ZF Services Windpower Feature

ZF Expands Facility to incorporate new business

ZF continues to look forward and bring on additional capabilities to better serve the wind market. Recent acquisitions of the Hansen brand in 2011 and the Bosch Rexroth brand in December of 2015, has increased the product range and supplemental offerings made available to the market. These additions to ZF’s wind turbine gearbox business are part of a long-term corporate strategy that expands reach and service to the wind market.

The various product lines have been brought together with the needs of the customer in mind in coordination with ZF’s transmission expertise, experienced staff, and development and production know-how. The acquisition of both of the brands, and the integration of the product ranges are a great opportunity to better serve customers with more flexibility.

ZF can now serve all the major global markets in North America, Europe and Asia with a product range that covers the entire megawatt spectrum.

ZF Expands Facility to incorporate new business

With the purchase of Bosch Rexroth’s wind turbine gearbox brand and the growth of the existing wind service business, ZF N.A. management made the decision to expand the capacity at the existing Vernon Hills service location. The expansion plans allow ZF to close down the existing Bosch facility in Lake Zurich and move all colleagues and service operations into Vernon Hills. ZF began the project in December 2015, with completion in May 2016, to include the full integration of the former Bosch organization. The scope of the project was multifaceted in size, equipment, storage, and testing.

ZF installed six new assembly work stations with additional overhead cranes ranging up to 40 tons. As far as size, ZF Services now utilizes 80,000 sq./ft. of dedicated work shop space within the plant, which along with the equipment additions allow a throughput of approximately 200 MW sized gearboxes per year. Because wind gearbox repair lead times are longer when compared to other industries, storage of work in process and finished goods are essential. With that in mind, the expansion includes component racking with capacity for 80 disassembled gearboxes. Lastly, ZF improved its test bench software which allows more precise and expanded vibration, temperature and sound measurements. Additionally, the new software allows ramp testing to meet the latest testing criteria from certain OEMs. The last addition to the test bench was an automated system to locate the torque supports and generator which will reduce the change over times by 8-12 hours.

Field Service When & Where it Counts!

When gearbox services are required, you need a factory authorized provider, utilizing certified parts and expertise. It is essential to utilize a provider ensuring the job is done right the first time! That’s where ZF Field Services can help you keep your assets running. Repair requests range from internal borescope inspections, HSS, IMS or combo bearing changes, or prebuilt shaft assemblies shipped to site for exchanges with less down time.

ZF Field Services has six fully trained wind field technicians in addition to our Authorized Service Providers (ASP’s) to offer a full range of on-site services to our customers. This knowledge in conjunction with the proper parts and tooling makes upgrades and essential maintenance activity the intelligent choice in up tower service options. So when scheduling and availability matters most, count on ZF Field Services to ensure a timely response to your needs.

ZF Field Services… your drivetrain provider, “Geared for Excellence, Driven by Service!”

Inventory and Storage Solutions to Service Your Business

When gearbox services are required, you need a factory authorized provider, utilizing certified parts and expertise. It is essential to utilize a provider ensuring the job is done right the first time! That’s where ZF Field Services can help you keep your assets running. Repair requests range from internal borescope inspections, HSS, IMS or combo bearing changes, or prebuilt shaft assemblies shipped to site for exchanges with less down time.

ZF Field Services has six fully trained wind field technicians in addition to our Authorized Service Providers (ASP’s) to offer a full range of on-site services to our customers. This knowledge in conjunction with the proper parts and tooling makes upgrades and essential maintenance activity the intelligent choice in up tower service options. So when scheduling and availability matters most, count on ZF Field Services to ensure a timely response to your needs.

ZF Field Services… your drivetrain provider, “Geared for Excellence, Driven by Service!”