dirk kootstra - trends in rotorblade manufacturing

TRENDS IN ROTORBLADE

MANUFACTURING

Specialist

in development

of advanced

composite products

Dirk Jan Kootstra – director & co-founder

Sandia Wind Turbine Blade Workshop - 31 August 2016

|

CONTENTS

» Company Profile

» Trends in Rotorblades

» Logistics

- Segmented blades

» Manufacturing

- Material layup & process control

» Summary

» Questions

2 TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

PONTIS ENGINEERING: INTRODUCTION

» 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

TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

PONTIS SERVICES

DESIGN• (offshore) Blade Design Assessment

• Full tooling design

• Root cause analysis

PROCESS ENGINEERING• Build to print Engineering Package.• Cost out & Efficiency Programs

• Material database and flow simulation

PROTOTYPING• On site prototyping • Process, Moulds & Material validations.• Six Sigma approach.• Full technology transfer and on-site training.

MANUFACTURING• LEAN Manufacturing programs• Cost-out programs• Factory layout• Moulds & Tooling experts


BLADE DESIGN

» Design assessment done on 89 mtr Off-Shore blade.

» Pontis was responsible for validating blade design from third-party blade designer.

» Full blade design capability (structural design – not aero design)

» Implementing Design for Manufacturing

» Carbon sparcaps – validation program with various carbon suppliers

» Pontis provided independent validation of different root connection systems

» CATIA , FEMAP, Solid Edge engineering

Pontis provides independent expertise and saves costs


PROTOTYPING

» 6 Different Designs Offshore blades built.

» Design, Process engineering, manufacturing

» Providing full build to print package

» Pontis Engineers work closely with OEM

» Independent mould & tooling validation

» Supplier Development

Pontis provides technology & the drive to make it happen


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CONTENTS

» Company Profile

» Challenges with Large Rotorblades

» Logistics

- Segmented Blades

» Manufacturing improvements

- Material layup

» Summary

» Questions


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TRENDS IN ROTORBLADES

1. Structural design – blades ranging to 100 mtr

2. Tolerances – tolerance field within 0.2 mm tip

3. Costs (wind vs aerospace) - €8 – 12/kg manufactured (epoxy)

4. Logistics – wind is a global business – local content.

5. Manufacturing – small series with high flexibility.


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CONTENTS

» Company Profile


» Logistics

- Segmented Blades

» Manufacturing improvements

- Material layup

» Summary

» Questions


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LOGISTICS - CHALLENGES

10

» Even offshore blades have to be transported.

» Trailer transport very challenging.

» Larger trailers – weight, stiffness

» Handling – blades are vulnerable


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SEGMENTED BLADES

Segmented blades look like a good solution:

» Joints (bolted or glued)

» Segmentation has manufacturing challenges.

» Costs – remain within cost profile

» Structural challenges


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GOAL:

» Develop improved manufacturing routines and a novel

infusion technology which will significantly reduce the

blade production costs related to quality by 40%, which

represent about 20% of total costs of the wind turbine.

SEGMENTED CHALLENGES:

» Rotor diameter of 184 meter -> high loads to be

transferred through connection.

» Full carbon root segment with connection face diameter

>4 mtr.

CURRENT STATUS:

» Turbine and Blade design completed

» Funding for prototype needed; Project halted.

OFFSHORE 10MW, GEARLESS WIND

TURBINE


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ROTORBLADE EXTENSION

13

GOAL:

» Extension of existing blades


» Maintain blade accuracy during alignment of sections.

» Develop robust process outside controlled environment in

blade production facility.

» Reconnection of spar cap with regards to alignment to

secure sufficient load transfer.

» LPS no challenge, due to full access to inner structure

CURRENT STATUS:

» Robust process developed and validated.

» Testblade produced in 2013 and passed all tests.

» Commercially overtaken by new blade designs


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BLADE INSERT CONNECTION SOLUTION

14

GOALS:

» Develop and produce more precise blades to further improve

manufacturing quality and aero performance.

» Reduce transportation costs by develop logistically better suited

blades.


» Cost of insert solution towards other options.

» Accuracy of aligning segments.

» Defining right material choice for solution.

Current Status:

» First modular blade concept of 49mtr is commercially available

» The ‘Very Long Blade Project' for ETI has being produced. This 80m

blade is to be tested at Narec/UK

» Technology bought by large OEM


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BOLTED SEGMENTATION

15

GOALS:

» Segmentation of blade through bolted solution


» Maintain original blade spec. (mass, stiffness, freq.)

» Spar cap joint.

CURRENT STATUS

» Tip replacements designed and implemented .

» Various design assessments' and prototypes in the business

» Steel to composite solutions applied

Image: GAMESA Innoblade® connectionImage: Enercon

SOLUTIONS FOR LARGE ROTORBLADES 11-03-2016

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PATENTS FILES

16

Vestas

General Electric

General Electric

Modular Wind


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CONTENTS

» Company Profile


» Logistics

- Segmented Blades

» Manufacturing

- Material lay-up & Process control

» Summary

» Questions


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DESIGN AND MANUFACTURING

CONFLICTS

18

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


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MANUFACTURING

19

“Typical” mould cycle time for serial production rotorblade

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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MATERIAL FLOW (TREND)

20

-500.00

0.00

500.00

1000.00

1500.00

2000.00

2500.00

0 20 40 60 80 100 120

Mat

eri

al in

[kg

]Blade lenght [m]

M AT E R I A L F LO W I N KG / H R( P E R M O U L D LO A D I N G )

GOALS:

» Maintain short cycle times

MATERIAL CHALLENGES:

» Mould loading of high amounts of

material.

» In 15 years time the material flow has

increased with a factor of nearly 10.

» Accuracy increased as well.

» loading materials, mass INCREASE

length^~2.6* increase lay-up time

potential ^~2.6*

Current Status:

» Manual labor


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PRACTICAL CHALLENGES

» dimensions (Max chord) become

exceptionally large

» Manufacturing Requirements still based on 45m

blade

» bonding paste pot life

» Managing overall MFG process ranging

from logistics to downtime


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MATERIAL LAY-UP (SOLUTION)

22

Ready for Automation

Manufacturing Benefit

• Less man hours

• Quicker cycle time

Design Impact

• Less intricate parts that can be

made by machine

Preforms


• Reduce in-mould cycle time

• More consistent high quality product

Design Impact

• More time spent optimizing laminate

layout for preforming purposes.

• Additional moulds

Prefabs


• Reduce in-mould cycle time

• More consistent high quality product

Design Impact

• Neutral

35% inmould cycle time reduction achieved


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MATERIAL DEVELOPMENTS

PRE FABRICATED” MATERIALS:

»Rodpack – APPLIED AT SPARCAPS.

»Pultrusions (mainly carbon)

»Root connection solutions.

Resin developments:

»Epoxy and polyester improvements

»Thermoplastic coming (PU and MMA)


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PROCESS CONTROL

24

» Most control visually or manually – operator

dependency

» Cover quality by paper procedures and

training

» In-Process sensoring perceived expensive.

» Limited feedback of process to

development.

BUT

» We need to change mentality

» This is an industrial process


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INDUSTRIAL PROCESS (BMW I3)

25

Car Factory:

• 400 MM€ investment

• max 40000 products a year. (140/day)

Blade Factory:

• 20 – 100 MM€ investment.

• max 840 products a year

Preform approx. 5 kg

“Full” automation looks not feasible for blades (now)


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INFUSION OF RESIN

26

Automation


• Less critical – operator assisted

• Controlled cycle time

Design Impact

• Controlled material property.

10095

90

85

8075

70

6560

55

50

45

40

35

30

25

20

15 Fully injected visually

10

5

0

Estemated time manual 1 day two days, depens on size between 0 and 120 min Depens on resin mix, temperature,

Heat-up

time

Overshoot thermal reaction

If the sensors

are connected

by PLC or PC,

the phases can

Stage 1: Build-up package Stage 2: Setting check Stage 3: Infusion Stage 4: Curing time Stage 5: Demould

Cooling down

Curing

Material layup

(reinforment material

Time

Injecting resin mix

Tem

p (

C̊)

Vacu

um ch

eck

Tem

pera

ture

chec

k

Dega

ssin

g Re

sin

(mix)

Resin

mix

chec

k

Mix

calcu

latio

n

Possible

demold

point

Sensors implemetation will

optimize the quality of the

process

The sensors can

increase time, and

provide measuring

The sensors can increase time, and provide

measuring values during the cure cycle of

the laminate

Possible

demold point

TG sensor

(material green

L

Most critical step – failure gives unrepairable error

“Black Box“ approach with most manufacturers

Material Quality and Properties mostly defined here.


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FIRST STEPS

27

Automation


• Less critical – operator assisted

• Controlled cycle time

Design Impact

• Controlled material property.

• Return on Investment ?

Support the operator and make him responsible!

Photo: Hedrich


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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


Summary

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SUMMARY

30

BLADE DESIGNS TO CHANGE FOR LOGISTICS

COMPOSITE MANUFACTURING TO GROW INTO

FAILSAFE MANUFACTURING.

COST ASPECT MAIN HURDLE TO TAKE

LABOUR DEPENDENCY TO BE DECREASED

FIRST STEPS TAKEN IN MATERIALS AND EQUIPMENT

UNTIL THEN WE IMPROVE (LABOUR) PROCESSES


THANK YOU

[email protected]

www.pontis-engineering.com

mailto:[email protected]

http://www.pontis-engineering.com/