Custom Heavy-Duty 80-200tons RGV Systems for Wind Turbine Assembly Lines
As global efforts to reduce carbon emissions intensify and the demand for sustainable energy continues to rise, wind and solar power are becoming central to the clean energy transition. In 2024 alone, China added nearly 80 GW of new wind power capacity, setting a record high and pushing total wind installations to over 520 GW—nearly half of the global total.
The growth is not limited to China. Emerging markets are rapidly expanding:
- The Asia-Pacific region saw a 7% YoY increase in new wind installations.
- Africa and the Middle East recorded a stunning 107% YoY growth.
- While growth in Europe and North America has slowed, they remain the second and third-largest wind markets globally.
Why Wind Power Manufacturing Needs Customized Heavy-Duty Transport Solutions
The wind energy sector is characterized by massive components—from turbine towers and nacelles to gearboxes, blades, and castings.
- Wind turbine blades can reach 30–50 meters in length, weighing up to 15 tons.
- Gearboxes and nacelle assemblies can exceed several dozen tons.
- Transporting and assembling these components requires precision, automation, and safety.
That’s where HENSEN steps in. With over two decades of experience in customized Automated Guided Vehicle (AGV) and Rail Guided Vehicle (RGV) manufacturing for heavy-load transportation, we provide turnkey intelligent solutions—from design and manufacturing to onsite deployment.
Case Study: HENSEN RGVs for Wind Turbine Manufacturing Line
In a major project for Mingyang Group’s intelligent wind turbine manufacturing facility in Baotou, Inner Mongolia, HENSEN delivered a complete flexible assembly line transport system, including:
🔩80-Ton RGVs for Hub Assembly Line
- Quantity: 3 units
- Dimensions: 4800mm (L) × 3200mm (W) × 840mm (H)
- Features:
- Custom rotating table fixture
- Remote-controlled 120° indexing rotation (forward or reverse) for hub alignment
- Side-mounted automatic charging brushes for efficient unmanned charging
- Fully integrated into the flexible assembly process
- ⚙️ See image: Rotating table configuration
⚙️ 200-Ton RGVs for Nacelle Assembly Line
- Quantity: 10 units
- Dimensions: 8500mm (L) × 3250mm (W) × 540mm (H)
- Features:
- Custom fixture interface with pre-drilled mounting holes to support various tooling requirements
- Automatic charging system for continuous workflow
- ⚙️ See images: RGV configurations with nacelle tooling
Full Line Integration: Automation Meets Flexibility
HENSEN delivered a complete intelligent transport system integrating:
- 🔁 Automatic parking system
- 🕒 Takt time synchronization
- 🔋 Unmanned charging system
- 📡 Data transmission and MES interaction
- 🧠 Centralized control
- 🚨 Laser obstacle detection & emergency stop
- 🧑🏭 Manual override modes for key workstations
Supports three operational modes:
- Forced Takt Mode – Movement only after manual confirmation
- Free Takt Mode – Autonomous progression
- Manual Mode – Operator-controlled movement
This project is now among the most advanced wind turbine nacelle and hub assembly lines in China and even globally—setting a new standard for flexible automation and intelligent logistics in the renewable energy manufacturing sector.
Partner with HENSEN for Your Wind Power Logistics Needs
If you’re in the wind energy sector and struggling with the transport of oversized, heavy components or looking to improve automation and workflow efficiency, HENSEN offers the expertise and customized RGV/AGV systems you need.
✅ 20+ Years of Industry Experience
✅ Proven in Wind, Power, and Industrial Manufacturing
✅ Custom Engineering, Full Integration, Onsite Support
📩 Contact us today to explore tailored solutions for your wind power project.
