Published

11 months ago

January 8, 2025

Alice Rush

On Power-Up this week, LM Wind Power’s method using thermal imaging to estimate power performance, ZF’s system which allows the generator to be rotated independently from the gearbox, and a patent for a flame-throwing trumpet.

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Phil Totaro: This is Power Up, where groundbreaking wind energy ideas become your clean energy future. Here’s your hosts, Allen Hall and Phil Totaro.

Allen Hall: First up this week, Phil, is an idea from LM Wind Power, and this idea uses thermal imaging to turbine turbulence and then to use that data to predict the power calculations and energy production.

on an actual wind turbine blade. So this approach is thermal imaging can detect turbulence and losses on a blade. If you can use that data then in a calculation, in a predictive model, then you can pretty well estimate what the power output of a turbine would be. This is a really useful piece of information.

If you’re trying to predict the outcome of a wind farm and what the power production will be like.

Phil Totaro: Yeah. And this is, this is not new in terms of utilizing, infrared technology. We’ve actually done this before in the industry, not only for, remote inspections and things like that.

But to apply this technology to an operational asset where you’re using that output for modeling purposes is unique because what they’re able to actually detect is changes in surface roughness. So when it comes to figuring out leading edge erosion and how much is that actually dinging your performance and your annual energy production, this comes in kind of handy.

But it’s my understanding that, LM isn’t the only company that’s been investigating this, right?

Allen Hall: Yeah. There’ve been several efforts in the EU to do this. We’ve had some of them on the podcast. The technique is very fascinating, because you wouldn’t think you could see turbulence with an infrared camera and, but you can.

And once you do that, then you can use the BEM method of calculating power production, which is how a lot of Blazer design is with the BEM method. The tools are all available. The missing link was just really determining how much turbulence there was on a blade. And this idea makes an infinite amount of sense if it can be put into production.

There’s a lot of theoretical things we talk about on the podcast that are really hard to implement. This is going to be one of them. Getting some real thermal images off of blades is not the easiest thing in the world to do.

Phil Totaro: Yeah, but it makes for a valuable IP for a company like LM to own and there’s a high degree of likelihood that this technology could be obviously leveraged by GE their parent organization, or even licensed to some of these other companies.

Our next

Allen Hall: idea is

Phil Totaro: from ZF Frederick

Allen Hall: Schaffen, AG, and it is a patent that presents an innovative design for maintaining wind turbine gearboxes with integrated generators. Now, the key innovation is a special gearing system that allows the generator rotor to be rotated independently from the gearbox output shaft during maintenance.

And this enables technicians to safely position and lock the rotor for service without having to completely remove the gearbox. There’s a lot of operational improvements. If this could be done, Phil, is this being implemented anywhere? Have you seen it out in the field?

Phil Totaro: Yes, actually. So that’s a really great question because, ZF is obviously a pioneer in gearbox technology and has designed a lot of the going back a number of years, 15, 20 years, they were the pioneer of a lot of the large capacity.

Gearboxes, they famously brought a gearbox for a 10 megawatt wind turbine to the Wind Energy Hamburg event one year. And, we’re starting to get even bigger. But you mentioned something else that was pretty key to this, which is, There’s a lot of companies that are starting to shift towards this kind of integrated semi direct drive, what they call semi direct drive.

It’s basically a permanent magnet generator connected and coupled to a, at least a two or maybe three stage gearbox. So that you can you know, at least get a a decent RPM going. The higher the RPM you can get on the generator, the more efficient and smaller the air gap you can usually maintain on the generator.

So having that technology implemented, but also a way to facilitate service, because as you mentioned, in the past with, without this technology and without this design, somebody wanted to. service a and an integrated generator design, particularly on a larger onshore or what this was originally designed for, which is an offshore machine.

You would have to bring out a big crane. And you might have to actually physically decouple, or you could try using one of these onboard cranes. There’s a few companies out there that are obviously doing that technology as well. But it still meant you had to physically decouple.

So the fact that they’ve designed something that is integrated into the system that allows you to decouple without physical removal of the gearbox or the generator, that’s actually very useful from a maintenance standpoint. And that’s why this is one of the more Useful inventions and clever inventions that is, actually has a practical purpose in the industry.

Allen Hall: Now for our fun patent of the week is a 1981 application that describes a trumpet modified to shoot controlled flames. from its bell. Now the inventor created the system using a butane cartridge mounted on the trumpet’s body with a valve mechanism allowing the musician to control the gas flow and a spark wheel ignition system at the bell that creates an impressive flame shooting out the end of the trumpet.

Now, Phil, in the era of Michael Jackson getting his hair caught on fire from pyrotechnics, this idea seemed that it would have a very short lifetime, because that happened just after this patent would have been released.

Phil Totaro: Yeah, and I don’t know that I’ve ever actually seen anybody do this in real life with a flamethrower trumpet, although Ron Burgundy famously did have his flamethrowing flute in Anchorman, cool. Hollywood at least likes ideas like this, and maybe that’s the only way we can ever see it implemented.

Allen Hall: Would they have had to pay rights for that, to put that in the movie? Even though it’s a trumpet that’s shown in the patents, would it have been pretty much any instrument that shot off flames that was blown into a flute or a trumpet?

Phil Totaro: mean, the mechanism is still the same. Alan, this is actually a really good and important question for everybody to hear and understand. I actually don’t think so, because the patent application we’re talking about for the trumpet, it’s specific to a trumpet. And so that, that actually comes into play a lot in even, the wind energy sector that we talk about, because there’s all kinds of ideas that people have where they write the patent claims very specifically to offshore wind or onshore wind.

And you’ll also see companies go the other direction where they write something highly generic, whether it’s related to a generator or a blade. They may not say. A wind turbine blade. They may even be talking about utilizing the technology on a fan blade in a turbo generator or an airplane engine.

So to answer your question, no, I don’t think they owe royalties for this guy’s flamethrowing trumpet patent. But it’s, it does actually make a big difference the way you construct your claims because if flamethrower trumpet man had had just been, a little less specific about this being a trumpet in his patent claims, then he might’ve been able to get some royalties out of I think it was Warner Brothers that was the producer and distributor of of Anchorman.

So who knows? Maybe Will Ferrell owns the patent for

Allen Hall: the flamethrowing flute.

https://weatherguardwind.com/infrared-estimate-zf-gearbox/

Renewable Energy

Raw Stupidity: Yet One More Reason that Trump Must Go

Published

18 hours ago

December 13, 2025

Alice Rush

From the Huffington Post:

A senior FBI officer struggled to answer basic questions about antifa, despite characterizing the organization as “the most immediate violent threat” the US faces.

At a House Committee on Homeland Security hearing on Thursday, Michael Glasheen, operations director of the national security branch of the FBI, said he agreed with President Donald Trump that antifa is one of the greatest national security threats to the country.

The answer, of course, is that “Antifa” is a concept, not an organization. It refers to anyone who is against fascism. It has no headquarters, no leaders, and no members.

Now, it is true that people with these views can be violent. When my father led a crew of his fellow anti-fascists, flying a B-17 bomber in World War 2, they completed 29 successful missions, destroying Nazi oil refineries. Were Nazi soldiers killed in the process? I never asked him that, and he probably didn’t know, as they were flying at 29,000 feet, but it seems extremely unlikely that no one died.

In peacetime, we antifa people are non-violent. We may be marching for BLM, or encouraging the use of science in policymaking, or expressing our view that the United States should not have a king.

The FBI must understand this; they must be saying this purely to placate Trump. No one can be that stupid.

Raw Stupidity: Yet One More Reason that Trump Must Go

Renewable Energy

Hydrokinetics Gone Awry

Published

2 days ago

December 12, 2025

Alice Rush

When I came across the meme at left, I was instantly reminded of a guy who called me from Baltimore, MD about 15 years ago, anxious for me to hunt up investors in an invention he had created. I was having a hard time understanding the concept he was describing, and so he told me, “Think of it as a river in a box.”

“Ah! Now I get it. You have a box full of standing water. You add energy to it to get it moving, and then our extract energy from the moving water. And you think that you can extract more energy than you put into it.”

“Yes!” he said excitedly.

I calmly told him that this violates the laws of physics, specifically the first and second laws of thermodynamics, but he wasn’t “having it.” I wished him a pleasant good night and asked him to let me know when he had built a working prototype.

I’m still hoping to hear from him again.

Hydrokinetics Gone Awry

Renewable Energy

Benefits of Solar Power Solution in Manufacturing Facilities

Published

2 days ago

December 12, 2025

Alice Rush

In today’s dynamic manufacturing world, energy is more than just a utility; it’s the spark that keeps production running. Industrial facilities, powered by massive engines and heavy machinery, often operate 24/7, driving output but also consuming enormous amounts of electricity.

The issues? Soaring energy costs and a growing environmental footprint.

Sometimes it’s like a cycle that often feels impossible to break, but what if your facility could draw energy from a cleaner, more reliable, and cost-effective energy source?

Yes, you heard it right, and that’s where solar power comes in!

As electricity prices continue to rise and corporate sustainability goals become more pressing, manufacturers are rethinking how they power their commercial operations.

Therefore, solar energy is emerging as a game-changing solution, offering reliability, long-term savings, and a sustainable path forward for the Australian manufacturing industry.

In this blog, we’ll explore how manufacturers are successfully implementing solar power, featuring real-world case studies from Cyanergy that highlight both the business advantages and environmental impact.

So, let’s explore how solar energy can help your manufacturing facility reduce costs and enhance efficiency, achieving long-term sustainability.

In this blog post:

Why Solar Energy Is Essential for Modern Manufacturing Facilities?

In Australia, manufacturing facilities typically have large roof or yard footprints, significant and relatively
stable electrical loads, including lighting, motors, HVAC, and other machinery. So, the energy used every day is
enormous.

By harnessing the sun’s energy, factories can significantly cut operating
costs, reduce carbon emissions, and gain greater control over long-term energy stability.

Beyond the environmental benefits, solar power also strengthens a company’s competitive edge and brand reputation in
an increasingly eco-conscious market.

Here we’ve penned down the importance of solar power in the manufacturing industry:

Energy cost mitigation

So, how solar energy reduces manufacturing costs in Australia?

With electricity prices rising and energy market volatility increasing, incorporating solar energy offers a
way to
reduce grid dependency and lower utility costs in the long term.

Ensure Operational Continuity & Resilience

Solar panel systems, when paired
with
battery storage, can help smooth peak energy demand, reduce grid dependence, and improve functioning
time.

Promote Sustainability and Brand Value

In larger industries, many manufacturers are under pressure from customers, regulators, investors, and
internal
stakeholders to reduce
their carbon footprint.

Solar helps them to achieve energy freedom, powering businesses with a sustainable energy source.

Increase Asset value & ROI

Solar systems, when sized appropriately and properly optimised, can deliver payback in a few years and
continue to
provide savings thereafter.

According to Cyanergy’s capability statement, we delivered a 490
kW system that generated 752 MWh for a manufacturing client, with a 37-month payback period.

This shows that industrial-scale solar can deliver real, practical results for manufacturers.

Now, let’s examine solar power solutions for manufacturing facilities, case studies, and best practices to ensure a
clear understanding.

Case Studies from Cyanergy: Real-World Manufacturing Success in Australia!

In this part of the blog, we have selected three examples from Cyanergy to illustrate how manufacturing facilities are utilising solar energy.

These are not generic installations; these are production-oriented businesses taking real steps across different states of Australia.

1. Uniplas Mouldings International – Wetherill Park, NSW

Project Overview

System size: 490 kW solar system installed in staged phases
Investment: AUD $591,823.71.
Annual generation: 752 MWh
Yearly energy costs before solar: approximately $647,000.
After solar: $456K, which is approximately 55% of the previous
Payback period: 37 months

Why it matters

For Uniplas, a large industrial manufacturer, the solar system not only significantly reduces their operating energy
costs, but the payback of just over 3 years means that the return on investment is also attractive for the
business.

The staged approach also allowed them to access multiple subsidies and implement the project rapidly; for example,
the first stage of 200 kW was completed in four weeks.

This clearly shows how manufacturing operations can incorporate
solar without any significant disruption.

2. AC Laser – Thomastown, VIC

Project Overview

System size: 99.45 kW
Annual generation: 141.75 MWh
Annual electricity cost before solar: $79,000.
After solar: $38,160, a reduction of more than 50%
Payback period: 26 months

Why it matters

This is a smaller-scale manufacturing facility compared to Uniplas, yet the results are impressive: a more than 50%
cost reduction and a shorter payback period.

This shows that not only large-scale commercial properties but also mid-sized manufacturing operations can benefit
from solar, not just large ones.

Insights Gained from the Case

Don’t wait until your business is huge, as size is scalable.
The solar system’s size aligned well with the manufacturing load, saving thousands of dollars.
Rapid ROI shows manufacturing facilities can justify solar as a capital investment for their business.

3. Specialised (Cycling-Industry manufacturer) – Port Melbourne, VIC

Project Overview

System size: 39.6 kW
Annual generation: 47.32 MWh
Electricity cost before solar: $26,720; after solar: $17,770
Payback period: 45 months

Why it matters

Although smaller, this project depicts that solar energy is a viable option for manufacturing across various sizes
and sectors, even in facilities with a relatively small carbon footprint.

The case emphasises sustainability as a business value and how solar can support brand positioning as well as cost
savings.

Major Takeaways

Solar supports both cost and branding sustainability
goals.
Even medium-sized systems can provide meaningful savings.
The ROI
generated must be viewed in terms of both financial and reputational benefits for any
business, whether it’s large or small.

Is Now the Right Time for Manufacturers to Transition to Solar Energy?

After knowing the numerous benefits of solar solutions, you may be tempted to go solar. However, transitioning from
traditional energy sources to solar energy comes with a cost.

From government
incentives to long-term cost savings, the financial case for solar energy is compelling.

Still wondering, is it time for businesses to go solar? Here’s why you should act now:

Electricity prices continue to rise in many markets, strengthening the return on investment for solar
energy.
Many governments and utilities offer incentives, favourable tariffs, or rebates
for industrial solar projects.
Day by day, the pressure for sustainability reporting and corporate social responsibility (CSR) is
intensifying. Manufacturing facilities with high energy loads are often subject to inspection.
Technology costs have fallen recently, making solar panels and inverters
more affordable than ever and reducing payback time.
With the right sizing and execution, the solar system becomes a long-term asset that pays for itself,
releasing capital for other manufacturing investments.

Best Practices for Manufacturing Facilities Considering Solar

Solar can be a powerful game-changer for manufacturing companies and large commercial buildings when implemented correctly.

But that doesn’t mean it’s as easy as flipping the switch.

Therefore, before investing in Solar power, ensure you understand every step that leads to real savings and sustainable success for your business.

1. Conduct a detailed energy assessment & align solar to load

Before installation, it is essential to understand your manufacturing facility’s energy usage patterns, including the peak usage limit, daily load curves, and seasonal variations.

The better the match between system size, orientation, and actual usage, the higher the yield and the quicker the payback.

At Cyanergy, we provide a customised design based on site analysis.

2. Use staging or modular deployment

If you have a large manufacturing site, you may benefit from staging the solar solution in phases.

For example, in Uniplas’s case, the installation was divided into three stages. This enables access to multiple subsidies, enhances cash flow, and mitigates the risk of disruption.

3. Optimise your system size & measure consumption rate

Over-sizing or under-sizing can both cause significant loss in a business. Therefore, the design should minimise waste and maximise the use of solar energy on-site.

As in AC Laser’s mid-sized facility, a 99 kW system fits their load and delivers huge savings.

4. Check your rooftop or plant infrastructure

Is your rooftop compatible with solar panel installation?

For manufacturing facilities, factors such as roof strength, shading, orientation, structural constraints, and maintenance access are crucial.

Ensure the facility can support panels, inverters, wiring, and monitoring systems without compromising building aesthetics.

5. Perform regular monitoring & performance tracking

Everything requires a certain amount of care and maintenance to function properly over time. The story is the same for a solar panel system.

Real-time monitoring allows you to spot performance issues, shading effects, degradation, and inverter downtime.

Cyanergy emphasises continuous monitoring post-installation.

6. Research on financial modelling & payback analysis

When going for solar, always calculate realistic payback periods, ensure system cost fits within capital budgets,

You should also check the available incentives, tax benefits, payback time, and how to stack several rebates for maximum savings.

For example, many Cyanergy projects offer a 2–4 year payback, with several solar rebates that can be combined with the VEU Rebate.

7. Align with sustainability and your brand strategy

In manufacturing factories, incorporating solar energy can be a substantial component of a broader sustainability strategy. Why?

Solar reduces your dependency on harmful fossil fuels, cutting greenhouse gas emissions.

It positions your brand and promotes your business, demonstrating corporate responsibility and improving stakeholder perception.

8. Maintenance & lifecycle planning

Solar systems require periodic maintenance, inverter replacements, cleaning, and monitoring.

So, manufacturing facilities should incorporate service arrangements into their design. Plan for system longevity, degradation, and eventual replacement or upgrade to ensure optimal performance.

9. Consider adding Battery storage

Even though optional, integrating battery storage or demand management can enhance value by enabling peak shaving, reducing demand charges, and storing excess energy for nighttime use or during grid outages.

10. Engage stakeholders and minimise disruption

In manufacturing, you can’t easily stop production. Plan your solar installation during low-production periods, coordinate with your team, and prioritise safety to minimise downtime.

Final Notes: Ready To Take The Next Step?

For manufacturing facilities, solar power isn’t just about being eco-friendly; it’s a smart business move for Australians. Cyanergy’s case studies showed that even large manufacturers can achieve paybacks of 2–4 years, reduce costs, lower emissions, and enhance brand value.

With proper planning, energy assessment, correct system sizing, phased installation, and active monitoring, solar can deliver lasting benefits.

So, if rising energy bills or sustainability goals are on your radar, it’s time to view solar energy as an innovative manufacturing solution, apart from just a renewable energy source.

Reach out to Cyanergy, conduct an energy audit, and engage a solar specialist with manufacturing experience today. Cyanergy is here to help!