Press Release
ZF Wind Power commissioned 30 MW test rig
- World’s most powerful validation test rig has successfully completed the commissioning phase and is now ready for operation at ZF Wind Power’s Test and Prototype Center, located in Lommel (Belgium), in the presence of Matthias Diependaele, Minister-President of Flanders; delegation of Flanders Investment & Trade (FIT) and Flanders Innovation & Entrepreneurship (VLAIO); and the mayor of Lommel
- This state-of-the-art 30 MW test rig can validate complete powertrain systems for both onshore and offshore wind turbine applications
- With the investment in the 30 MW test rig, ZF Wind Power’s Test & Prototype Center is ready to validate the next generations of wind turbine powertrains and gearboxes. It illustrates the company’s commitment to their partners to be a system partner on the road to a sustainable future
Lommel, Belgium. The wind energy sector is at a pivotal juncture, facing significant challenges that demand innovative solutions. The industry strives to meet global energy demands and sustainability goals, the need for robust and reliable powertrain systems has never been more critical. ZF Wind Power meets this rapidly growing demand by commissioning a 30 MW test rig, while strengthening their position as a system partner on the road to a sustainable future.
The successful commissioning of a 30 MW test rig for powertrains is essential to address the challenges of the industry. This state-of-the-art test rig, part of ZF Wind Power’s Test and Prototype Center, enables comprehensive testing and validation of complete powertrains and powertrain components, ensuring they can withstand the rigorous demands of modern wind turbines. By investing in this advanced testing infrastructure, ZF enhances the efficiency, reliability, and longevity of wind energy systems, paving the way to a more sustainable future.
Pioneering with the world’s largest validation test rig: Extensive validation is the foundation of ZF Wind Power’s innovations
As a leading innovator, ZF Wind Power is continuously increasing the torque levels of their gearboxes and powertrains. The team strives for high quality and invests largely in validation. “Extensive validation is the foundation of ZF’s innovations. Testing allows us to contain the risks inherent to the wind industry and it is essential to receive approval from customers, insurers, and certification agencies to launch new designs,“ says Bert Verdyck, Head of Product Portfolio Management of ZF Wind Power.
“To extend our portfolio, we started installing the world’s largest test rig in 2023,” continues Mr. Verdyck. “Now, in 2025, we are proud to announce the test rig is up and running and ready to develop the next generation powertrains.”
With a length of sixty meters, the rig tests the dynamic behavior of the main bearings, the gearbox, and the generator on the system level under real conditions with functional load tests, dynamics, and robustness tests. It covers a maximum torque of 45 MNm, a maximum bending moment of 64 MNm, and a maximum axial force of
7 500 kN.
Co*Evaluate at ZF Wind Power’s Test & Prototype Center: from modular gearbox platform concepts to next generation powertrains
The 30 MW test rig is an integral part of ZF Wind Power’s Test and Prototype Center, located at the Belgian headquarters. This center features multiple test rigs for components, assembly, sub-assembly, climate testing, load or no-load testing and more. Additionally, an upcoming lubrication test rig will further enhance the company’s capabilities. The center is a hub of ZF’s expertise in wind gearbox innovation, system development, and validation. By consolidating all instrumentation, assembly, and testing activities at a single location, the team significantly increases the efficiency of operations. The setup also supports partners' demands for rapid time-to-market projects.
With the expansion of the Test & Prototype Center, ZF Wind Power extends capabilities from modular wind gearbox platforms to complete powertrain system validation. “Together with our partners, we cooperate on every challenge in the development of new products; from Co*Design to Co*Service, like building modeling tools and introducing new production processes,“ says Felix Henseler, CEO of ZF Wind Power. In system integration tests, the test program is closely developed by both parties.
By combining the test campaigns, data are exchanged, and it is possible to test the complete system at ZF’s Test and Prototype Center. This approach minimizes logistical efforts, testing time, and costs while ensuring optimal test results. It reduces testing time by three to four months compared to traditional methods, which involve double testing at the partner’s location for the system test and gearbox testing at ZF. “This commitment highlights our dedication as a system partner to collaborate on innovative projects and empower a sustainable future together with our partners,” states Mr. Henseler.
Boosting the wind industry and the economy
The 30 MW test rig being developed by ZF Wind Power is not only a groundbreaking advancement in the wind industry. “For the Flemish economy, this project is a key asset. The establishment of the Test & Prototype Center in Lommel not only positions us as a leader in wind technology innovation, but it also shows that Flanders has all the competitive assets to continue attracting investments in innovation and industry,“ explains Matthias Diependaele, Flemish Minister-President. The Flemish government's support underscores the strategic importance of this initiative, aligning with regional goals for economic growth and technological leadership.
ZF's commitment to sustainability is evident in this investment. “The 30 MW test rig is part of our broader strategy to drive sustainable energy solutions,” says Felix Henseler. By enabling the development of more efficient and reliable wind turbines, ZF is contributing to a greener future. “This aligns with our goal of achieving climate neutrality by 2040 and supports global efforts to transition to renewable energy sources,” Mr. Henseler concludes.
