Renewable

Energy.
rothe erde® slewing bearings
rothe erde® rings
psl® rolling bearings
2 Using renewable sources of energy. 3

Global strength – thyssenkrupp rothe erde Slovakia a.s.

thyssenkrupp rothe erde Germany GmbH

Rothe Erde India Private Ltd. thyssenkrupp rothe erde (Xuzhou)

Ring Mill Co. Ltd.

local presence.
thyssenkrupp rothe erde UK Ltd
OOO thyssenkrupp rothe erde RUS
Xuzhou Rothe Erde Slewing
thyssenkrupp rothe erde Italy S.p.A. thyssenkrupp rothe erde USA Inc.
Bearing Co. Ltd

thyssenkrupp rothe erde Spain S.A.

thyssenkrupp rothe erde Japan Ltd.

thyssenkrupp Brasil Ltda -

As part of a global group, we are a strong, Division rothe erde

reliable partner offering you stability and

planning certainty for your projects. Our
extensive knowledge base in a wide range
of applications has made us a global leader.

You can find us

where we are needed.
Our global brands rothe erde® slewing bearings, rothe erde® rings
and psl® rolling bearings form the basis of long-standing
customer relationships through our wide range of slewing
bearings, rings and rolling bearings and our individualized
customer solutions.

The depth of production we can offer is impressive. All national

and international plants are bound, without exception, by the
quality concept. Experienced and highly specialized employees
with proven know-how work for constant innovation and adhere
to the highest quality standards in the world. The reliability and security which come from being a
global group enables thyssenkrupp rothe erde to pro-
Our outstanding position enables us to tackle projects by interdis- vide you with fast and flexible decisions. With produc-
ciplinary approach and to import technology from other sectors. tion sites in 10 countries and associated ring roller
Our company has been a reliable partner to all the manufacturers mills, thyssenkrupp rothe erde and its subsidiaries
of wind energy equipment since wind energy was first used. represent a global company with a local presence.
4 Using renewable sources of energy. 5

Wind energy plants –

onshore and offshore.
Along with innovative solutions for pitch
and yaw bearings, the main focus lies on
developing main bearings. thyssenkrupp
rothe erde has been crucially involved in
its role as the global market leader for
slewing bearings. Intensive research
and development has resulted in the
successful deployment of thyssenkrupp
rothe erde products in wind energy plants
(both onshore and offshore) throughout
the world.

The driving force.

Finite resources and rising energy prices constitute a global
challenge. At thyssenkrupp rothe erde we are taking on this
challenge through our development of pioneering solutions.

With the aim of achieving advances in providing environmentally

friendly energy, we are installing increasingly efficient wind energy
plants throughout the world, which are now able to compete
against fossil energy resources. We at thyssenkrupp rothe erde
are a strong, progressive partner in the field of onshore and off- The carbon dioxide (CO2)-free energy
shore systems. Our constant search for innovative breakthroughs gained through wind power is now
enables our customers not just to be part of the new energy era ever more important. Germany is
but to advance it, and to make crucial contribution to securing a not just the leader in this technology,
more environmentally friendly future. but also uses wind as the top
alternative source of energy. The
company’s commitment to renewable
energies has made it a reliable partner
to all the important wind power plant
manufacturers since the sector
came into being.
6 Using renewable sources of energy. 7

Wind energy plant 3

expertise – from top

to bottom.

The demands placed on the various

4
bearings and rings in wind turbines
necessitate custom designs. In addition to 5
the rings which provide the secure connec-
ting element for the tower, we can supply
you with suitable products – individually to
fit your requirements – wherever you need
them for diameters of up to 6500 mm for
main bearings and 9600 mm for yaw and
pitch bearings.

Many years of experience and skill in 2

dimensioning ball and roller slewing
connections enable us to provide optimal
designs for the specified loads and
operating conditions. [ 1 ]  Foundation bottom flange
[ 2 ]  Tower flange
[ 3 ] Top flange
[ 4 ]  Yaw bearing
[ 5 ]  Pitch bearing
[ 6 ] Gearbox bearing, disks,
spur and ring gears
[ 7 ]  Main bearing
1
8 Using renewable sources of energy. 9

rothe erde slewing bearings meet ®

[ 3 ] The Pitch Bearing

the most stringent requirements.

rothe erde® pitch bearings are given a preload with defined torque
resistance values during production as a means to prevent unwanted
false brinelling. Special UV and ozone resistant double-lip-seals
provide optimal protection for the raceway system.

Rotor pitch must be adjustable to produce maximum output from

the generator. Pitch bearings in particular have to withstand
the continuous load changes. Single and double-row four-point
contact ball bearing and three-row roller bearings are ideally
suited for these applications.

rothe erde ® ball and roller slewing bearings with special seals.

3
[ 1 ] The Main Bearing
thyssenkrupp rothe erde uses patented production technology to
manufacture induction-hardened raceways without soft spots on
main bearings. The process is suitable for double-row taper roller
bearings and three-row cylindrical roller bearings with diameters
up to 6500 mm.

rothe erde ® slewing

bearings configured
as three-row cylindrical
roller bearings or double-row
taper roller bearings with
special seals.

[ 2 ] The Yaw Bearing

2
The yaw (azimuth) bearing is used primarily for positional adjust-
ment, keeping the nacelle properly oriented in the wind. Single and
double-row four-point contact ball bearings are ideally suited for
these applications. Three-row roller bearings are used on MMW
scale turbines.
Preloaded rothe erde ®
ball and roller
slewing bearings.
10 Using renewable sources of energy. 11

2-row taper roller bearings in O-arrangement

The main bearing – • up to 6500 mm external diameter

• bronze cage or low-wear coated steel cage
• (WPC – wear protection cage)
• rings or induction-hardened

the central link.

• bolted or bolt-free assembly possible

3-row cylindrical roller bearings

The object of the main bearing is to enable
the transmission of the torques from • up to 6500 mm external diameter
aeromechanical energy conversion to the • bronze cage or low-wear coated
current-producing generator – with the steel cage (WPC – wear protection cage)
least loss possible – and simultaneously to • rings or induction-hardened
brace against the forces and moments • bolted and bolt-free assembly possible
which arise. The main bearing is therefore
the central element of any drive train
concept.

Whether one-row or multiple-row cons-

truction, clamped or bolted installation,
case hardened or slip-free induction-
hardened raceways – we design these 2-row taper roller bearings
in close consultation with you and manu-
facture the appropriate solutions for • up to 1900 mm external diameter
diameters of up to 6500 mm. • steel cage or welded pin-type cage
• rings or austempered
(bainitic or martensitic)
• shrink-fit

Spherical roller bearings 1-row taper roller bearings

• up to 2800 mm external diameter • up to 3400 mm external diameter
• integral brass or steel cage • steel cage or welded pin-type cage
• rings case hardened or austempered • rings case hardened using
(bainitic or martensitic) case hardening steel
• shrink-fit

Cylindrical roller bearings

Toroidal roller bearings
• up to 2200 mm external diameter
• bolted brass cage • up to 2100 mm external diameter
• rings case hardened or austempered • bolted brass cage
(bainitic or martensitic) • rings austempered
• shrink-fit • shrink-fit
12 Using renewable sources of energy. 13

Tailored solutions –
not run of the mill.
Specialized applications demand individual
solutions. Our slewing bearings are develo-
ped and constructed exactly to your requi-
rements. In close consultation with you, we
find unique solutions for the construction,
material composition and performance.
To cater for this we have different forms of construction, hardening
processes and configurations available – all of which are practical
and have been proven throughout the world.

We believe that solutions should be designed to fit the customer’s

requirements from planning to manufacture and beyond. As a
global group with 11 companies and 16 manufacturing plants in
10 countries, we are able to maintain close contact with our
customers by virtue of our local presence. Through decades of
expertise gained in the wind energy sector, we are capable of
finding efficient and innovative solutions in partnership with you.

thyssenkrupp rothe erde relies on APQP4Wind to minimize risks.

APQP4Wind is an initiative of the Danish Wind Industry Association
and leading wind turbine manufacturers for the transparent imple-
mentation of customer requirements within the development,
planning, and production processes.

The aim is to reliably meet customer requirements even before the

product enters into series production. APQP (Advanced Product
Quality Planning) originated in the automotive industry, where it
was established as a standard. With APQP4Wind, this standard is
adapted to the special requirements of the wind industry and sig-
nificantly lower volumes. thyssenkrupp rothe erde has been one of
APQP4Wind‘s first component suppliers since its inception in 2017
and has been working to establish the standard ever since. Requi-
rements of APQP4Wind were successively implemented and the
employees were fully trained.
14 Using renewable sources of energy. 15

Production
chain – all from
one source.

With us, you choose a partner capable of

covering the entire production chain. From
raw materials to the finished product, all
the main components of the slewing
bearings are manufactured in-house.

For the manufacture of our slewing bearings we only use steels

whose suitability for the respective application has been proven
beyond a doubt. Inspections are made throughout the entire
production chain. The steel used is of the highest purity with
minimal oxygen and sulphur content in order to prevent long-
term material fatigue. In the case of large-dimension bearings
and rings this secures the optimal combination of hardness and
fracture strength. Once we have selected and manufactured the
correct material, our rolling mills manufacture the rings. These
rings form the basis for further production stages of machining
through to finishing and assembly.

In addition to rings we manufacture all the other components,

such as balls, rollers and cages at our plants. This guarantees
very strict quality control and traceability throughout the entire
production process. In addition, the great vertical production
range enables lead times to be shortened considerably with the
accompanying improvement in planning ability. Knowledge of the
materials and components, their properties and composition
guarantees innovative results which can be achieved in close
collaboration with the customer. This ensures that you will receive
complete solutions from a single source, with all requirements
catered for, right down to the smallest detail.
At the beginning is the raw material
steel - but not all steels are the same. Only individuals who are able to view the entire production chain in
Only individuals with the relevant detail are capable of providing you with effective advice to satisfy
knowledge of materials can recognize your requirements. With this knowledge we are able to assist and
and make full use of all the technical advise our customers through all project phases from initial advice
options. on planning the system to its construction and installation. Our
services continue after shipment has taken place. Trained and
experienced service inspectors are available to assist you with all
questions.
16 Using renewable sources of energy. 17

Hard shell –
tough core.
Using specially developed
hardening processes, our Case-hardening
engineers provide the slew- Careful carburization, austem-
ing bearings not just with a pering and controlled cooling
procedures mean that we can
long service life, but also harden entire bearings up to
very high surface hardness diameters of 2500 mm.

and the ability to withstand

extreme loads by virtue of
the depth of hardening.
This is how we create opti-
mal conditions for all given
applications.

Our plants offer a full range of thermo-che-

mical and inductive processes to achieve
the desired results. Targeted carburization
and austempering lead to optimal material
characteristics from the required hardness
to the correct toughness. Cooling proces-
ses then achieve an obvious reduction in
the retained austenite and eliminate possi-
ble weaknesses throughout the entire race- Induction process
way geometry.
Patented manufacturing pro-
Specific sections of certain workpieces can cesses enable us to achieve
even be provided with different, and hence slip-free progressive induction
exactly suitable, hardening profiles using hardening of main bearings –
non-slip induction hardening, and this can for two-row spherical roller
be done on diameters of up to 6500 mm. bearings as well as three-row
cylindrical roller bearings –
for diameters ranging up to
6500 mm.
 Using renewable sources of energy. 19

Production possibility main bearing Production possibility pitch and yaw bearing

Commitment to quality - 12 MW 12 MW

we meet customer
thyssenkrupp rothe erde till thyssenkrupp rothe erde till

Ø 6500 mm Ø 9600 mm
8 MW 8 MW

requirements.
Status Quo of market Status Quo of market

Ø 4000 mm Ø 4000 mm

rated power

rated power
outside diameter outside diameter
slewing bearings slewing bearings

While the growth of wind energy plant size This is where we test the future.
has brought the established processes
and technologies close to their limits, In order to test our products as realistically as possible and thus
thyssenkrupp rothe erde has steadily minimize the risk for our customers, we rely on tests with real com-
panion structures on a scale of 1:1. In addition to several rotor
continued developing its bearing concepts. bearing test benches, a new pitch bearing test bench considerably
expands our possibilities.

For example, both the inner and outer rings of a main bearing There, we receive the possibility to test the next generation of pitch
can be bolted to the adjoining sections. While this permits easier bearings by using an original hub and an original blade of an off-
installation of the main bearings than when shrinking them on, shore wind turbine. This includes all designs as well as the challen-
it also eliminates relative movements of the bearing against the ges for systems >10 MW. It is possible to simulate the required
driveshaft. service life within months. With these opportunities, thyssenkrupp
rothe erde has developed a test center that is unique worldwide.
Prior to shipping, our slewing bearings are thoroughly tested in In addition to testing the specific components, the results are
every possible aspect. The latest testing methods and efficient directly incorporated into our calculation methods and thus serve
forms of analysis offer valuable clues to stability, service life, per- as validation for all thyssenkrupp rothe earth pitch, yaw, and main
formance and load limits. The tests are performed in the full-size bearings.
plant under realistic conditions, with thorough inspection of the
individual components. Additionally, we investigate and improve the structural behavior
Environmental factors such as temperature and air humidity are and lubricant compatibility of our products on site, thus providing
included in the tests. We are able to examine the slewing bearings you the bearings of the next generation.
on a scale of 1:1 under conditions approxmating reality using
a number of in-house pitch and main bearing test benches.
R&D Center To include new developments for systems in the multi-megawatt
class, thyssenkrupp rothe erde was careful to increase its
thyssenkrupp rothe erde has production capacity at an early stage.
created a new R&D centre to
ensure important testing can be With the current equipment it is possible to manufacture main
carried out quickly and bearings with an external diameter of up to 6500mm. Today,
efficiently. our production capability is well in excess of the current market
average of approximately 4000 mm for a 6-megawatt main
bearing.
20 Using renewable sources of energy. 21

Full service – a strong

partner from A to Z.

Top quality at all levels

Full implementation includes not just
In addition to all the ISO standards we also cover DNV
the production, but also the extensive certification. An overview of our quality management:
know-how offered by our global company
Systematic and detailed scrutiny of contracts
network for application in your wind energy and specifications.
project. This allows us to assist you from
Consideration of customers‘ requirements
start to finish and in any situation. throughout the entire development and
construction process.

It starts with a good plan. Continuous monitoring of raw materials and

all production stages and bearing components
The Finite Element Method (FEM) is an efficient method of develo- up to shipment.
ping the optimal slewing bearings solution for any wind energy sys-
tem together with you. An analysis is made based on the rigidity of Assurance of the utmost cleanliness of the main
the adjoining structures and a subsequent full calculation of the bearings through assembly in shielded spaces.
entire system. The results provide information on the safety and life-
time of the bearings, but also indicate options for optimizing the Internal and external audits of all processes
adjoining structures. FEM enables potential weaknesses to be identi- including their supply chains.
fied and eliminated at an early stage of the planning.
Quality certification by means of customer
Reliable support after assembly is complete. audits which are performed in an open and
cooperative manner.
Our work does not end with the shipment of the main bearing.
You can also benefit from our know-how and expertise during Further development and steady optimization
normal operation. Make use of our advisory and training service, of test procedures such as ultrasound testing,
for example, when carrying out servicing and maintenance lubricant monitoring, testing of geometries, etc..
with your own team. Benefit globally from the know-how of our
engineers who will work for you on-site. In short: keep your Usage of APQP4Wind for risk minimization.
turbine turning!
22 Using renewable sources of energy. 23

Focusing the power of the

sun and the tides.
Corrosion protection is especially rothe erde® slewing bearings absorb all radial and axial forces
and the resultant tilting moments in a single self-retaining, ready-
important in hydroelectric and tidal power to-install bearing unit with an excel-lent weight/performance ratio.
stations to prevent damage caused by Compact design, an excellent weight/performance ratio, an open
center and integrated gearing make rothe erde® slewing bearings
seawater. the ideal choice for tidal power stations.

thyssenkrupp rothe erde uses special sealing systems with mating rothe erde® slewing bearings are supplied as yaw, pitch or rotor
surfaces made of stainless steel, which have an extensive track bearings, depending on the application. Integrated sealing sys-
record in the offshore industry. tems can be provided as well.

Efforts continue to make better use of

existing potential of solar power systems,
and thyssenkrupp rothe erde is a major
contributor.

On PV systems, rothe erde® slewing bearings and worm drives It withstands high axial and radial forces, and tilting moments. The
ensure optimal solar tracking performance. Slewing bearings and rothe erde® worm drive eliminates the need for a brake, and due
worm drives also position the mirrors which focus the sun’s rays at to the geometry of the gearing the drive is selflocking.
Hydroelectric power stations solar thermal stations, producing heat which is converted to rothe erde® slewing bearings and worm drives deliver dependable
produce electricity at flow rates electricity in a conventional power station. operation without the need for extensive maintenance.
as low as 2 - 2.5 m per second. rothe erde® worm drives are not complicated to install, and the
The rotor which drives a genera- Slewing bearings featuring proven designs and compact worm rugged design ensures many years of low-maintenance operation.
tor has a very low rotational drives, which are supplied ready-to-install deliver absolute
frequency. precision to maximize system efficiency. The worm drive offers the
advantages of a slewing bearing and a worm drive gear in a single
unit.
Components Technology
Bearings

thyssenkrupp rothe erde GmbH

Tremoniastraße 5  –  11
44137 Dortmund, Germany
P: + 49 231 186 - 0
F: + 49 231 186 - 2500
www.thyssenkrupp-rotheerde.com

09.2018/4/0.5/EP/CN/FV_MS_10428