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Next Generation Offshore Wind Turbines – 7MW Busbar Systems

Project Overview

A global manufacturer of offshore wind turbines was developing generator busbars for the next generation of 7MW machines. The customer required an innovative, cost-effective, and reliable manufacturing partner capable of improving the design, production process, and long-term supply performance.

Challenge

The initial customer design was highly complex, difficult to manufacture, and extremely costly. The project required a cost-efficient manufacturing route for intricate ring-rolled busbar assemblies, incorporating brazing, insulation, and testing. Furthermore, the customer’s contract included stringent performance requirements — with 100% on-time, in-full (OTIF) delivery targets backed by significant penalty clauses for delays.

Solution

H V Wooding worked collaboratively with the customer’s engineering team to review the design criteria and identify opportunities for improvement. A new busbar design and packaging solution were proposed to simplify manufacturing and reduce costs. A full production process was developed covering ring rolling, insulation, brazing, and assembly, supported by sample production for evaluation and validation. To ensure long-term continuity, a framework agreement was established for ongoing supply.

Results

The partnership resulted in a technically and commercially superior solution. H V Wooding’s engineering expertise directly influenced the customer’s design team, leading to improved manufacturability and reduced assembly time on site. The newly developed process ensured 100% OTIF performance, securing confidence in delivery reliability and eliminating contractual risk for the customer.

Added Value

Through design optimisation and process innovation, H V Wooding delivered up to 50% cost savings compared with the original concept. The customer benefitted from a single-source, fully managed supply chain and enhanced product performance. This collaboration established a dependable manufacturing route for future offshore wind turbine projects and reinforced H V Wooding’s position as a trusted partner in the renewable energy sector.

Trusted by Leading Brands

H V Wooding works with leading organisations across the renewable energy, electrical, and advanced engineering industries, including GE Renewables, Schneider Electric, Honeywell, Rolls-Royce, and CERN. Our precision manufacturing capabilities and technical expertise enable innovation and reliability in every project.

Commitment to Quality

Certified to ISO 9001:2015, ISO 14001:2015, and ISO 45001:2018, H V Wooding maintains the highest standards of quality and process control. Our in-house Buffer Management System, advanced metrology, and application of LEAN and FMEA methodologies ensure repeatable precision, traceability, and on-time delivery across all high-performance manufacturing projects.

Laser Cutting

H V Wooding provides precision laser cutting services in copper, aluminium, and electrical steels for laminations, busbars, and complex components. We deliver fast-turnaround prototyping and mid-volume production with tight tolerances and clean edges.

Wire Erosion

H V Wooding provides precision wire erosion (EDM) services with tolerances down to ±5 microns. We manufacture components for the aerospace, EV, medical and research sectors, offering exceptional accuracy, clean finishes and rapid turnaround.

Presswork & Tooling

H V Wooding designs and manufactures precision press tools and provides high-quality presswork for a range of industries. Our in-house toolroom ensures fast turnaround, consistent quality and cost-effective solutions from prototype to volume production.

Busbar Manufacture

H V Wooding designs and manufactures precision copper, aluminium and flexible busbars for power, EV and renewable energy systems, with full insulation and finishing options.

Powder Coating

Powder coated busbars for EV, hybrid and energy systems. UK-made with holiday-tested insulation, precise fit and over 50 years’ precision manufacturing expertise.

Motor Stator/ Laminations

H V Wooding produces precision electrical steel laminations using laser cutting, wire erosion and press tooling. We support prototyping through to series production for magnetic assemblies, motors, transformers and research applications.

Electroplating

In-house electroplating in tin, zinc, nickel and silver. Rack and barrel options, with lab and X-ray testing to ensure coating accuracy, durability and quality.

Assembly

Mechanical, busbar and general sub-assembly services. Welding, fitting, packaging and line-side delivery with ISO-certified quality and cost-effective outsourcing from H V Wooding.

Renewable Energy

Busbars, laminations and assemblies for wind, solar and tidal energy. H V Wooding supplies GE, Vestas and Siemens with precision renewable components from design to volume production.

Electric Motors

Adding value to our customers by optimising the design and manufacturing of complex Motor Laminations and Core Packs. Our core activity in this arena is focused around demanding and complex high end motor applications where we are able to offer customers years of experience in working with a wide range of materials and complex geometries to achieve the demands of the new generation industries.

Electrical Switchgear Manufacturing Solutions

Supporting our customers manufacturing world class products in the Electrical Switchgear, Power Generation and Power Distribution markets.

Electric & Hybrid Vehicle

UK manufacturer of busbars, motor laminations and core packs for hybrid and electric vehicles. Prototype to mid-volume production with precision processes including wire EDM, laser cutting and stamping.

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