Altra Industrial Motion provides a range of drivetrain products essential for renewable energy applications including wind, solar, and biomass technologies. Their engineering teams collaborate with major OEMs to deliver custom solutions such as caliper brakes, couplings, and actuators, addressing specific challenges like limited space and performance optimization. The document outlines various case studies where Altra's solutions, including hydraulic brakes and cooling systems, have significantly improved the efficiency and reliability of renewable energy systems.

1. Applications & Innovations
Renewable Energy
Market

2. We’re committed to the
Renewable Energy Market
The companies of Altra Industrial Motion offer many critical
drivetrain products utilized in renewable energy applications
including
brakes, power packs, geared motors, couplings, shaft locking
devices and linear actuators.
Altra Brands Deliver Value Throughout the Drivetrain
Altra Industrial Motion is positioned to provide OEMs with
exceptional drivetrain value by ensuring component compatibility
and optimized performance combined with time-saving,
single-source convenience.
Extensive Technical Experience in Renewable Energy
Applications
Major OEMs routinely rely on the vast renewable energy application
knowledge of Altra’s engineering teams that collaborate to
thoroughly analyze specific customer applications and then apply
the latest technologies in design, materials and manufacturing.

3. Caliper Brake Solutions From Altra
Provide Reliable Performance On
Wind Turbines Around The World
Application ProfileApplication Profile

4. www.svendborg-brakes.com
• As they meet the world’s growing demand for wind energy, global
wind turbine OEMs rely on Svendborg Brakes and Twiflex Limited for
innovative hydraulic caliper braking solutions.
• These two Altra brands work closely with major turbine OEMs as they
develop new turbine models of various designs and capacities, while
improving efficiency, performance, and cost-effectiveness.
• Svendborg engineers have developed a series of hydraulically-applied
caliper brakes specifically for rotor and yaw braking applications on
direct drive, compact drive and conventional wind turbines.
• Twiflex is recognized by OEMs as a high quality manufacturer of rotor
and yaw caliper brakes used in small- to medium-sized wind turbines
(typically 20-200 kW). The brakes provide both static and dynamic
stopping functionality.
• Complete package solutions include custom hydraulic power units
Caliper Brake Solutions From Altra
Provide Reliable Performance On Wind Turbines
Around The World
www.twiflex.comP-7811-C.pdf *Source: Global Wind Energy Council; www.gwec.net

5. 60 kW Wind Turbines
Problem:
A major European manufacturer of small wind turbines
contacted Twiflex for a rotor and yaw braking solution for their
new 60 kW horizontal axis turbine. The brakes are primarily
used for parking duty, but also provide emergency stop
functionality. Very limited space envelopes for both brake
positions presented a significant application challenge.
Solution:
Twiflex engineers designed a modified VKSD-FL (floating)
spring-applied, hydraulically-released brake rated at 119 KN
braking force for a 2mm pad air gap.
• Asbestos-free ‘hi-co’ lining
• Unique ‘parked-off’ feature
• Custom mounting arrangement derived to meet the
particular space constraints
• Brake pads were supplied with embedded wear leads to
give an indication of the “fully-worn” condition
Application Profile
Special VKSD-FL Spring-Applied Brakes

6. Offshore Wind Turbines
Problem:
A major wind turbine OEM needed a reliable rotor braking
solution for offshore turbines with rotor diameters of 76 meters
(250 ft.). The 2 MW turbines are located in Middelgrunden off
the coast of Copenhagen. Rotor brakes, positioned on a
high-speed brake disc are used to reduce RPM and stop blade
rotation in the event of an emergency in connection with an
active stall regulation.
Solution:
To meet the application requirements, Svendborg supplied
BSFH 330 Monospring caliper brakes with Sintermetal brake
pads for high heat dissipation and long life.
• Each brake provides a clamping force of 6,744 lbs. (30,000
N)
• Operating range between -20˚C to +55˚C (-4˚F to 131˚F)
• Special finish coating for corrosive environments
Application Profile
BSFH 300 Series
Application Profile

7. Wind Turbines
Problem:
A Korean wind turbine manufacturer needed a compact solution
to cool the generator and converter inside its 4 MW turbines.
High temperatures inside turbine nacelles can negatively impact
the turbine component performance over time.
Solution:
Svendborg Brakes’ supplied a custom, free-standing cooling
system, including a pump, motor and valve manifold. The
compact system pumps coolant through the generator, converter
and heat exchanger positioned on top of the nacelle. It creates a
constant, controlled temperature inside the nacelle to ensure
optimum turbine operation.
• Pressure relief valves protect system, generator and converter
• Heater for startup temperatures below 5°C
• Traceable test reports for all system components
• Automatic air venting
Application Profile
Custom Cooling System
Application Profile

8. Wind Turbine Drive Shafts
Problem:
Operators of a large wind farm in the Western U.S. needed to
update several of their older turbines. Replacement drive shaft
couplings, positioned between the gear drive and the
generator, were needed fast.
Solution:
To meet the application requirements, TB Wood’s provided
Form-Flex shaft couplings that consisted of two hubs, a
spacer, and two high-strength carbon steel flexible discs.
• Units featured a splicer type slip spine for easy installation
• Torque rating up to 270kNm (2,400,000in.lbs.)
• Zero backlash
• Angular and parallel misalignment compensated between
two connected shafts
• Couplings delivered in 7 weeks
Application Profile
Form-Flex®
Couplings

9. Residential Wind Turbines
Problem:
A leading manufacturer of small residential wind turbines
required reliable linear actuators for use with their blade pitch
adjustment technology. The ability to adjust blade pitch
improves efficiency.
Solution:
Robust Warner Linear K2x actuators were supplied to meet
this unique application challenge.
• K2x units demonstrated superior performance over
competitive models in life cycle tests
• 2,800 lb. load capacity
• Heavy wall extension tube is 30% stronger than competitive
actuators
• Nitrotec®
treated steel extension rod is 40% stronger than
competitive models
• Heavy-duty sealed, double ball bearing motor
Application Profile
K2x Linear Actuator
Application Profile

10. Helical Wind Turbines
Problem:
A leading manufacturer of small wind turbines contacted
Warner Electric to provide an emergency braking solution for
their compact 5m x 3m helical turbine.
Solution:
Warner Electric engineers developed the new ERD SZ 450a
maintenance-free brake that would fit into the extremely
compact space envelope.
• ERD brake provides emergency fail-to-safe protection
(during power outages).
• 450 Nm torque rating achieved with only 20W energy
consumption
• Reversed brake mounting which allows the brake to
mount directly to the generator
• Power supply also provided
• Hundreds of units have been supplied
Application Profile
Modified ERD Electrically-Released Brake
With Cover

11. Application Profile
Wind Turbine Elevator Drive
Problem:
A leading manufacturer of commercial rope hoists recently
selected Bauer gear motors for use in their new wind turbine
elevator hoist system. The compact hoist fits within the tight
confines of wind turbine towers and allows maintenance
personnel, tools and materials to be safely transported up to the
base of the turbine nacelle positioned at the top of the tower.
Solution:
Bauer engineers worked closely with the customer’s team to
optimize the elevator drivetrain. Ultimately, modified Bauer
BK17 Series helical bevel gear motors were selected over
competitive models.
• Special gearing ratios
• Relatively low weight
• High torque rating of 243 lb.ft. (330 Nm)
• Smaller footprint and Temperature range to -35˚C
• A”parachute” brake with a manual release was also utilized
Modified BK17 Series Gear Motor

12. Solar Panel Mounting System
Problem:
RBI Solar, an industry-leading designer and manufacturer of
solar panel mounting systems for commercial applications,
needed a reliable coupling solution for its new single axis tracker
product. The Sunflower™
mounting system rotates rows of
photovoltaic (PV) modules on the East/West axis to follow the
sun and maximize energy production. In large-scale commercial
installations rows can be 400 ft. long, made up of approx. 35 ft.
sections (approx. 12 modules). The couplings connect the drive
motor to the drivetrain at the end of each row of PV modules.
Solution:
TB Wood’s provided LO95 L-Jaw couplings that utilize a Hytrel®
“spider” element with a torque capacity of 401 in.lbs. TB Wood’s
worked closely with RBI to revise its standard L-Jaw coupling
bore design to accommodate RBI’s unique shaft geometry and
provide a more secure hub-to-shaft connection.
Application Profile
Modified L-Jaw Couplings

13. Solar Panel High Voltage
Capacitors
Problem:
A large Japanese consumer electronics firm supplied high
voltage capacitors to a solar panel manufacturer. The
capacitors began to malfunction due to an electrical
discharge problem which led to a recall.
Solution:
The faulty capacitors were refitted with Huco MultiBeam
couplings. PEEK material was utilized since the P.D. across
the Huco coupling is 35,000 volts.
• PEEK material has:
- high dielectric strength (20 kV/mm)
- very good electrical insulation properties
• Up to 2.5 Nm peak torque
• Up to 7 degree angular misalignment
• Up to 0.2 mm radial offset
Application Profile
PEEK MultiBeam Couplings

14. Movable Solar Arrays
Problem:
Linear actuators are routinely utilized to adjust panel angles on
large solar arrays. This movement allows the panels to be
positioned toward the sun for maximum efficiency. The actuators
must also be able to securely hold the panels in the desired
positions since solar arrays are often located in high wind areas.
Solution:
The new, patented Warner Liner H-Track meets the demand for
rugged actuators used on solar arrays and other industrial
applications. The innovative H-Track electric actuator provides
the performance of hydraulics without the space requirements
and expense of a full-size hydraulic system.
• Self-contained hydraulic actuation
• Units resist drifting and hold a load stationary without power
during load reversals
• Force rating of 4800 lbs. (21 kN)
Application Profile
H-Track Electric Actuators
Application Profile

15. Vertical Axis Crossflow
Tidal Turbine
Problem:
Neptune Renewable Energy required a powerful braking
system for their newly-developed Proteus tidal turbine
designed to be moored in estuarine locations with powerful
currents. The turbine consists of a vertical axis, crossflow
rotor, mounted in a venturi diffuser duct beneath the deck.
Solution:
Twiflex Limited provided (2) VKSD-FL disc brake calipers to
act on the turbines vertical shaft-mounted disc, housed in the
gen-set, positioned over the turbine shaft.
• Dual-function: emergency stop and parking brake
• Two units provide a total braking torque of 150 kNm
• Accommodates an axial disc float of ±6mm
• Hydraulic power pack enables fine control of braking time
Application Profile
Twiflex VKSD-FL Spring-Applied,
Hydraulically-Released Brakes

16. Horizontal Axis
Tidal Turbine
Problem:
A braking system was required for the world’s largest tidal
turbine (75 ft. tall). The fully submersed turbine features a
unique twin rotor set and is designed to harness ebb and flow
tides while generating 1 MW of power.
Solution:
Wichita engineers developed a custom, spring-applied,
hydraulically released brake to meet specific customer
requirements.
• Dual function: emergency stop and parking brake
• Torque is generated utilizing oil-in-shear technology
• 1.5 MNm static torque
• Shaft speed: 6-8 RPM (optimum generator speed)
• Hydraulic power unit also supplied
Application Profile
Custom HBS42-14 Wet Brake

17. Application Profile
Biomass Furnaces
Problem:
Heizomat GmbH, located in Germany, is a market leader in the
design and manufacture of environmentally-friendly wood chip
heating plants for residential and commercial customers.
Heizomat required a comprehensive gear technology source to
drive their integrated wood chip feeder conveyors. Their primary
selection criteria were high quality and low noise levels.
Solution:
Bauer parallel shaft geared motors, including Types BF06, BF10,
BF20, and BF20Z models, were chosen for the application.
• BF and BS Series geared motors feature a hardened wear
sleeve and spray ring
• Low noise gearing
• Completely enclosed, sealed against dust and moisture.
• Torque rating to 18500 Nm
BF and BS Series Geared Motors

18. Wood Pellet Mills
Problem:
A major global manufacturer of biomass machinery and process
plants, was looking for a more reliable foundry for base castings
used on its wood pellet mills. The mills produce uniform wood
pellets for use in biomass furnaces. Various machine
components are installed and attached to the 5 ft. wide x 6 ft.
high, 6,000 lb. gray iron base casting. The OEM’s existing
casting supplier was having issues with quality and delivery.
Solution:
TB Wood’s (TBW) has been supplying the OEM with high-
quality, Made-To-Order (MTO) 60 in. diameter, 30-groove gray
iron sheaves for many years. Based on the history of high
product quality and dependable service, the OEM contacted
TBW for a competitive quote and ultimately awarded them the
base casting business. In order to improve casting
manufacturability, quality, and machinability, the TBW
engineering team redesigned the molding method and changed
where the casting is parted.
Application Profile
Base Castings and MTO Sheaves

19. Biomass-Fired
Steam Turbines
Problem:
A leading global provider of power generation technologies
required coupling solutions for use on three steam turbines at a
series of new biomass power plants located in the UK. The
required couplings pushed the boundaries of disk coupling
design due to size constraints, huge peak torque requirements
from the generators, and a large amount of axial growth from the
turbines.
Solution:
Bibby engineers spent many hours working with the OEM
engineering team while designing a series of custom Turboflex
HS couplings to connect the turbines to the gearboxes and the
gearboxes to the generators.
• Multiple large custom couplings supplied with lengths to
1428 mm (56 in.) and diameters to 680 mm (26.7 in.)
• Max torque capacities to 822,000 Nm (606,276 lb.ft.)
• Max speed ratings to 8754 RPM
Application Profile
Custom Turboflex HS Couplings