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CHALLENGES IN THE DESIGN
AND MANUFACTURING OF
LARGE WIND TURBINE BLADES
Specialist
in development
of advanced
composite products
Pim de Laat
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CONTENTS
» COMPANY PROFILE
» BRIDGING DESIGN & MANUFACTURING
» CHALLENGES IN DESIGN » BLADE MASS » BLADE STABILITY/BUCKLING » MATERIALS
» CHALLENGES IN MANUFACTURING » PRACTICAL CHALLENGES » TECHNOLOGY » QUALITY
» SOLUTIONS
» SUMMARY
» QUESTIONS
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016
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PONTIS ENGINEERING:
INTRODUCTION
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016
» Founded in 2007
» 25 Specialists in Composite Engineering Six Sigma trained
» Offices in Netherlands (Amsterdam), USA (Boston, Ma)
and Asia (Beijing)
» Global customer base incl 7 stock market listed
companies.
» Pontis focusses globally on growing markets for innovative
composite solutions.
» Expertise in wind:
• Blades ranging from 6 to 89 meter
• 6+ offshore blades built
• More than 10 technology transfers done
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BRIDGING DESIGN &
MANUFACTURING
Manufacturing Requirements
Fast production
Lowest cost
Six sigma quality, no rejects
Robust and simple process
Design Requirements
Lowest loads (Lowest weight)
Smooth blade
Accurate profile tolerances
Slender blade design
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016
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DESIGN CHALLENGES
DESIGN OF BIG BLADES LEADS TO MULTIPLE CHALLENGES:
CONFLICTING REQUIREMENTS:
» Aerodynamics
» Blade stiffness
» Blade mass -> Loads
» Blade stability (e.g. TE buckling)
» Logistics
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016
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BLADE MASS
KEEPING THE MASS AT AN ACCEPTABLE LEVEL
» What is this level?
» Balance between mass, loads, costs and aerodynamics
POWER IS LENGTH^2 (SWEPT AREA)
MASS IS LENGTH^~2.6*
DUE TO THIS, WE ARE FORCED TO CONSIDER NEW TECHNOLOGY/OPTIONS
» Superior material selection
» Adapt loads to structure e.g. 3rd webs
» Root connection technology
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016
*depends on blade family.
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BLADE STABILITY/BUCKLING
NEW BLADE DESIGN DRIVERS
» Higher Loads
» Lager panel spans --> TE buckling
» Thinner Spar-Caps* --> Spar cap buckling
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016
* use of different materials
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MATERIALS
MATERIAL PROPERTIES
» mech. prop. no longer sufficient ->
requirement for higher material properties
E-glass HM Glass Carbon
» Polyester --> Epoxy --> PU and MMA?
MATERIAL PROCESSING
» Prepreg, Infusion, Pultrusion and root
connection
» Location, logistics experience (skill set)
HSE etc.
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CONTENTS
» COMPANY PROFILE
» BRIDGING DESIGN & MANUFACTURING
» CHALLENGES IN DESIGN » BLADE MASS » BLADE STABILITY/BUCKLING » MATERIALS
» CHALLENGES IN MANUFACTURING » MANUFACTURING GENRAL » PRACTICAL CHALLENGES » TECHNOLOGY » QUALITY
» SOLUTIONS
» SUMMARY
» QUESTIONS
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016
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MANUFACTURING GENERAL
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016
“Typical” mould cycle time for serial production rotor blade
2002 2013 20??
» Focus Material lay-up.
» Full automation still too expensive
» Average ROI 3 – 5 yrs
» Need for more flexible dedicated
solutions
» Manufacturing of smaller parts may
increase the supply chain.
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PRACTICAL CHALLENGES
» DIMENSIONS (MAX CHORD) BECOME
EXCEPTIONALLY LARGE
» TE THICKNESS, TOLERANCES STILL BASED
ON 45M BLADE
» BONDING PASTE POT LIFE APPLICATION TIME?!
» MANAGING OVERALL MFG PROCESS RANGING
FROM LOGISTICS TO DOWNTIME
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TECHNOLOGY
» PRODUCTION STATUS COMMUNICATION
INCREASINGLY CRITICAL FOR LARGER BLADES
(JIT)
» LOADING MATERIALS, MASS INCREASE
LENGTH^~2.6* INCRECE LAY-UP TIME
POTENTIAL ^~2.6*
» BLADE INFUSION, INCREASING COMPLEXITY
» COMPONENT HANDLING, TOOLING, PARTS ETC
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016
*depends on blade family.
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QUALITY
» COST OF DEVIATIONS GROW EXPONENTIAL WITH LENGTH
OF THE BLADE (MATERIAL AFFECTED)
» CONSISTENT QUALITY (PROCESS STABILITY/CAPABILITY)
» CONTROL/PROCESS DRIVEN QUALITY ISSUES
» WHAT IS ACCEPTABLE?
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CONTENTS
» COMPANY PROFILE
» BRIDGING DESIGN & MANUFACTURING
» CHALLENGES IN DESIGN » BLADE MASS » BLADE STABILITY/BUCKLING » MATERIALS
» CHALLENGES IN MANUFACTURING » PRACTICAL CHALLENGES » TECHNOLOGY » QUALITY
» SOLUTIONS
» SUMMARY
» QUESTIONS
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016
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SOLUTIONS: MODULAR
BLADES
TREND TO CONSIDER MODULAR BLADE CONCEPTS AS WELL AS BLADE EXTENSIONS
IN GENERAL ALL CONECTIONS ADD MASS, BUT COULD BE A GAME CHANGER WHEN THE FOLLOWING IS CONSIDERED:
» Logistics
» Increase supply chain
» Ease of repair
» Accuracy
» Blade family extension
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SOLUTIONS : NEW DESIGN
FEATURES
PONTIS PATENT APPLICATION
» Damage tolerant edge.
» Low modulus TE that can not
buckle.
» Move the load carrying material
inwards, however overall change
in mass is neutral when increased
stability is considered.
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SOLUTIONS : MATERIAL LAY-UP
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016
35% inmould cycle time reduction achieved
Ready for Automation
Manufacturing Benefit
• Less man hours
• Quicker cycle time
Design Impact
• Less intricate parts that can be
made by machine
Preforms
Manufacturing Benefit
• Reduce in-mould cycle time
• More consistent high quality product
Design Impact
• More time spent optimizing laminate
layout for preforming purposes.
• Additional moulds
Prefabs
Manufacturing Benefit
• Reduce in-mould cycle time
• More consistent high quality product
Design Impact
• Neutral
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DESIGN IMPROVEMENTS (2 OF 2) SOLUTIONS: PROCESS
AUTOMAZATION
ADVANCE KITTING OF CONSUMABLES
AUTOMATION INFUSION
» Sensing technology (in mould??)
» Improved resin quality
CURE OPTIMIZATION THRU SENSING
» Insulation optimization
» Automated cure cycle thru sensing
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016
Photo: Hedrich
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SOLUTIONS: CONTINUOUS
IMPROVEMENT
GOAL TO CONSTANTLY IMPROVE MFG PROCESS;
» Time,
» Quality,
» Costs
» How:
- Standardization of process, - Kaizen events (small task groups) - Involvement of personal - 5S --> lean journey
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SUMMARY
» CONTRADICTION BETWEEN DESIGN AND
MANUFACTURING INEVITABLE
» EXPONENTIAL MASS INCREASE WILL
REQUIRE SUPERIOR MATERIALS AND BLADE
ARCHITECTURE
» DESIGN CHALLENGES ON BLADE
STABILITY/BUCKLING
» INCREASED MANUFACTURING CHALLENGES
FOR BIG BLADES
» MANAGE BLADE QUALITY --> SIX SIGMA
» ADAPT /TAILOR PROCESSES TO SPECIFIC
PRODUCT DEMANDS
» TREND TOWARDS OPTIMIZATION PROGRAMS
CHALLENGES IN THE DESIGN AND MANUFACTURING OF LARGE WIND TURBINE BLADES NOVEMBER 2016