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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.

GreenSpur Rethinks Generators for More Efficient Wind Turbine Operations

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.

GreenSpur Rethinks Generators for More Efficient Wind Turbine Operations

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.

GreenSpur Rethinks Generators for More Efficient Wind Turbine Operations

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.

https://weatherguardwind.com/greenspur-axial-generators-more-efficient-wind-turbine-operations/

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Storm Damages ENGIE Wind Farm, Mexico Plans 7 GW

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Storm Damages ENGIE Wind Farm, Mexico Plans 7 GW

Allen covers a storm that damaged ENGIE’s South Dakota wind farm, Sumitomo exiting two Belgian offshore farms, Envision’s loss in Denmark, and Continental building its own wind farm.

Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTubeLinkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!

Happy Monday everyone.

Sometimes … Mother Nature reminds the wind industry who is really in charge. Late last month … hurricane-force winds ripped through Hyde County, South Dakota … tearing into the Triple H Wind Farm operated by French energy giant Engie. One hundred and thirty-one miles per hour … as strong as a Category Four hurricane. More than twenty of the site’s ninety-two turbines … damaged. The two-hundred-fifty-megawatt complex is out of service … and turbine supplier GE Vernova is on-site now … assessing the wreckage. No injuries … but the governor declared a state of emergency. The machines that harvest the wind … taken down by the wind itself.

Now … while one wind farm goes dark in the American plains … ownership is reshuffling across the North Sea. Japan’s Sumitomo Corporation has exited two Belgian offshore wind farms … selling its stakes to joint venture partner Jera Nex BP. That is the partnership between oil major BP and Japan’s largest power generator Jera. Jera Nex BP now has full ownership of the two-hundred-nineteen-megawatt Northwester 2 … and has raised its stake in the one-hundred-sixty-five-megawatt Nobelwind to eighty percent. Both farms operate out of Ostend, Belgium … and have been generating power since 2017 and 2020. Sumitomo walks away … Jera Nex BP doubles down.

Meanwhile … in Denmark … China’s Envision Group is seeing red for the first time in fifteen years. The company’s global innovation center in Silkeborg … a strategic research hub for wind turbine components and advanced manufacturing … posted a loss of just under one-point-three million Danish kroner. That is a swing of more than one hundred fifteen percent from last year’s profit. The culprit is not the technology … it is the currency. The U.S. dollar fell nearly twelve percent against the Danish krone in 2025 … and Envision’s books took the hit. Revenue also dropped eighteen percent … but management says the underlying operations remained stable. The machines still work … the math just changed.

And speaking of money flowing into wind … a Turkish energy company just tapped an unusual source. Aksa Enerji … the largest publicly listed independent power producer in Turkiye … has secured one hundred twenty-four million dollars in financing backed by China’s export credit agency Sinosure. The money will fund a one-hundred-megawatt wind-plus-storage project in the southern province of Mersin. This is the first renewable energy project in Turkiye to receive a license as a storage-integrated facility. Aksa now operates power plants across seven countries … with more than three gigawatts of total capacity. Chinese capital … backing Turkish wind … with battery storage baked in from day one.

Now … here is a story that might surprise you. Continental … the German tyre maker … yes … the tyre company … is building its own wind farm. Three Nordex turbines … each standing two hundred sixty-seven meters tall … right next to its tyre factory in Korbach, Germany. When they are online … those turbines and the factory’s existing solar panels will cover two-thirds of the plant’s electricity demand. Fifty-five gigawatt-hours a year … powering rubber mixing and extrusion lines … directly from the wind. Continental calls it a model for its production sites worldwide. Cheaper power … more predictable costs … and less exposure to volatile energy markets. The wind industry just gained a tyre company as a customer … and a competitor for electrons.

And finally … south of the border. Mexico has eight gigawatts of wind power installed today … more than thirty-three hundred turbines across sixteen states. But the next chapter is already being written. The government plans to add nearly seven gigawatts of new wind capacity this term … part of a broader push for thirty-two gigawatts of new generation overall. More than two gigawatts of wind projects are pending allocation right now … and the industry estimates this next wave could mobilize four to five billion dollars in investment … building thirteen to fourteen new wind farms before the decade is out. The final decisions come in October.

Here is what stands out this week. The wind industry is no longer just selling kilowatt-hours to utilities … it is selling energy independence directly to manufacturers … and that changes the customer base entirely. At the same time … capital for new wind projects is coming from places it never came from before … export credit agencies … cross-border joint ventures … and government allocation programs with billions on the line. The money is there … but so are the risks … currency swings … extreme weather … and the constant reshuffling of who owns what. For wind energy professionals … the takeaway is simple … the industry is growing … but the business model around it is getting more complex by the quarter.

The turbines keep turning.

And that’s the state of the wind industry for the 5th of July 2026. Join us for the Uptime Wind Energy podcast tomorrow.

https://weatherguardwind.com/engie-storm-mexico-gw/

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Renewable Energy

How Trump Outwitted the Founding Fathers Will Be an Enduring Mystery

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What Trump has done to this nation and how he accomplished it will be the subject of much discussion by historians for as long as human civilization exists on Earth.

Certainly, the Founding Fathers never imagined that Americans would elect such a manifestly terrible person, and that congress would be so feckless to keep him in power.

How Trump Outwitted the Founding Fathers Will Be an Enduring Mystery

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Renewable Energy

The Economics of Mass Deportation

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The only one in America whose life is improved by mass deportation is Donald Trump.

Ignorant and hateful people (the MAGA base) love the idea of punishing people with brown skin. Yet working class white supremacists actually lose financially, as prices rise due to loss of workers in low-income jobs in agriculture, restauranting, childcare, landscaping, construction, hospitality, etc.

The Economics of Mass Deportation

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