The power-generating turbine market is seeing growth across the board. Wind turbines are increasing in size, and water turbines in rivers and oceans are starting to reach maturity. Smaller urban wind turbines are springing up like mushrooms, the world over. This growth also entails a greater demand for permanent magnet technology. Turbine manufacturers are primarily seeking out system partners who can keep pace. After all, in such a dynamic world being the first is often all down to flexibility. Or the largest.
Flexible PM technology for water- and wind turbines
“Bakker is a 100% system partner for manufacturers of smaller to larger water and wind turbines: from knowledge supplier, co-engineer, supply-chain manager, to manufacturer of permanent magnets and PM assemblies”
Bakker Magnetics in Science Park Eindhoven has built up many years of experience as a PM specialist, at every level of the renewable energy turbine market. Bakker is a 100% system partner for manufacturers of smaller to larger water and wind turbines: from knowledge supplier, co-engineer, supply-chain manager, to manufacturer of permanent magnets and PM assemblies. The very largest wind turbines are produced by only a handful of multinationals. Despite often having PM technology in-house, they still require assistance at times. This was the case two years ago, when an international manufacturer wanted a 12-megawatt offshore wind turbine built: the largest in the world. That’s when they called on Bakker Magnetics, precisely due to our flexibility.
“That’s when they called on Bakker Magnetics, precisely due to our flexibility“
The World’s Largest
This towering wind turbine stands 260 meters tall, with a rotor span of 220 meters. Capable of powering 16,000 homes, the turbine is an advancement of an earlier 6-megawatt model. However, a change in permanent-magnet topology was made at a late development stage. “Due to the time pressure and complexity of the new topology, they couldn’t develop and mount the magnets in-house,” explains the specialist from Bakker Magnetics’ Magnetic Technology & Assemblies division. “They needed a partner with not just deep PM expertise but also the agility to deliver a high-profile project within a tight schedule. We had been in contact previously and clearly made a strong impression, then the assignment came. It was time to roll up our sleeves.”
Delicate Precision Work
The turbine features a generator with a 10-meter diameter rotor, requiring over 100 magnet modules mounted around it. Working in tandem with the client, Bakker optimized the modules and built a dedicated production line for precise magnet placement. “It was incredibly delicate work,” says the engineer. “Each module is a meter long, with cavities for the magnets. These magnets are large and strongly repel one another. A single mistake could ruin an entire module.” Using the specially designed production line, the magnets were inserted safely and precisely, one by one.
Bakker also developed and delivered the magnet assembly for a second 12-megawatt turbine, plus extra modules for testing. “We completed both development and production in under two years,” says the specialist. “For a project of this scale, that’s exceptionally fast. It was real co-creation, being flexible, approachable, and closely aligned with the client. That’s what defines Bakker Magnetics.”
“We managed to accomplish everything, development and production, in under two years. For a project of this scale, this was extremely fast. This was down to true co-creation“
Optimum Performance
According to the engineer, top-quality assemblies are key to ensuring maximum turbine performance. “Consider an electric motor. The more accurately magnets are positioned, the higher the output, simple as that. We also ensure optimal adhesion, leading to safer and more reliable operation with minimal maintenance. We design with long-term threats like high temperatures, counter fields, and corrosion in mind. Wind turbines need to perform flawlessly for 25 years. A small reduction in efficiency or gradual demagnetization due to poor assemblies could lead to enormous financial consequences. There’s no doubt: producing top-tier magnet assemblies is a true specialism.”
Streams and Urban Wind
The two massive turbines were prototypes, proving the concept’s viability. Bakker Magnetics will now also manage the series production of the magnet modules—clear evidence that no turbine is too large for the company. “But we’re also very active in smaller markets,” says the specialist. “One exciting area is Wave, Tidal & Stream—turbines placed in ocean waves, tides, or rivers. Water holds more energy potential than most people realize. The technology is similar to wind energy but underwater. A large blade is driven by water currents, and magnet modules on the outer ring rotate alongside coils, generating electricity in the generator.”
Urban wind turbines are another growing segment. These smaller systems, up to about 200 kilowatts, are increasingly found on farms and industrial sites. “They’re often built by SMEs, and we’re happy to support them with our PM technology,” the engineer adds.
Direct Drive
Conventional turbines often use asynchronous generators and gearboxes to reach high speeds. Today, especially offshore, many turbines use direct-drive generators with permanent magnets. These allow for power generation at lower speeds and eliminate the need for gearboxes. “This dramatically reduces maintenance needs,” says the specialist. “That’s critical, especially for turbines installed at sea. Plus, direct drive systems are 1–2 percent more efficient. It might not sound like much, but with a 12-megawatt turbine, the extra output is massive.”
“The perfect decision, positioning and fitting of magnets means we can make your turbine that bit more efficient, giving your company a head start“
Protection Against the Elements
Given that water and wind turbines often operate in corrosive environments, robust corrosion protection is essential. “Turbine manufacturers are generally well-informed in this area, and we support them wherever we can,” explains the engineer. “Neodymium magnets are naturally prone to corrosion, so they come with standard coatings. We can also apply marine-grade paint or fully enclose the magnets in epoxy. While corrosion is a real concern, the industry has ample experience managing it effectively.”
Head Start
The renewable energy turbine market continues to evolve rapidly, making it an exciting space for a company like Bakker Magnetics, especially when engaged early in the development process. “The sooner you involve us, the more value we can offer,” says the specialist. “Optimally placing and securing magnets can give your turbine that critical efficiency edge. We bring years of experience and a track record of success, including our work on the world’s largest wind turbine. No challenge is too great.”
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