HARMONISING DESIGN & MANUFACTURING OF ROTOR BLADES · HARMONISING DESIGN & MANUFACTURING OF ROTOR...
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Transcript of HARMONISING DESIGN & MANUFACTURING OF ROTOR BLADES · HARMONISING DESIGN & MANUFACTURING OF ROTOR...
PONTIS OCTOBER 2012
HARMONISING DESIGN & MANUFACTURING OF ROTOR BLADES February 26th 2013 Edgar Suselbeek
CONTENTS
» Company Profile
» Design and manufacturing conflicts
» Manufacturing improvements - Business case 1: Preforming for Tygo75 blade
» Design improvements - Business case 2: Modulisation LE & TE
» Summary
» Questions
2 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
3 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
PONTIS ENGINEERING
» Founded in 2007 by DJ Kootstra and S. van Breugel.
» Development of advanced composite products, including equipment.
» Team of 16 dedicated engineers & specialists based in Europe (The Netherlands), Asia (China), and the Americas (USA).
» Customer base of renowned companies, 6 Stock market listed customers.
» One-stop-Shop solutions from Conceptual Design to Logistics.
» Pontis focusses on five rapidly growing sectors for innovative composite applications.
CONTENTS
4 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
» Company Profile
» Design and manufacturing conflicts
» Manufacturing improvements - Business case 1: Preforming for Tygo75 blade
» Design improvements - Business case 2: Modulisation LE & TE
» Summary
» Questions
DESIGN AND MANUFACTURING CONFLICTS
5 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
Manufacturing Requirements Fast production
Lowest cost
Six sigma quality, no rejects
Robust and simple construction
Design Requirements Lowest loads (Lowest weight)
Smooth blade
High profile tolerances
Slender blade design
DESIGN AND MANUFACTURING CONFLICTS
6 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
Example of tight tolerance large blade
TE thickness 2-10 mm
CONTENTS
7 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
» Company Profile
» Design and manufacturing conflicts
» Manufacturing improvements - Business case 1: Preforming for Tygo75 blade
» Design improvements - Business case 2: Modulisation LE & TE
» Summary
» Questions
Automation Manufacturing Benefit • Less man hours • Quicker cycle time
Design Impact • Less intricate parts that can be made
by machine
MANUFACTURING IMPROVEMENTS
8 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
Preforming 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
BUSINESS CASE: PREFORMING FOR TYGO75
9 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
» Tygo75 − Pontis in house IEC class1 blade design for
6MW offshore market
− Blade is designed using Pontis preforming technology and blade infusion simulation to optimize manufacturing cycle time
» Benefits − 50% reduction in-mould layup cycle time
− 10% of the cost of other automated solutions
− Improved quality control
Scope: Calculate manufacturing improvement of preforming on Tygo75 blade
10 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
CONTENTS
» Company Profile
» Design and manufacturing conflicts
» Manufacturing improvements - Business case 1: Preforming for Tygo75 blade
» Design improvements - Business case 2: Modulisation LE & TE
» Summary
» Questions
DESIGN IMPROVEMENTS (1 OF 2)
11 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
Corrugated Spar Blade Performance • Potential weight savings for
equivalent strength.
Manufacturing Impact • Complex to produce, especially
if spar caps are included for max benefit.
Wing Box Construction
Blade Performance • Potential weight savings for
large chord blade sections.
Manufacturing Impact • More parts. • New approach/ learning curve
carbon stringers spar cap shear webs
Transverse ribs
DESIGN IMPROVEMENTS (2 OF 2)
12 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
Modulisation Blade Performance • Replaceable, customer specific
and/or upgradable higher performance parts
• Weight savings
Manufacturing Impact • Connection solutions required • More (complex) parts
modular tip
Materials Blade Performance • Lighter blade
Manufacturing Impact • Switch in process • Currently high cost
BUSINESS CASE: MODULISATION LE & TE
13 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
Scope: Considering benefits & tradeoffs of a modular LE/TE
LE module TE module
Spar Caps
Shear Webs
Composite Panels
Tygo75 blade
Tradeoffs Weight neutral, to limited weight increase
Additional mould, assembly process
14 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
LE attachment
Benefits Improves long term performance
Anti-erosion, anti-icing, lightning protection configuration
Consistency in manufacturing
LE module
Increase of performance up to 3% during the lifetime of the turbine.
BUSINESS CASE: MODULISATION LE & TE
15 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
Tradeoffs Connection methods
New manufacturing methods
Additional moulds & assembly process
TE attachment
Benefits Weight saving
Advanced aero dynamic features
No structural part
TRADITIONAL TE
MODULAR TE
Weight saving of 4-6 % over the full length of the blade
BUSINESS CASE: MODULISATION LE & TE
SUMMARY
16 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013
» Conflicting interests design and manufacturing inevitable.
» Solution is to find optimum for each product.
» Important start is to make the manufacturing part of design in an early stage.
» In the development of large blades alternative options should be considered as traditional techniques will not be sufficient anymore. − Preforming technology can save up to 50% in-mould lay-up time for only 10%
of costs other automation solutions.
− Modulisation can bring up to 4-6 % weight savings.
− Lower weight means higher performance.
THANK YOU
Contact • [email protected] • www.pontis-engineering.com
17 | ADVANCES IN ROTOR BLADES FOR WIND TURBINES : 26 FEBRUARY 2013