Service, repair and remanufacturing of wind turbine gearboxes, main shafts and industrial drives with a 4-MW test bench
NGC Transmission Equipment (America), Inc.
Fort Worth, Texas (USA)New on Amplifa
About NGC Americas
NGC Transmission Equipment (America), Inc. is a subsidiary of NGC Gears, a business unit of the NGC Group, and serves the American market from its location in Fort Worth, Texas. The company offers service, repair and remanufacturing of wind turbine gearboxes and main shafts as well as a photovoltaic slewing drive series. In the 130,000-square-foot service center, high-precision mechanical machining, cylindrical gear grinding on a Höfler RAPID 1600, gear measurement on the Klingelnberg P 150 in a climate-controlled environment, full-load testing up to 4 MW on the in-house test bench, non-destructive testing and root-cause analysis are performed, among other things. More than 90,000 NGC main gearboxes and 450,000 pitch and yaw gearboxes are in operation worldwide. Customers come from the wind energy, photovoltaics, cement, steel, mining, material handling, oil & gas and rail transport industries. In addition to factory training, field service, down-tower repairs and a core exchange program, the company maintains spare parts warehouses and onsite storage.
- Site
- Fort Worth, TX, USA
- Processes
- Gearbox manufacturing / design of gearbox products (wind, industrial, solar), Gearbox service, repair and remanufacturing of wind turbine gearboxes and main shafts, High-precision mechanical machining (in-house machining & tooling), Cylindrical gear grinding (gear grinding), Gear inspection / tooth microgeometry measurement (gear measuring), Full-load gearbox test (load & spin test up to 4 MW, back-to-back, vibration capture via 12, Non-destructive testing (NDT), Root-cause analysis
- Materials
- Steel (gearbox/gear alloys), Cylindrical gear grinding, Gear measurement (Klingelnberg P 150), 4-MW full-load test bench, Non-destructive testing, Root-cause analysis, Industrial component cleaning
- Industries
- Wind energy, Solar/photovoltaics, Cement, Steel, Mining, Material handling
- 01
Engineering / gearbox design
- 02
In-House Machining & Tooling
- 03
Cylindrical gear grinding (Höfler RAPID 1600)
- 04
Gear measurement / tooth microgeometry (Klingelnberg P 150)
- 05
Industrial component cleaning
- 06
Assembly / remanufacturing
- 07
Full-load gearbox test up to 4 MW
- 08
Non-destructive testing & root-cause analysis
- 09
Field service / core exchange
Materials & Processes
Steel (gearbox/gear alloys)
Material for gearbox, gear and shaft components in the service, repair and remanufacturing process.
Cylindrical gear grinding
Höfler RAPID 1600 for reconditioning and re-certifying used gears of any diameter.
Gear measurement (Klingelnberg P 150)
Fully automatic CNC-controlled inspection of tooth microgeometry before and after the grinding process.
4-MW full-load test bench
Back-to-back load and speed tests with 12 acceleration sensors, oil temperature and oil flow control to confirm gearbox condition.
Non-destructive testing
Component inspection as part of gearbox and main shaft reconditioning.
Root-cause analysis
Analysis of the causes of gearbox failures to prevent consequential damage.
Industrial component cleaning
Parts washing system with degreasing, high-pressure nozzles and hot steam prior to inspection, assembly and painting.
Sites
Fort Worth, TX
USCorporate Office, Service & Repair Facility, Remanufacturing, Testing, Training
- Materials
- Steel (gearbox/gear alloys)
- Höfler RAPID 1600 cylindrical gear grinding machine
- Klingelnberg P 150 CNC precision measuring center
- 4MW gearbox test bench (dynamometer, back-to-back)
- Industrial parts washing system
- Temperature-controlled measuring/grinding environment (thermal panels, separate air conditioning)
- Spare parts warehouse / onsite storage
Components & Services
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Gearbox manufacturing / design of gearbox products (wind, industrial, solar)Engineering | – | – | – | – | – |
| Gearbox service, repair and remanufacturing of wind turbine gearboxes and main shaftsMontage | – | – | – | – | Steel (gearbox/shaft components) |
| High-precision mechanical machining (in-house machining & tooling)Zerspanung | – | – | – | – | Steel (gearbox/shaft components) |
| Cylindrical gear grinding (gear grinding)Zerspanung | Operational gear tolerances are | – | – | – | Case-hardening steel (gear alloys) |
| Gear inspection / tooth microgeometry measurement (gear measuring)Prüfung | Operational gear tolerances | – | – | – | – |
| Full-load gearbox test (load & spin test up to 4 MW, back-to-back, vibration capture via 12Prüfung | – | – | – | – | – |
| Non-destructive testing (NDT)Prüfung | – | – | – | – | – |
| Root-cause analysisPrüfung | – | – | – | – | – |
| Industrial component cleaning (parts washing system: degreasing, high pressure, hot steam)Oberfläche | – | – | – | – | – |
| Painting of gearbox components (as part of reconditioning)Oberfläche | – | – | – | – | – |
| On-site field service (troubleshooting, installation, repair, warranty service,Montage | – | – | – | – | – |
| Core exchange program (replacement gearboxes)Montage | – | – | – | – | – |
| Factory training (borescope masterclass, FDMD/FDM2/FDM R8+/FDMX up-tower repairEngineering | – | – | – | – | – |
| Gearbox manufacturing for oil & gas (industrial gearboxes)Engineering | – | – | – | – | – |
5 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Cylindrical gear grinding machine | Höfler RAPID 1600 | 1 | Cylindrical gears of any diameter (gear grinding for re-certification) | – | Fort Worth, TX, USA |
| CNC precision measuring center (gear measurement) | Klingelnberg P 150 | 1 | Gear microgeometry (fully automatic, CNC-controlled) | – | Fort Worth, TX, USA |
| Gearbox test bench (dynamometer, back-to-back) | 4MW Gearbox Test Bench | 1 | Load and speed tests up to 4 MW, 12 acceleration sensors, oil temperature/oil flow control | – | Fort Worth, TX, USA |
| Industrial parts washing system | – | 1 | Degreasing, high-pressure nozzles, hot steam | – | Fort Worth, TX, USA |
| Temperature-controlled measuring/grinding environment (thermal panels, separate air conditioning) | – | 1 | Housing for Rapid 1600 and P150 | – | Fort Worth, TX, USA |
Additional services
Reference customers
History
- 2015
Commissioning of a brand-new site in Fort Worth, Texas to support the local market.
- 2016
First participation as an exhibitor at the 45th Turbomachinery & 32nd International Pump Users Symposia in Houston, TX (September 12–15, 2016).