Rotor Lock
Repair
Repair rotor lock systems onsite instead of replacing them — reducing downtime by 30–60%.
Uptower Solution
Rotor Lock
Trusted by wind operators and OEMs across Europe and North America
- Vestas
- Siemens Energy
- NextEra Energy
- GE Vernova
- Enercon
- Nordex
- EDF Renewables
- Welcon
- RWE
- CS Wind
- EEW
- Muehlhan
- Nicon Industries
- Orsted
- Cadeler
- Vattenfall
- Smulders
- Windar
- Titan Wind
- SubC Partner
- Semco Maritime
- LM Wind Power
- Iberdrola
How It Works Restore The Rotor Lock.
Restore The Rotor Lock.
Without Disassembly.
Worn or damaged rotor lock holes are re-machined directly in the nacelle with a mobile CNC boring system. No crane. No transport. No rotor lock replacement. Repairing onsite instead of replacing reduces downtime by 30-60%.
Boring the hole back to a tight fit
A rotor lock depends on a relatively tight fit between locking pin and locking hole. Wear, or damage during pin insertion and retraction, can open a gap that may allow small movements of the rotor - and even small movements can make certain maintenance and repair tasks on the high-speed side of the turbine complicated or even impossible. Precision boring restores the hole to OEM specification, with an expected lifetime similar to the original.
Built for the nacelle
- All machining is performed in-situ, even where nacelle space is tight
- Covers electromechanical and hydraulic rotor lock designs on Vestas, SGRE and GE turbines
- Every repair follows a documented method statement matched to the rotor lock type
30-60%less downtime than replacement
1-2 daystypical time on site
~half a dayaverage repair per lock position
Why repair beats replacement
Replacing a rotor lock system means crane mobilization, transportation and major disassembly. Machining the holes where they sit eliminates all of that - the rotor lock is restored, tested and signed off at a significantly lower total repair cost.
Technical Specifications
Typical duration 1–2 days on site
Bore tolerance OEM specification
Surface finish Precision machined bore
Certification ISO 9001 | OEM-spec
Equipment Mobile CNC boring system
Turbine types Vestas, SGRE, GE
Expected lifetime Similar to original
ISO 9001UPTOWER REPAIROEM SPECIFICATIONCOST EFFICIENT
Repair Instead Of Replace Damaged rotor lock holes are restored onsite through precision machining, eliminating the need for complete rotor lock replacement.
No Heavy Logistics All machining is performed inside the nacelle, avoiding crane mobilization, transportation, and major disassembly.
Reduced Downtime Onsite repairs reduce downtime by 30–60%, bringing turbines back into operation faster.
Reducing Total Cost Of Repair When repairing instead of replacing and eliminating heavy logistics, the total repair cost is significantly reduced.
How it works
Our Process
01
Quotation Request
The wind turbine maintenance team report damage to one or several rotor lock holes to CNC Onsite. Our technicians respond on the same day to assess the damage. We will issue a quote once the defect has been analysed. The customer signs the purchasing order, and the repair can commence almost immediately.
02
Planning
We plan the rotor lock hole repair in advance to work efficiently once we are on-site. The rotor lock type determines the exact repair method which we follow to restore the hole. All repairs are based on “method statements” to ensure a correct and efficient process – every time.
03
Implementation
Our technicians usually start work in the morning, transporting the machine to the nacelle. The team will use our in-house developed machines to repair the rotor lock. Upon completion, the rotor lock is tested.
04
Handover
After the rotor lock has been repaired, the customer signs off and wind turbine inspections and services can take place.
05
Follow-up
We offer customers a discussion with the technician who will then carry out the next inspection. Our follow-up program complies with our high quality standards.
Contact Our Team Let Us Find
Let Us Find
The Right Solution
Whether it's a repair, machining project, or custom machine solution, our engineers are ready to help you find the most efficient way forward.
Request received.
An engineer will get back to you within one working day.
Global reach
Wherever your turbines stand
On site within days Worldwide call-out, 24/7. Technicians mobilize within days of a purchase order.
Onshore & offshore The same in-nacelle method works at sea - no offshore crane deployment needed.
Five continents A proven repair track record on wind turbines across five continents.
FAQ
Frequently asked questions
Can damaged rotor lock holes be repaired?
Damages to the rotor lock holes can be repaired using the right precision machines. The repairs to the rotor lock hole are carried out in-situ in the wind turbine nacelle, even if space is limited.
CNC Onsite has developed several solutions to be able to handle a large variety of turbine types.
How are the rotor lock holes repaired?
The repair process of the rotor lock hole varies depending on the specific rotor lock system chosen for that turbine.
Common to all solutions are that the repair is performed up-tower in the nacelle.
Even in tight conditions in the nacelle, the rotor lock repairs can be completed.
Our technicians can repair a wide range of rotor locks designs, both electromechanical and hydraulic types.
A damaged rotor lock hole has been detected. What is the process to repair it?
The customer, usually the wind wind park technicians, contacts CNC Onsite. Within a few hours, our technical team responds to dicuss the damage with the customer who will typically send photographs of the damage. We will then assess the extent of the rotor lock damage.
As soon as the customer signs the purchasing order, the CNC Onsite team and wind turbine owner will agree on a date to repair the affected rotor locks.
How many rotor lock holes can be repaired?
It is possible to repair all damaged rotor lock holes. If more holes are affected, this will be taken into consideration in the overall planning of the task.
How quickly can the rotor lock technicians come to the wind farm/park?
CNC Onsite’s rotor lock repair technicians can be onsite, usually within days. How long does it take to repair a rotor lock hole?
The time it takes to repair a rotor lock holes highly depends on the number of damaged rotor lock holes and the extent of the damage.
To optimize the repair process CNC Onsite will as part of the planning for job, go through the preparations needed in the turbine, the actual repair work and the final verification test.
On average the actual repair work on a rotor lock position will take around half a day.
What does it cost to repair a rotor lock?
Each job is different. The costs will depend on the number of damaged rotor lock holes, severity of damages, turbine type and the location to name a few.
As part of the task clarification, CNC Onsites evaluates the work and submits a quotation for the repair work.
