German drive specialist Flender has launched a revolutionary new wind turbine drive concept, REVO, setting a world-first benchmark in torque density by achieving 300 Newton metres per kilogram (Nm/kg).
This breakthrough enables wind turbines to be built more compactly and efficiently while either maintaining or increasing power output, significantly lowering the cost of producing wind energy.
REVO represents a major leap for the wind power industry as turbines continue to grow larger and more powerful, both onshore and offshore, in response to rising global energy demand and sustainability goals.
The compact design of the REVO drive system reduces the outer diameter of turbine gearboxes by up to 25 per cent for the same power output, resulting in lighter nacelles and easing transportation and installation challenges.
“With REVO, we are setting a new standard in wind power technology,” said Andreas Evertz, CEO of the Flender Group.
“By increasing torque density, we boost efficiency while reducing material usage — making the wind industry even more competitive and sustainable.”
The lower mass at the top of turbine towers enabled by REVO translates to cost savings in tower and foundation construction, while a 70 per cent reduction in CO₂ emissions compared to gearboxes from 2010 demonstrates a strong environmental benefit.
The innovation is the result of global collaboration among Flender’s engineering teams, combining optimised planetary gear stages, new gear materials, induction hardening, and next-generation low-noise journal bearings for enhanced reliability and compliance with European noise regulations.
Andreas Klein, Vice President of Drive Systems and Gear Engineering at Flender’s wind segment, noted: “Torque density — sometimes also named power density — refers to how much torque a drive can transmit per kilogram of material. It’s a key metric for the overall CAPEX of a wind farm.”
Tommy Rahbek Nielsen, President of Winergy, Flender’s wind energy brand, highlighted the competitive advantages: “In recent years, we’ve already managed to double the torque density of our drives.
“With REVO and the achievement of the 300 Nm/kg mark, we’re unlocking even more possibilities for our customers — greater output in the same footprint, or more compact components without sacrificing performance and reliability.
“Together, we select the optimal technology package for each project.”
Currently on display at Winergy’s facility in Voerde, Germany, the REVO prototype showcases its striking compactness compared to previous drive systems.
According to Nielsen: “The prototype is intended to inspire conversations with our customers as we work together to develop the best drive solutions for new projects.
“Our shared goal is to make wind energy as efficient and cost-effective as possible.”
Flender’s global engineering capabilities and close collaboration have driven the development of this unique prototype, which applies advanced technological trends and materials to set a new benchmark in wind turbine technology.
“With REVO, we offer a solution tailored to the demands of today’s and tomorrow’s wind energy projects,” added Andreas Evertz.
“We’re proud to present this innovation — a step forward in securing the future of energy supply.”
As the wind energy sector faces increasing urgency to deliver cost-effective and sustainable solutions, Flender’s REVO drivetrain embodies a significant technological advance that reduces energy production costs and supports the expansion of wind power worldwide.
This innovation exemplifies the company’s commitment to enhancing turbine performance, lowering environmental impact, and helping achieve global energy transition goals.
