Wind turbines are becoming increasingly powerful and larger both onshore and offshore. At the same time, the energy debate has shifted towards supply security and affordability. Against this backdrop, the German drive specialist Flender today presents a new generator concept under its wind energy brand Winergy at WindEnergy Hamburg: Winergy GENERA, a validated generator design concept and a technology package from which solutions for individual turbine projects can be assembled.
'With Winergy GENERA, we achieve more with less,' said Tommy Rahbek Nielsen, President of Winergy. 'We combine very low noise development with high power density and improved reliability while eliminating magnets and rare earths – even in high-performance turbine classes. This reduces material usage and improves the economic efficiency of wind projects.'
More power per kilogram
The validated GENERA design delivers power densities of up to 700 W/kg. This corresponds to an increase of 10 percent compared to the previous version and comparable competing products and is currently unmatched in the wind industry. The generator length has been reduced by 25 percent compared to the previous generation, allowing the generator to fit into the nacelle for power classes over 10 MW while remaining transportable with standard trucks and containers. Since the concept does not require external cooling fans, no auxiliary power is consumed for cooling – which increases the annual energy production of the turbine.
Noise emissions are 6 dB(A) lower than those of the previous generation, contributing to quieter operation of the system. Lower noise levels of the generator provide project developers with more leeway at noise-sensitive locations and promote local acceptance.
A generator design without rare earths
GENERA is based on a doubly-fed induction generator (DFIG), is available in all power classes, and does not rely on rare earths in any of these classes. The difference becomes relevant from 10 MW: In this range, alternative generator concepts typically use permanent magnets that contain rare earths, whereas this is not the case with GENERA. Rare earths are only available in limited quantities, and their extraction and processing are concentrated in a few regions worldwide, exposing turbine manufacturers to price volatility and supply risks. A generator design that does not rely on them eliminates this dependency from the drivetrain.
Depending on project requirements, the windings can be specified in either aluminum or copper. Copper remains scarce: The International Energy Agency forecasts a global supply deficit of around 25 percent by 2035, and copper prices reached record highs in early 2026. The option to specify aluminum provides turbine manufacturers with a second option for a material that affects both project costs and supply security.
'Winergy GENERA shows that high performance and cost efficiency are not contradictory,' added Jörg Sieber, Vice President Wind Generators in Flender's wind segment. 'We increase power density, reduce noise levels, and lower material consumption – in a single solution. This helps our customers improve the overall economic efficiency of their wind projects.'
Optimized for the entire drivetrain
GENERA is designed for use with any gearbox and is particularly optimized in combination with the Winergy REVO system, Flender's gearbox concept for wind turbines. REVO was the first drive concept to achieve a torque density of 300 Nm/kg, enabling more compact system designs or higher power at the same size. Together, the two concepts form a drivetrain that combines new technology with proven components.
The key benefits of this drivetrain combination include an optimized gear ratio for high efficiency across the entire system, as well as reliable support regarding reactive power and grid compatibility, along with smooth integration into wind turbines.
'Winergy GENERA is not a standalone generator but part of a system approach,' emphasized Nielsen. 'By coordinating gearbox and generator design, especially in combination with REVO, we can offer our customers drive solutions designed for future generations of systems.'
Tailored to individual requirements
Not every project requires the entire technology package. 'Together with our customers, we configure the optimal solution for each project instead of pursuing a one-size-fits-all approach,' said Nielsen. From the choice of winding material to noise and logistics specifications, GENERA offers configuration options while maintaining uniform standards for reliability.
Monitoring throughout the entire lifecycle
GENERA is integrated into Flender's service and digitalization offering. With AIQ, Flender's drive intelligence, which is also available for the Winergy portfolio, the condition of the entire drivetrain can be monitored – from the main bearing to 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 the AIQ web portal, which provides an overview of both individual turbines and the entire wind farm.
The competent service of Winergy's condition monitoring specialists translates the monitoring data into concrete maintenance recommendations. Together with long maintenance intervals, this aims to reduce unplanned downtime and maintenance costs and ensure high availability of the turbines.
A contribution to safe and affordable energy
Efficiency in the drivetrain directly affects the costs of wind energy and how quickly capacities can be expanded. A lower component mass reduces the demands on towers, foundations, and logistics, and compact designs enable access to locations that would otherwise be difficult to reach.
'Wind energy has become a central pillar of a secure energy supply in Europe,' said Andreas Evertz, CEO of the Flender Group. 'Every kilogram of material saved and every efficiency point gained makes wind energy more competitive – and competitiveness determines how quickly the industry can expand. GENERA and REVO are our contribution to this.'
At WindEnergy Hamburg
GENERA and REVO will be presented from September 22 to 25, 2026, at the Winergy booth in Hall B5, Stand 130, with GENERA being publicly introduced for the first time on the opening day of the fair. Also on display will be the AIQ drive intelligence, the wind coupling portfolio focusing on the ARPEX ARV, and the comprehensive Winergy Service360 portfolio.
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