and structural design of the test bench, load application systems, control and measurement architecture, as well as civil works, installation, and commissioning. The facility
was specifically engineered to reproduce realistic, multi-axial load conditions representative of modern and future offshore wind turbines.
At its core, the objective was to enable full-scale testing of main bearings under real-world conditions. By doing so, the facility helps reduce development risk, shorten validation cycles, and support continued innovation as turbines move toward unprecedented power levels.
Development Phase: Collaboration from the Start
From the early development phase, the project was characterized by close collaboration between LORC, Schaeffler, and R&D Test Systems. Schaeffler contributed deep application knowledge and clear testing requirements based on real bearing designs and operating experience. LORC provided the long-term infrastructure vision, while R&D Test Systems translated these needs into a robust and scalable test system.
The development phase focused on addressing a number of fundamental engineering
challenges, including:
- Replicating extremely high static and dynamic loads
- Ensuring sufficient stiffness and stability of the test bench structure
- Designing load application systems capable of reproducing realistic turbine load cases
- Integrating control and measurement systems suited for detailed bearing analysis
This early alignment between application requirements and test system design proved
essential to the project's success.
Civil Works: Building the Foundation
A critical milestone was the foundation construction, which had to safely absorb and distribute the extreme forces generated during testing while maintaining long-term structural integrity and measurement accuracy.
R&D Test Systems completed the reinforced concrete foundation as a dedicated project phase. Weighing approximately 3,700 tons, the foundation was engineered specifically for the demanding load cases defined jointly with project partners. Its completion marked the transition from planning and design to physical realization of the facility.
Installation and Assembly: Scaling Up
With the foundation complete, the project moved into installation and final assembly. One of the most significant milestones was the lifting and positioning of the 560-tonne test load unit — the core of the facility’s load application system. Measuring 16 meters in length, 9 meters in width, and more than 8 meters in height, the unit was installed using Lindø’s 1,200-tonne gantry
crane under tight tolerances.
This phase made the facility's scale tangible. Designed to test full-size main bearings for turbines up to 25 MW, the test bench was widely recognized as the world’s largest of its kind.
Commissioning and Handover
Following mechanical completion, the focus shifted to commissioning and validation. This phase ensured that load systems, control architecture, measurement equipment, and safety functions all performed according to specification across the full operating envelope. Successful commissioning confirmed that the facility could reproduce complex, realistic load scenarios representative of modern wind turbine operation. With this, the project transitioned from delivery to operation, and the facility was formally handed over to LORC.
R&D Test Systems: Project Completion
Reflecting on the completion of the project, Allan Bjerg Pedersen, Director at R&D Test Systems, emphasizes both the technical achievement and the collaboration behind it:
“Delivering this facility alongside LORC and Schaeffler has been a major milestone for us. From early design to final handover, the project has required close collaboration and a shared commitment to engineering excellence. We are proud to see the Main Bearing Test Facility fully operational and ready to support the next generation of wind turbine technology.”
Outcome and Industry Impact
The Main Bearing Test Facility at LORC significantly strengthens the global test infrastructure available to the wind industry. It enables:
- Full-scale testing of main bearings for turbines up to 25 MW
- Improved understanding of bearing behavior under realistic, multi-axial loads
- Reduced technical risk in turbine and component development
- Faster validation of next-generation designs
The project stands as a clear example of how close collaboration between test center, component manufacturer, and test system supplier can deliver infrastructure that supports the continued scaling of wind energy — reliably and responsibly.
For further information please contact Project Director Allan Bjerg Pedersen, alb@rdas.dk, +45 81 10 32 00
Visit: www.rdtestsystems.com