ZF Wind Power enters the next level of System Co*operation to empower a sustainable future together with their partners

According to the International Energy Agency, the global renewable energy capacity will have to expand by three times its current size by 2030 to keep global emissions aligned with the Paris Agreement.

However, to achieve this ambitious expansion, we must come together as an industry to mature and prepare for scalability across the entire value chain. By sharing our vision and objectives, we not only enhance our individual companies’ power but also our collective industrial authority. “Participatory approaches transform meeting participants into active partners. Working closely as partners at every stage of development and implementation is vital for strengthening the future supply chain to empower a sustainable future together,” states Felix Henseler, CEO of ZF Wind Power.

Close System Co*operation: a major win for all parties in a dynamic and competitive wind market

From the start of the gearbox development, ZF and its partners share knowledge in planning, research, and design. “From engineering collaboration at the beginning to close service partnerships after installation… We see close relationships and trust as fundamental to enabling processes and outputs. Close cooperation builds new knowledge and skills for everyone involved,” describes Felix Henseler.

Co*Design: through early-stage prediction & guidance

With over 45 years of experience and constant innovation, ZF Wind Power is more than just a gearbox developer. They are a strategic partner throughout the entire product lifecycle. Utilizing unique ZF-extensive simulation models, the team identifies, together with their partner, the best powertrain design during the concept and design optimization phase to ensure optimal wind turbine performance. “Our holistic simulation approach allows for quick and easy comparison of drivetrain concepts and gear designs, tailoring them to the specific needs of our customers’ wind turbines,” explains Martin Knops, CTO of ZF Wind Power.

As an example, ZF’s integrated simulation platform, which combines different aspects involved in predicting wind turbine tonality, allows the development of Noise Vibration and Harshness (NVH) optimization and risk mitigation strategies early in the design phase, resulting in flawless project execution, faster development, and minimal iterations after prototyping. “Our expertise positions us as a consultancy partner, helping customers save time and find optimal solutions, already in the Co*Design phase,” defines Martin Knops.

Co*Evaluate: from component to powertrain level

ZF Wind Power’s investment in the 30 MW Test and Prototype Center shows their dedication to quality, reliability, and validation. They collaborate with partners to streamline testing and enhance design simulation models. By co-developing test programs and sharing data, the team avoids redundant testing and ensures efficient validation. This collaboration allows for comprehensive system testing at ZF’s Test and Prototype Center, minimizing logistical efforts, testing time, and costs while maximizing results. “Our approach reduces testing time by three to four months compared to traditional methods, which is a significant advantage in the competitive wind market,” summarizes Martin Knops, CTO of ZF Wind Power.

Co*Produce: through smart industrialization & industrial innovation

ZF’s global production network gives local manufacturing global connectivity, combining cost efficiency and customer proximity with global supply chain advantages. Through advanced software tools and smart industrialization, ZF and partners showcase leadership in industrial innovation (e.g., A three-lines-serial (gearboxes, offshore, and onshore powertrains) production hub in Lommel, Belgium, supplies solutions for the complete European market). This approach further optimizes operations for a just-in-time supply chain, ensuring seamless integration, interconnectivity, and flexibility to meet high-performance product demands.

Co*Logistics: for sustainable and optimal delivery

ZF collaborates with partners to optimize logistics, ensuring sustainable and cost-effective transport of materials and products. Joint efforts and deep-dive studies focus on enhancing inbound and outbound delivery performance, improving efficiency, reducing lead times, and minimizing buffer stocks.

The sustainable water transport of the V236-15.0 MW^TM powertrain highlights the importance of deep-dive logistical studies. “After various expert studies, we chose inland waterways and international sea transport,” says Hans Akkermans, CCO of ZF Wind Power. “This reliable and sustainable method optimizes logistical processes and contributes to a sustainable future.”

Co*Service: for continuous availability

Thrive, ZF Wind Power’s all-inclusive service concept, ensures global availability through digital solutions and worldwide services. It combines a global reach with a regional, personal approach. “Thrive’s strength lies in its personal touch, connecting with partners and their needs,” says Sivakumar Jayapal, CSO of ZF Wind Power. Thrive offers four tailored partnership agreements, allowing partners to invest only in what their business needs.

Ready for the future today

ZF collaborates with partners in every development stage to produce reliable, intelligent gearboxes and powertrains that meet global onshore and offshore demand. “Our cooperation enables us to manufacture innovative powertrains for offshore turbines producing up to 80 GWh/year and onshore variants with up to 7.2 MW output,” says Felix Henseler, CEO of ZF Wind Power. The modular gearbox design and SHIFT platform assembly meet current and future market needs. “These advanced gearboxes and powertrains will accelerate the shift to clean wind energy. We are ready to empower a sustainable future together with our partners,” concludes Henseler.