Wind turbines are becoming increasingly powerful and larger, both onshore and offshore. At the same time, the energy debate has shifted toward security of supply and affordability. Against this backdrop, the German drive specialist Flender has now unveiled a new generator concept: Winergy GENERA, a validated generator design concept and a technology package designed to enable the creation of solutions for individual turbine projects.

“Improves the cost-effectiveness of wind projects”

“With Winergy GENERA, we achieve more with less,” said Tommy Rahbek Nielsen, President of Flender subsidiary Winergy. “We combine very low noise levels with high power density and improved reliability, all while doing without magnets and rare earth elements—even in high-power turbine classes. This reduces material costs and improves the cost-effectiveness of wind projects.”

More power per kilogram

The validated GENERA design delivers power densities of up to 700 watts per kilogram. This represents a 10 percent increase compared to the previous version and comparable competitor 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 even for power classes exceeding ten megawatts and enabling transport via both standard trucks and containers. Since the design does not require external cooling fans, no auxiliary power is consumed for cooling—which increases the turbine’s annual energy production.

Noise emissions are six dB(A) lower than those of the previous generation, contributing to quieter operation of the turbine. Lower generator noise levels give project developers more leeway at noise-sensitive sites and promote local acceptance.

A generator design without rare earth elements

GENERA is based on a doubly-fed induction generator (DFIG), is available in all power classes, and does not rely on rare earth elements in any of these classes. The difference becomes significant at ten megawatts and above: In this range, alternative generator designs typically rely on permanent magnets containing rare earth elements, whereas this is not the case with GENERA. Rare earths are available only in limited quantities, and their mining and processing are concentrated in just 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 powertrain. Depending on project requirements, the windings can be specified as either aluminum or copper. Copper remains in short supply: 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 offers turbine manufacturers a second choice for a material that affects both project costs and supply security.

“Winergy GENERA demonstrates that high performance and cost efficiency are not mutually exclusive,” added Jörg Sieber, Vice President of Wind Generators in Flender’s Wind segment. “We increase power density, reduce noise levels, and lower material consumption—all in a single solution. This helps our customers improve the overall economic efficiency of their wind projects.”

Optimized for the Entire Powertrain

GENERA is designed for use with any gearbox and is particularly optimized for use 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 Newton-meters per kilogram, enabling more compact turbine designs or higher power output for the same size. Together, the two concepts form a powertrain that combines new technology with proven components. Key advantages of this powertrain combination include an optimized gear ratio for high efficiency throughout the entire system, reliable support for reactive power and grid compatibility, and seamless integration into wind turbines.

Drive Solutions for Future Turbine Generations

“Winergy GENERA is not a standalone generator, but rather part of a system-based approach,” Nielsen emphasized. “By coordinating the design of the gearbox and generator—especially in combination with REVO—we can offer our customers drive solutions designed for future turbine generations.”

Tailored to Individual Requirements

Not every project requires the entire technology package. “Together with our customers, we configure the optimal solution for each project rather than 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 consistent standards for reliability.

Monitoring Across the Entire Lifecycle

GENERA is integrated into Flender’s service and digitalization offerings. 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 through the gearbox and coupling all the way 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 expert service provided by Winergy’s condition monitoring specialists translates the monitoring data into concrete maintenance recommendations. Together with long maintenance intervals, this is intended to reduce unplanned downtime and maintenance costs and ensure high turbine availability.

A Contribution to Safe and Affordable Energy

Drivetrain efficiency directly impacts the cost of wind energy and how quickly capacity can be expanded. Lower component mass reduces the demands on towers, foundations, and logistics, and compact designs enable access to sites that would otherwise be difficult to reach.

A Cornerstone of a Secure Energy Supply

“Wind energy has become a cornerstone of a secure energy supply in Europe,” said Andreas Evertz, CEO of the Flender Group. “Every kilogram of material saved and every efficiency gain makes wind energy competitive—and that competitiveness determines how quickly the industry can expand. GENERA and REVO are our contribution to this.”

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