Presentations
From Replacement to Repair: How Modular Axial Flux Generators Enable Lifetime Extension and Circularity
Joe Burchell, Managing Director, CGEN Engineering
Session
Abstract
CGEN Engineering is developing a modular axial flux generator architecture to transform end-of-life strategies for both onshore and offshore renewable assets. The design is truly modular in both rotor and stator, where each module can be independently manufactured, replaced, or upgraded. This enables circularity by reducing waste, extending component lifetimes, and allowing reuse or recycling of individual modules rather than replacing entire systems. The CGEN system integrates direct module-level monitoring, allowing precise fault isolation. Faulty modules can be bypassed, preventing turbine derating or unplanned downtime, with repairs scheduled at optimal intervals. This supports extended operational lifetimes and improved reliability, directly reducing LCoE by >10% and OPEX through higher availability. Proven benefits include over 50% reduction in manufacturing time, more than 30% reduction in mass, and
