World Largest Wind Turbine Main Shaft Bearing Test Rig Enters Commissioning Phase and Set for Operation

The development of the world’s largest main bearing testing facility, currently under construction at the Linde Offshore Renewable Energy Center (LORC), has reached a major milestone. R&D Test Systems, the engineering company behind the project, has successfully completed the lifting and installation of the 560-tonne test load cell, the heart of the new test rig.

This test rig is the world's most powerful main bearing test rig, representing an investment in the tens of millions of euros. Measuring 16 meters long, 9 meters wide, and over 8 meters high, the system incorporates a drive system designed to simulate the extreme loads experienced by offshore wind turbine components. The heaviest single component is a shaft weighing 260 tons and measuring 5 meters in diameter, highlighting the scale and complexity of the installation.

The main bearing test rig's test load cell can apply dynamic bending loads exceeding 100 MN·m. This is designed to simulate the loads experienced in extreme offshore wind conditions. The test rig can also provide axial thrust exceeding 10 MN and support dynamic loading in six degrees of freedom, including horizontal, vertical, torque, pitch, and yaw moments, comprehensively covering the complex stress scenarios experienced by main shaft bearings in actual operation.

Through accelerated life testing, the rig can simulate the actual operating loads of the main bearing in an offshore environment over a 20-year period in just 6-8 months, shortening the R&D cycle. Furthermore, it can replicate complex conditions such as once-in-a-century typhoon-level wind speeds and temperature fluctuations, enabling simulation of extreme operating conditions.

This spindle test rig can test large spindle bearings with an outer diameter of 3.5m and a weight of 15t. Suitable for offshore wind turbines exceeding 25MW, it covers mainstream bearing designs for both gearbox-equipped and direct-drive turbines. The test rig also features a modular design, enabling rapid replacement of test components to accommodate future upgrades.