German drive specialist Flender presented a new generator concept today at WindEnergy Hamburg that aims to cut material use, noise and supply risk in large wind turbines.
The concept, called Winergy GENERA, is a validated design and technology package from which solutions can be configured for individual turbine projects.
The launch comes as turbines keep growing in output and size, both onshore and offshore, while the energy debate has moved toward security of supply and affordability.
“With Winergy GENERA we are doing more with less,” said Tommy Rahbek Nielsen, President of Winergy, Flender’s wind energy brand.
GENERA reaches power densities of up to 700 W/kg.
Flender says this is 10 per cent higher than previous versions and comparable competing products, and that the figure is currently unmatched in the wind industry.
Generator length is 25 per cent shorter than in the previous generation.
That allows the unit to fit into the nacelle and keeps transport by standard truck and container possible for power classes above 10 MW.
The design is based on a Double Fed Induction Generator and is available across power classes without depending on rare earth materials.
The difference matters most above 10 MW, where alternative generator concepts typically rely on permanent magnets containing rare earths.
Those materials are available in limited quantities, and their mining and processing are concentrated in a few regions, which exposes manufacturers to price volatility and supply risk.
Windings can be specified in aluminium or copper depending on project needs.
Copper remains in tight supply.
The International Energy Agency projects a global supply deficit of around 25 per cent by 2035, and copper prices reached record highs in early 2026.
The aluminium option gives manufacturers a second route for a material that affects both cost and delivery reliability.
“Winergy GENERA shows that high performance and cost-efficiency are not contradictory,” said Jörg Sieber, Vice President Wind Generators in Flender’s wind segment.
Noise emissions are 6 dB(A) lower than in the previous generation, giving developers more headroom at noise-sensitive sites and supporting local acceptance.
The design requires no external cooling fans, so no auxiliary power is consumed for cooling, hence boosting the turbine’s annual energy output.
GENERA works with any gearbox but is optimised for Winergy REVO, Flender’s gearbox concept.
REVO was the first drive concept to reach a torque density of 300 Nm/kg.
Together, the two products offer an optimised gear ratio for high efficiency across the system, robust reactive power support, grid compatibility and smooth integration into wind power plants.
The generator is also part of Flender’s service and digitalisation offering.
Through AIQ, the company’s drive intelligence, operators can monitor the entire drivetrain from the main bearing through the gearbox and coupling to the generator.
AIQ Orbit combines up to eight AIQ Pulse vibration sensors with integrated speed monitoring and consolidates the data in a web portal covering individual turbines and whole wind farms.
Winergy’s condition monitoring specialists turn that data into maintenance recommendations, which, together with long service intervals, is meant to reduce unplanned downtime and maintenance costs.
Flender says not every project needs the full technology package.
Customers can choose options ranging from winding material to noise and logistics constraints, while reliability standards stay consistent.
Efficiency in the drivetrain has a direct effect on the cost of wind power and how quickly capacity can be added.
Lower component mass reduces requirements for towers, foundations and logistics, and compact designs keep hard-to-reach sites accessible.
“Wind energy has become a central pillar of a secure energy supply in Europe,” said Andreas Evertz, CEO of the Flender Group.
GENERA and REVO are both on display at the Winergy stand in hall B5, Stand 130, from September 22 to 25, 2026.
GENERA is being shown to the public for the first time on the opening day of the fair.
Also on show are AIQ drive intelligence, the wind coupling portfolio with a focus on the ARPEX ARV, and the Winergy Service360 portfolio.