EDWIM

Motivation

The production of large-scale wind turbine components, such as gearboxes and generators, has traditionally been complex, labor-intensive, and energy-intensive. The EDWIM project addresses this challenge by developing a digital, automated, high-performance, replicable, and sustainable manufacturing model for series production. The goal is to optimize processes, improve quality, conserve resources, and strengthen European competitiveness in the wind energy sector – an important step toward the energy transition and sustainable industrial production.

Goals and Approach

EDWIM demonstrates a fully digitized manufacturing ecosystem in the “Gearbox” and “Generator” pilot applications. Intelligent production chains, digital traceability, and process optimization ensure efficiency and reproducibility. To this end, Fraunhofer IWS is developing an additively manufactured copper inductor for the induction hardening of wind turbine gearbox gears. The process uses a powder-bed-based manufacturing method, selective laser melting, which melts metal powder layer by layer using a laser. The process enables the production of complex geometries with internal cooling channels. In addition to the additive manufacturing process, the process chain also includes the removal of powder from the internal channels, heat treatment to achieve the desired material properties, and subsequent manufacturing steps such as welding or mechanical finishing.

Innovation and Prospects

EDWIM combines digitalization, automation, and additive manufacturing into a new, scalable production approach. The Fraunhofer IWS inductors optimize hardening processes, shorten cycle times, and improve component quality. The project creates a networked, sustainable production environment that can be transferred to other energy-intensive industries – a step toward intelligent, competitive manufacturing systems in Europe.