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Next Generation of Offshore Wind Turbines

A worldwide manufacturer of Wind Turbines, developing the Generator Busbars for the next generation of offshore 7MW machines.

The increasing demands on cost of electricity and reliability in the sector required an innovative approach.

Challenges

  • Customer design was difficult to manufacture and very expensive.
  • Develop a cost effective manufacturing solution for complex ring rolling and assembly. Including Brazing and testing.
  • Ensure that Busbar assemblies were fully insulated.
  • Ensure that production solution guaranteed 100% “on time in full” delivery performance. (High penalty clauses in contract)

Solutions

  • Review design criteria and areas for improvement with customer design engineers.
  • Proposed new design for Busbars and packaging solution.
  • Developed production solution for ring rolling, insulation, brazing and assembly.
  • Provided samples for evaluation and testing.
  • Framework agreement in place for future supply.

Brief description of what difference we made… immediately and longer term:

  1. Introduced a greatly improved technical and commercial solution.
  2. HV Wooding technical resource steered design with engineering group
  3. Improved assembly time at customer site
  4. Reliable supply chain in place.

Added Value

  1. Customer benefitted by working with HV Wooding technical resource to give substantial technical improvement.
  2. Saving the client up to 50% – comparing initial design to engineered solution.
  3. Guaranteed 100% delivery performance – ensuring customer optimises manufacturing throughput.

Busbar Manufacture

H V Wooding specializes in the production of copper, aluminium, and cuponal busbars for use in switchgear components, control panels, panel boards, fusegear, and transformers, catering to a diverse range of industries including Switchgear, Railway, Renewable Energy, Marine, Data Centre, and Power Electronics sectors.

Motor Stator/ Laminations

Core Packs, Motor Laminations, Stators, Rotors, Expert Manufacture via multiple manufacturing methods for the EV sector

Wire Erosion

We produce a varied scope of components from prototyping and small batches for F1 to volume production for multinationals across sectors including Aerospace, Medical, Research, Automotive, Electric & Hybrid vehicles & Defence

Laser Cutting

Applications for this service are wide-ranging including Battery Terminals and Contacts within the growing Hybrid & Electric Vehicle sector to Busbars for Power Electronics, Electrical Systems and Transportation.

Electroplating & Powder Coating

Specialists in sub-con electroplating. Experienced in-house electroplating services including - Tin Rack Plating, Silver Rack Plating, Zinc Rack Plating, Nickel Rack Plating, Tin Barrel, Silver Barrel, & Zinc Barrel. Owing to increased capacity we are now offering the following finishes to the general market. We offer specialist Powder Coating for busbars for the Electric Vehicle market.

Presswork & Tooling

Precision presswork / metal stamping delivered in volume and on time. We have 50 years’ experience and expertise of providing economic presswork solutions to major names within the electrical switchgear, electronic, power generation, medical, marine and automotive industries.

Assembly

Our advanced sub assembly facility allows our customers to outsource the assembly at low risk, and focus on their core business activities, secure in the knowledge that we will provide them with a fast, cost-effective service. Reducing inventories, part numbers and supply base saves time and effort and can also result in significant cost savings.

Renewable Energy

Supporting our customers in manufacturing world class products in the Wind Energy, Solar and Hydro (Tidal & Wave) sectors. The increasing demands on the cost of electricity and reliability in the sector requires an innovative approach and we are adding value to Global Supply Chains through our innovative approach.

Electric Motors

Adding value to our customers by optimising the design and manufacturing of complex Motor Laminations and Core Packs. Our core activity in this arena is focused around demanding and complex high end motor applications where we are able to offer customers years of experience in working with a wide range of materials and complex geometries to achieve the demands of the new generation industries.

Electrical Switchgear

Supporting our customers manufacturing world class products in the Electrical Switchgear, Power Generation and Power Distribution markets.

Electric & Hybrid Vehicle components

H V Wooding is a leading provider in the fabrication of pre and post bonded Motor Laminations, Core pack assemblies, Stators, and Rotors, from initial prototyping to large-scale production. We offer a variety of manufacturing methods tailored to the unique needs of your project, utilizing state-of-the-art Wire Erosion, Laser Cutting and Stamping technologies to deliver optimal solutions.

More projects

Science & Research - CERN

A twin-aperture, 10 m long, prototype magnet was designed by CERN to gain experience in the construction of full scale twin-aperture Dipole Magnets. HV Wooding were given the task to produce the Twin-aperture Dipole magnet Laminations. Click to read a Case study demonstrating our ongoing work with CERN on the Large Hadron Collider - and the positive impact from our input.

Ventilator Challenge UK

British engineering firms were called on to switch to making medical ventilators as concern grew about the effects of the coronavirus pandemic.  This follows an appeal by Boris Johnson, who held an emergency conference appealing for an urgent effort to address the national shortage.

Data Centre Busbars

A Global Social Media Platform were looking to enhance the performance, reliability and efficiency of their Data Centre Operation. This project involved HV Wooding in the design optimisation and manufacture of Busbars.

Next generation of Tidal Turbines

A Global manufacture in the “Renewables Sector” are developing the next generation of Tidal Turbines. In order to optimise engineering performance they needed a partner to help facilitate both the design and manufacturing solution of “Laminate Sections” for the Permanent Magnet Generator.

High Volume of Metal Stampings and Busbars

A leading Global manufacturer of Electrical Automation and Control Solutions have a high volume of Metal Stampings and Busbars used within their product groups. These include regular repeat items and also spot ordered parts that are delivered to multiple locations.

“Hybrid Drivetrain” for Motorsport and Transportation applications

A Global manufacturer of “Hybrid Drivetrain” for Motorsport and Transportation applications. A key market for flywheel energy storage technology is the public transport sector. This technology can save fuel and reduce green house gas emissions by up to 30% in a city bus for example.

Strategic outsourcing partner

A leading international manufacturer of electrical accessories were producing all components in house. In order to focus on core activities and increase profitability, they needed a strategic outsourcing partner that they could trust. After a detailed evaluation, they decided to outsource all presswork components to HV Wooding.

Looking to reduce the cost of manufacture

UK Atomic Energy Authority is a UK government research organisation responsible for the development of nuclear fusion power. Requirement to manufacture Busbars for MAST upgrade.
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