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There’s no doubt we’re in the midst of a climate crisis. In an attempt to curb global warming, we’re reducing our reliance on fossil fuels and focusing on renewable energy sources such as wind. Today, more than 23,000 wind turbines are operating worldwide, converting wind into reliable, large-scale renewable power and supporting energy systems across the globe.
Each wind turbine component plays a critical role in this process, from the rotor blades that capture kinetic energy to the gearbox and generator that convert it into usable electricity. Alongside these major assemblies, precision-engineered components such as springs perform essential mechanical functions. They support load control, vibration management, braking systems, and operational safety, influencing turbine reliability and service life.
At Lesjöfors, we have decades of experience manufacturing specialist springs for demanding renewable-energy applications. In this post, we explore the main components of a wind turbine, how they work together, and the role springs play in supporting performance, durability, and long-term operational stability.
A modern wind turbine is made up of several major components, each designed to support energy capture, power conversion, and operational stability.
As with any large structure, a wind turbine relies on a reinforced concrete foundation to support its weight and anchor it securely, maintaining stability under high winds and vibration. On onshore wind turbines, the foundation is located underground, while on offshore turbines, it sits beneath the water's surface. Offshore wind turbine foundations can take various forms depending on the depth of the water, and in some cases may be floating.
Another key component of a wind turbine is the tower, which can range in height from 80 to 120 meters, depending on the blade rotation circle. It elevates the turbine blades to higher altitudes to capture wind energy more effectively. The tower is generally constructed of steel to give it strength and stability against high winds and other environmental forces.
The rotor consists of the hub and blades and is located at the top of a turbine tower. The rotor rotates the blades that capture wind energy, and the hub connects the blades to the tower.
Wind turbine blades are aerodynamic and wing-shaped for maximum resistance. They’re usually made of lightweight material, such as fiberglass, so that they can easily rotate under the force of the wind’s energy. The most commonly used wind turbines have three blades, each at around 50 meters in length.
The nacelle in a wind turbine is situated at the top of the tower, and it contains key components such as the generator and gearbox, which convert the kinetic energy from the wind into electricity. The nacelle protects these important parts from the elements, ensuring they stand the test of time and perform as they should.
Extension, torsion and compression springs, such as we produce here at Lesjöfors, have a wide range of applications in wind turbines. For example, springs adjust blade position in both onshore and offshore wind turbines. They are also used in generator control systems and to absorb shocks and vibrations in various parts of a turbine, ensuring stability and efficiency under environmental elements.
With the main components identified, the next step is to look at how these systems work together to produce electricity from wind energy.
The yaw system plays a critical role in optimizing energy capture, and it can be found in the nacelle of a wind turbine. It has sensors which detect the wind direction, turning the nacelle accordingly for maximum efficiency. The yaw system is especially useful in environments with changeable wind conditions as it continuously monitors wind direction and adjusts the orientation of the turbine components as needed.
Extension springs (or tension springs) are used in yaw systems to maintain the alignment of the nacelle in line with the wind direction. Ensuring consistent tension, extension springs hold the position of the nacelle and blades against strong winds, preventing wear and damage and optimizing efficiency.
In wind turbines, the pitch system adjusts the angle of the blades, so they face the wind for more efficient energy capture. As the wind changes direction, so do the blades, maintaining optimal rotor speed and power generation. The pitch system also keeps the turbine safe in extreme weather, by feathering the blades so they do not turn with the force of the wind, preventing dangerous overloading.
In the pitch system of wind turbines, springs support blade movement and various fail-safe mechanisms. For example, tension and/or compression springs are components of braking systems, helping halt rotor movements during extreme weather, even following system failure. They’re also used in pitch systems to bring blades to a feathered position automatically when power is lost in high winds. Robust springs, as we manufacture at Lesjöfors, are an important part of maintaining wind turbine safety.
The gearbox of a wind turbine is located within the nacelle and plays an essential part in converting rotational forces into electricity. The gearbox has a series of gears which take the rotational speed of the rotor and increase it to the high speed needed by the generator to create electricity. A wind turbine gearbox can increase rotational speeds by as much as 100 times.
Springs are used in various parts of wind turbines to absorb shock and vibration. They are important components of the pitch and yaw systems, reducing the impact of strong winds or ground movements and protecting more fragile moving parts such as the gears. High-strength springs are also used in the foundations of wind turbines to dampen any vibrations generated by rotational forces, keeping the turbine stable.
There are various braking systems used in wind turbines for safety in extreme weather and power outages, and when conducting essential maintenance. Wind turbines have a mechanical braking system that stops the blades and rotor from turning when the system is shut down. Wind turbines also have aerodynamic brakes, which adjust the angle of the blades to slow rotation speeds in high winds. In addition, hydraulic braking systems are used in wind turbines to actively apply force to the rotor to slow it down if required.
Whether it be tension springs or compression, springs are used across the braking systems of wind turbines. In mechanical systems, high-strength springs apply force consistently to the brake pads, pushing them against the rotor shaft and slowing rotation. During power outages or extreme weather, springs apply mechanical brakes automatically, which is an essential safety feature of wind turbines.
The main types of wind turbine design are:
Horizontal-Axis Wind Turbines (HAWT) are the most common. This typical three-blade dynamic wind turbine can adjust the nacelle and blade orientation in line with changing wind direction. The rotor rotates horizontally similar to an aeroplane propeller, and this design is widely considered the optimum for energy capture.
Vertical-Axis Wind Turbines (VAWT) are less common. The rotor on this design of wind turbine rotates on a vertical axis and the blades can form a helix-type shape. The blades do not need to be rotated to face the wind, although it’s generally not considered as efficient at harnessing wind power as the HAWT.
To conclude, springs are essential components of wind turbines. They perform critical functions in the yaw and pitch systems, optimizing performance and energy capture. They also play a pivotal role in wind turbine safety as part of braking systems and fail-safe mechanisms, and contribute to the stability and strength of turbines against environmental and rotational forces.
At Lesjöfors, we have a 170-year spring manufacturing legacy. As a leading manufacturer for the renewable energy industry, we have years of R&D, a team of expert engineers and state-of-the-art manufacturing processes. We only work with the highest-quality materials, ensuring optimum elasticity, strength and performance in our springs.
Contact us now to discuss your requirements.
The key components of a wind turbine include the foundation, tower, rotor and blades, nacelle, gearbox, generator, pitch and yaw systems, braking systems, and electrical components that transmit power to the grid.
Wind turbines convert the kinetic energy of moving air into electrical energy. Wind turns the rotor blades, which drive a generator through a drivetrain, while control systems regulate speed, direction, and safety under changing wind conditions.
Most modern wind turbines are designed to operate for 20 to 25 years, depending on factors such as location, operating conditions, maintenance practices, and component quality. With proper servicing and targeted component replacement, many turbines can continue operating beyond their original design life.
Springs support critical mechanical and control functions in wind turbines, including blade pitch adjustment, yaw alignment, braking systems, and vibration damping. Their performance directly affects turbine reliability, safety, and service life.
Wind turbines use several spring types, including tension, compression, and torsion springs. These are designed to operate under high loads, variable forces, and demanding environmental conditions found in both onshore and offshore installations.
We are world-leading heavy duty spring manufacturers, delivering the greatest expertise in compression, torsion and tension spring manufacturing.
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