Wind Power Boom: What the Growing Build-Out Means for Component Manufacturing
- Zeilhofer HHT
- Jul 7
- 3 min read
The addition of wind turbines is picking up noticeably, and with it the demand for components. Hubs, generators, flanges and tower segments have to be manufactured in higher numbers. For component manufacturing, the wind power boom means above all one thing: produce faster, without compromising on ergonomics and quality.
For wind power component manufacturing, the boom means above all one thing: produce faster, without compromising on ergonomics and quality.
What the wind power boom means for component manufacturing
More turbines mean more components, and heavy ones at that. Manufacturing has to increase its cycle rate while shop-floor space and personnel remain limited. Handling technology decouples output from pure muscle power: heavy components are moved sway-free, workstations become more broadly staffable, processes reproducible.
This way rising demand can be met without increasing the workforce to the same extent, which would often not even be possible given the shortage of skilled labor.
Hubs, generators and flanges in focus
The central components are heavy and partly sensitive. For vertical lifting, the ZH90 lift axis up to 1,200 kg is suitable, for turning and joining an articulated manipulator up to 800 kg. Heavy flanges are a topic of their own, covered in the article Flanges, indispensable and often extremely heavy.
Where handling technology starts in component manufacturing:
Turn hubs and align them for assembly.
Reposition generator components sway-free.
Position and join flange connections precisely.
Handle tower segments and housings safely.
Quality and ergonomics despite the pace
Higher pace must not come at the expense of quality and health. Sway-free load guidance protects component and worker at the same time. What role ergonomics plays at the assembly workstation is explored in the guide to ergonomics at the assembly workstation. Whether the investment pays off is shown in What does a manipulator cost.
Zeilhofer Handhabungstechnik engineers every solution individually, is certified to ISO 9001 and works in accordance with TISAX Level 2 with prototype protection.
Practical example: hub assembly in series
In hub manufacturing, one task repeats a hundred times: the hub, several hundred kilograms depending on the turbine class, has to be turned several times and positioned exactly for bolting the blade bearings. Manually this is barely possible, and with the crane too slow and too imprecise for the series cycle.
An articulated manipulator with a turning device guides the hub sway-free into every required position, always the same and without effort by the worker. This keeps the cycle constant, regardless of who staffs the workstation. It is precisely this repeat accuracy that makes the boom in component manufacturing manageable in the first place.
Frequently asked questions
What does the wind power boom mean for manufacturing?
More turbines mean more heavy components. Manufacturing has to increase its cycle rate while personnel and space remain limited. Handling technology closes this gap.
Which components are particularly critical?
Above all hubs, generators, flanges and tower segments, because they are heavy and partly sensitive and have to be joined precisely.
How is quality maintained despite the higher pace?
Through sway-free load guidance, which protects component and worker and feeds every part reproducibly in the same position.
Which load capacities are possible?
Depending on the system up to 1,200 kg with the ZH90 lift axis and up to 800 kg with the articulated manipulator.
Equipped for the build-out?
Do you manufacture wind components and want to be equipped for the rising build-out? Our engineers are happy to advise you and design your solution individually, Made in Germany, from a single source.
For more depth on individual topics, see our guides on handling technology.
