Renewables infrastructure is going to come under increased pressure as clean energy demands increase exponentially, and this is where Hardman Brothers is perfectly positioned with our build-to-print and design-assist capabilities to help renewable energy projects boost key markers such as efficiency and torque transmission.
Component machining and gearbox refurbishments is one of our core competencies, and tied into our collaboration process we can optimise down to the finest detail to keep power output at the highest levels possible whilst reducing asset downtime incidents and stretch out infrastructure lifetimes.
The gearbox role in energy production cannot be understated – it is the intersection point where the low rotational speeds of wind or hydroelectric turbine rotors are converted to match the higher shaft speeds of the generator which produces our power.
To keep power output at its utmost, this speed conversion is the linchpin of the process and the efficiency required to prevent energy loss is at the heart of the gearbox function, which Hardman Brothers intrinsically understands.
A rigorous MO of design-assist and collaboration, build-to-print capabilities, advanced machining techniques, quality control and testing, and assembly (if required) is how Hardman built its reputation in the energy space.
This reputation is the primary reason why some of the nation’s largest energy providers look to us for gearbox component machining and complete gearbox refurbishment for their ongoing and transition projects
Turbine rotors generate significant rotational force, and it’s the gearbox components that handle this torque transmission to the generator for electricity production – only reliable, resilient and rigorously machined and tested gearbox components will stand up to the formidable operating conditions of traditional and renewal energy applications.
Hardman Brothers has enjoyed long-standing industry work in traditional energy markets, manufacturing all components for centrifugal gear boxes for oil and gas industry customers.
And by using this expertise attained through years of hard-won experience in these legacy energy sectors, Hardman is now transferring and deploying these skills for gearbox components repair/manufacture and gearbox refurbishments for the expanding renewable energy sectors.
Planetary gearboxes are commonly used in wind turbines primarily to increase the rotational speed of the turbine blades to match the power generator’s requirements.
There is also another reason the wind sector has a strong need for planetary gearboxes – pitch and yaw applications in its turbines.
With the housing atop each tower (nacelle) containing generator, gearbox, drive train, and control electronics, planetary gears are used in yaw control to rotate the nacelle to face the wind directly.
Additionally, planetary gears and gearboxes assist with pitch control to adjust blade angles for optimal energy capture and protection from high winds.
Durability in harsh conditions is another key advantage – a planetary gear system is built to resist the punishing weather conditions inevitably dished up in their chosen locations, providing reliable performance and reducing the need for frequent maintenance.
This is where our expertise can be deployed for component repair, and even complete gearbox refurbishments.
This is why Hardman Brothers have partnered with one of Australia’s oldest energy companies in Victoria’s Latrobe Valley, collaborating on and machining gear and drive-train systems for wind turbine sections.
Solar power systems utilise planetary gears as part of their solar trackers, which adjust the position of solar panels to follow the sun’s movement.
Hardman Brothers is perfectly positioned to design-assist and machine components for solar projects due to its expertise in planetary gear sets of varying sizes, including right down to micro-gear level. This solves the space constraint problem by providing a compact solution that delivers high power in a tinier footprint, crucial for solar trackers.
Also crucial is a smooth and continuous power transmission. Hardman-machined parts and components for planetary gearboxes ensure minimal vibration and noise, leading to more stable and efficient operation.
Planetary gearboxes are used in hydropower plants to convert the low-speed rotational energy from water turbines into higher speeds suitable for electricity generation. The ability of a planetary gear box to handle high loads and operate efficiently under varying conditions makes them ideal for this renewable energy application.
Components and parts machined by Hardman Brothers for these planetary gearbox configurations ensure continuous operation, reliable performance and long service life in hydropower applications.
Planetary gearbox refurbishments are right in our wheelhouse too, as we understand how these gearboxes can meet the high torque requirements created in hydropower environments, again reinforcing their advantage of durability in harsh conditions.
It’s not just the energy sector experiencing meteoric demand for gears and gearboxes – mining, industrial, transport and agriculture are all in the mix, and Hardman Brothers has deep expertise in all of these fields.
We offer the flexibility of changing gear ratios to meet individual customer requirements – a key advantage of our design-assist and collaboration approach with you on planetary gearbox component manufacture and refurbishments.
Contact us for help with your Gearbox components and refurbishments
Power generation relies heavily on pump shafts and impellers in power generation, working together to ensure the efficient and reliable operation of power plants.
A pump shaft must be manufactured and machined using high-quality materials and to exact specifications to minimise deflection, vibration, and wear as it transmits torque from the motor to the impeller.
Similarly, robust machining processes are mandatory for an impeller so its vanes (or blades) can accelerate fluids outwards from the centre of rotation to maintain high-pressure water flow
An impeller, as part of feedwater pumps, must be able to handle high pressure and temperature, ensuring continuous water circulation for steam powered plants.
Hardman Brothers is fully versed in impeller and pump shaft machining, providing these components to one of its home state’s longest-running power generators in the Latrobe Valley.
Utilising this transferrable expertise is front-of-mind for Hardman Brothers as the same precise impeller and pump shaft machining processes equally apply to the hydroelectric sector, albeit enabling a slightly different, but no less important function.
In hydroelectric plants, these pump shafts are part of systems managing water levels and flow rates, supporting turbine operations.
Impeller design-assist and machining is of paramount importance as the number of blades and their shape directly impacts pump performance, also maintaining water flow and pressure in auxillary systems.
This is no realm for newcomers – Hardman Brothers has demonstrated its capability in pump impellers and pump shaft machining for some of the nation’s most important power plants, and is actively seeking further partnerships in the era of Snowy 2.0.
