Amazing test systems

for multi-megawatt wind turbines.

Wind energy industry

EMPOWERING FORCES.
Wind energy industry

RENK TEST SYSTEM.

Your reliable partner for test rig solutions.

RENK Test System GmbH (RTS) is one of the world’s leading

providers of customized test systems used in development,
production, and quality assurance. Based on its many years of
experience, RTS develops innovative test rigs for nearly every
area of application in drive technology.

Wind power is one of the most important sources of energy

for the world of tomorrow. High quality wind turbines with
an increased efficiency and a high level of availability are the
deciding factors for competitiveness in wind industry. For
nearby 40 years, RENK offers innovative drive solutions for the
use in the on- and offshore sector. RENK test rigs continue to
impress with their superior technology and reliability when
testing wind turbine components and complete nacelles.

Our expertise extends from targeted consultation, concept

creation and validation, development and production up to the
commissioning of the systems at the customer’s location, with
subsequent training of the operating personnel. The entire
product range is completed by needs-oriented service, and
regular maintenance.

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 Power Reliablility Performance
Test rig concepts for Designed for highest utility Maximum benefit based
on- and offshore nacelles rates on tailored systems

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Wind energy industry
Nacelle test rigs
Fitting designs for different testing tasks
Different applications,
same focus.
Highest system reliability.
Wind turbines are highly complex systems
whose function is given by the interaction
of different components. In order to analyze
this interaction not only in rough operation,
it is necessary to simulate as many operat-
ing conditions as possible first on a nacelle
test bench.
The most complex test stands are needed
for the development of the main compo-
nents such as main bearings, gears or
generators in interaction with the other
components of a wind power plant or the
comprehensive testing of the entire system
including on-board network, sensors and
system control. With such Research and
Development test stands, all mechanical
and electrical parameters must be simula-
ted as realistically as possible.
The complexity of nacelle test benches has
many levels, depending on the intended
use, down to pure function test benches
at the end of the production line, sufficient
to turn the nacelle drive train under partial
load only.
The most important thing for all test bench
types is the reliability of the systems and
their availability. For this, a long-term and
trustful cooperation with the manufacturer
of the test system is necessary in order
to achieve the best possible operational
readiness on the basis of service, support,
spare parts and maintenance agreements.
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Different layouts,
one intention.
Maximum customer value.
The test rig electric drive system is pro-
viding all rotary loads on the specimen
drive train. This drive system must have a
very high torque and high dynamics in
order to simulate all operating conditions
occurring in the field. In the performance
range for testing future wind turbines,
RENK has various drive variants available,
from direct drive to gear support, depend-
ing on the respective test bench require-
ments.
In the rough operation of a wind turbine,
constantly changing forces from all direc-
tions generate dynamic 5DOF loads on
the turbine drive shaft. The total power of
this stormy environment is given in test rig
operation by the hydraulic load applica-
tion unit. To generate these forces and
moments, RENK can use a load applica-
tion unit with an hydrostatic disc (D-LAU),
which only introduces minimal interference
into the overall system and thus meets
the highest demands in terms of measure-
ment and control accuracy. Test systems
for applications in which the accuracy of
the applied wind load does not play a
significant role (e.g. production test ben-
ches) can be equipped with inexpensive
standard load application units with bea-
rings (B-LAU).
In cooperation with the multi-channel
measuring flange and other sensors, the
RDDS automation system records all
interactions between the test bench and
the test object in real time. Taking these
measured values into account, prescribed
wind profiles can be applied to the test
object reliably and with the highest quality.
The main electrical interface of the wind
turbine is the interconnection to the open
grid. For simple applications it is sufficient
to feed the power, generated by the test
object, back to the intermediate circuit of
the test bench for recuperation. However,
if this interconnection is also subject of the
tests, a grid simulator is to integrate to
simulate static and dynamic irregularities in
the public grid (harmonics, LVRT, HVRT,...)
in order to investigate their effects on the
wind turbine behaviour.
Because of the turbine control can also be
linked to the RDDS automation system,
RENK nacelle test rigs are prepared for full
HIL functionality and one-man control.
Wind energy industry

Giant Multi-axis Convenient

Test bench technology Complete DUT tested with One system integration for
matching massive loads realistic wind profiles control and data acquisition

Drive system

5 DOF load application unit with

hydrostatic disc (D-LAU)

RENK Multi-axis measuring flange

As the world's only provider of test
benches in the megawatt range,
RENK equips its load units with
optional multi-axis measuring flanges,
located at the hub point of the
nacelles main shaft.

Because only the loads introduced

directly at the hub point are relevant!

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Wind energy industry

Bearing test rigs.

Microscopic insights into giant specimens.

Special requirements. Clear test results.

Individual solutions. No test rig interference.

To test bearings, additional bigger support
bearings are required with higher load
ratings compared to the test bearing.
This is the only way to carry out tests with
overloads and to reliably assign measure-
ment data to the test item. But if the test
item is the maximum in its class, e.g. main
bearings of wind turbines, this requires
special solutions.
For this reason RENK has enhanced its
load application unit with hydrostatic disk
(D-LAU) to a very sophisticated bearing
test rig. With this design, very high loads
can not only be generated, but also reliably
measured thanks to the multi-axis measur-
ing flange, placed nearby the test bearing.
Because of the loads applied being returned
to the test structure, additional load reaction
blocks are not required. Contrary to the
pure load unit, the housing of the bearing
test bench enables the loads transmitted
to the test object to be fully returned to the
test bench.
Smaller bearings, such as pitch bearings,
are tested with standard test rig designs
with appropriate support bearings.
Regardless of which test bench design is
chosen, the focus is always on the best
possible analysis of the test item without
interference from the test bench. The inte-
grated data measurement system enables
the exact study of all bearing components:
- bearing rings
- seals
- rolling elements and cages
- lubricating oil
In addition to testing roller bearings, bear-
ing test rigs can also be designed for many
other bearing types in all load and speed
ranges.

With this test rig, RENK makes it possible

to test large bearings with high and pre-
cisely verifiable loads with reduced require-
ments regarding the building foundation.
Of course, with a corresponding extension
of the foundation, main bearings and main
bearing arrangements can also be tested
Large size bearing test rig
as part of the total design, similar to nacelle with standard support bearings
test stands. for bearing diameters up to 3.2m

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Wind energy industry

Sensitive Timeless Merciless

Detection of the smallest HALT tests - robust design for Defined overload to the
irregularities highly accelerated lifetime tests point of specimen destruction

5 DOF load application with

hydrostatic disc (D-LAU)

Drive system

Specimen adaption with

internal load recuperation

Main bearing test rig with hydro-

static load disc for bearing dia-
meters up to 6m.

Internal load recuperation

Based on the special design of the
RENK main bearing test rig with
internal load recuperation, additional
specimen support structures and
large test fields are not necessary.

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Wind energy industry

RENK test rigs in the wind industry.

Prepared for a multi-megawatt future.

Comprehensive testing. Scope of supply for the

Realistic impact. wind industry at a glance.

A test rig needs to reproduce operating – Nacelle test rigs

loads, and environmental conditions in – Main bearing and main bearing
the lab in order to test the specimen in a assembly test rigs
reproducible way, and track operating – Pitch bearing test rigs
states that actually occur. – Azimuth bearing test rigs
The more precise these analysis need to – Gearbox test rigs
be, the more realistically the influences – Coupling test rigs
on the test specimen need to be controlled. – Pitch drive test rigs
And despite the highly complex technology – Generator test rigs
that is often needed for this purpose, it’s – Grid simulation
essential that the test system operates – Digital twins
smoothly and safely.

Test rigs from RENK are developed with

a targeted focus on the customer’s respec-
tive testing requirements. Thanks to many
years of experience in building and operat-
ing our own test systems, we have a very
precise knowledge of the expectations
placed on this process.

Our capabilities cover the entire field of

drive technology in the wind sector as well
as extending from individual components
to the nacelle as a whole.

We set standards, and work together with

you to find the ideal solution in every sce-
nario – and for every challenge.

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Wind energy industry

Diverse Creative Focused

As different as your Approaches outside Continually concentrating
requirements the box on the testing procedure

Gearbox test rig

Research and development test sys-
tems for developing future gearboxes
as well as EoL test rigs for the quality
assurance in series production.

Pitch drive test rig

Test system for developing of the
pitch drive control system and
verification of pitch drive components.

RENK RDDS Digital twin

HMI
I/O
100 %

State machines
100 % Digital twin
Virtual test rig for implementing and
100 %

Alarm routines
testing new test runs and specimen
100 %
interfaces independend from hard-
Controllers ware test rig application.
100 %

Tested at virtual commissioning

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Wind energy industry

Service at RENK Test System GmbH.

Your partner for custom service concepts.

RENK Service
– Comprehensive
– Lifelong

Extend the lifetime of your

systems with tailored service
solutions. Inspection
– Regular inspections
– Determines condition of the system
– Specifies scope of maintenance

RENK Test System GmbH offers a wide

range of specific services, tailored to the
respective system.
Service
Benefit from over 60 years of experience in
Support Technical support
– By phone

test rig engineering. Contract – In person

– Remote maintenance

Use our customized offer, based on our

SSC service support contract (technical
support, inspection, and maintenance).

Maintenance
– Regular calibration
– Condition-based maintenance/overhaul

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Wind energy industry
RDDS (RENK Dynamic Data System).
Automation system for test rigs.
Sophisticated test systems
call for flexible automation.
The benefits of RDDS come into play with
highly complex development test stands in
particular.
Graphics editors for the control technology,
and sequence managing are ideal for
implementing all requirements in a flexible,
customized way. This is also supported by
the databaseoriented organization of the
test rig, and test process configuration, the
flexible system structure via the client/server
architecture, and the user-defined displays
for visualizing.
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RENK RDDS
– Flexible configuration
– Easy to use
One system for control,
monitoring, storage, and
visualization of your test
procedure.
– Extensive options for adapting the test – Raw data stored centrally for analysis,
procedure via open system architecture and individual assessments
– System structure based on industry – Automatic reporting for standard
platform TwinCAT, and standard industry test programs
hardware – Option to link to numerous
– Graphics editor for easy configuration standard software packages
of the test run with extensive library (e.g., for simulation and analysis)
elements
– Test run management for subsequent
reuse or modification
– Modifiable displays for visualizing
measuring data as defined by user
Follow the QR code
and learn more about www.renk-group.com/en/home

test system solutions

from RENK.

RENK Test System GmbH

Goegginger Str. 73
86159 Augsburg
Germany
Phone: +49 821 57 00-609
Fax: +49 821 57 00-610
Email: info.augsburg@renk.biz

www.renk-group.com

Details provided about the properties and usability of the products are purely for information purposes and do not
constitute a guarantee of these characteristics. The extent of goods delivered is determined by the subject matter
of the specific contract. No liability accepted for errors or omissions. Subject to technical alterations. © RENK 2021