Rotor Lock
Repair
Repair rotor lock systems onsite instead of replacing them — reducing downtime by 30–60%.
Uptower Solution
Rotor Lock
How It Works Restore the rotor lock.
Restore the rotor lock.
Without disassembly.
Wind turbines are equipped with a rotor lock system, a robust safety lock that keeps the blades at standstill during maintenance and inspection. The rotor lock system allows for controlled and precise positioning of the rotor blades. This is particularly important during maintenance tasks that require specific blade angles or when accessing certain parts of the turbine.
One or more locking pins are pushed into holes within the hub which allows control over the blades position for different repair and maintenance tasks – either on the blades themselves or in the turbine. The integrity of the system is crucial for safe as well as efficient maintenance and repair work.
The rotor lock systems can have different designs, but regardless of the design it is important to have a relatively tight fit between locking pin and locking hole. The holes can get worn over time or suffer damaged during insertion or retraction of the locking pin.
Wear and damages can lead to a gap between hole and pin, which may allow small movements of the rotor. This can cause safety issues as even small movements of the rotor can make certain types of maintenance and repair on the high-speed site of the turbine complicated or even impossible.
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.
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.
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.
