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GreenSpur Rethinks Generators for More Efficient Wind Turbine Operations

If you manage wind turbine operations, you’re probably acutely aware of just how much generator weight, complexity, and maintenance affect uptime and cost. In a recent Spotlight interview with the Uptime Wind Energy Podcast, Jason Moody, Chairman, GreenSpur Wind, explained how the company’s axial‑flux technology is reshaping generator design to meet today’s offshore and floating wind challenges.

Listen to the full interview to learn how GreenSpur is putting a whole new spin on wind turbine design

The Weight Problem and The Axial-Flux Solution

It’s typical for today’s direct‑drive generators used in offshore turbines to weigh more than 150 tons. Big machines for big jobs, right? But that weight has a structural ripple effect: heavy generators necessitate heavier towers, reinforced foundations, thicker steel, and larger blades— and all of that heft increases capital and installation expenses, initially, and contributes to ongoing maintenance and operations expenses.

When large generators are needed on floating platforms, those dynamic loads require even heavier ballast; structural integrity gets more complex. Some floating wind designs have tested hybrid and geared systems to reduce weight, but combined systems add complexity. While the industry’s goal, always, is to reduce LCoE, larger systems weigh more, and more complicated designs rarely improve efficiencies.

So for floating wind installations, particularly, GreenSpur’s axial-flux design – with a significantly reduced weight – offers clear advantages.

As Moody points out, hybrid and geared systems can be “even more complicated” – and not just on electrical efficiency.

“As they spin faster, they get hotter, and then…you need more high-tech cooling systems, which is another point of failure,” he said.

“So the LCoE really does start to suffer with these more complex, advanced systems.”

“What we’re trying to do is introduce a new technology that can address the problem (of excess with) and hopefully address some other problems as well.” – Jason Mondy, GreenSpur

What are the Advantages of Axial Flux Generators?

While most traditional radial-flux generators have concentric cylinders where magnetic flux flows between them (see more here), Greenspur’s axial flux design has the rotor and stator arranged as discs along the axis of the machine, and the magnetic flux flows parallel to this axis.

Because Greenspur’s axial flux generator employs a modular architecture, multiple smaller stages can be connected in parallel. This allows for easier scaling, customization, and potentially a lighter overall design for higher-power applications.

GreenSpur’s axial-flux generators are significantly lighter than traditional radial motors. And, unlike current generators that need active cooling systems (which bring their own maintenance headaches), axial‑flux machines reduce or eliminate this demand.

Also, because GreenSpur’s designs work with a variety of magnets – from low-cost ferrite to rare-earth materials – they offer a lot of cost control options, too.

How does an axial flux generator work? Uptime explains everything.

The Wheels are Turning Now

While axial flux is not a new design concept, GreenSpur’s implementation puts a new spin on things. Where else are axial flux design used? In Lamborghini’s Temerario, pictured, as well as in high-end vehicles from Mercedes Benz, Ferrari, Jaguar and other manufacturers.

Temerarior image from Yasa motors.

Other Operational Impacts for Turbine Installation, Maintenance

Lower weight means fewer cranes and smaller barges. Translation: Easier, less-expensive installation and repairs

Structural Compatibility is a lifetime benefit, as axial-flux components could slot into new turbines with few structural upgrades, and make retrofitting existing foundations easier

No active cooling means lower maintenance costs, as there are few issues with fluid leaks, fans and pumps.

Strategic Moves for Owners, Operators, and Managers

Axial‑flux generators offer a fresh paradigm: lighter weight, simpler design, potential cost reductions, and enhanced suitability for offshore and floating farms. For operations managers – and also investors – this is welcome news because it also means: shorter installation times, lower and less-costly maintenance, and simplified inventories.

Although axial-flux turbines aren’t yet mainstream, the promise of reducing the LCoE combined with more streamlined, efficient operations, is a powerful lure to get behind the technology.

Those who want to learn more about axial-flux integration, pilots or trial deployments should contact GreenSpur. As axial-flux engine production is already scaling up in the automotive industry, it will soon be wind energy’s turn to benefit from the technology and design.

This article is based on a June, 2025 interview with Jason Moody, Chairman, GreenSpur Wind. Listen to the entire conversation here, on Spotify, or WATCH on YouTube!

How to Prepare for Axial Flux Generators?

Tips and considerations for those ready for this efficient upgrade to wind turbine operations include:

Training: O&M crews must understand axial‑flux-specific drive electronics, winding structures, and maintenance procedures. proactive training plan will be essential.

Pilot Programs: Collaborate with GreenSpur or OEMs to install axial‑flux prototypes on pilot turbines, ideally in planned outages or new builds.

Develop Inspection Protocols: Begin documenting how axial‑flux units behave under load, vibration, thermal cycling, and blade pitch events.

Evaluate Asset Life Cycle Savings: Estimate savings from reduced downtime, simpler maintenance, lighter lifts, and material costs to put real numbers behind expected gains.

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