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


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


» Company Profile




» Summary

» Questions

DESIGN AND MANUFACTURING CONFLICTS


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


Example of tight tolerance large blade

TE thickness 2-10 mm

CONTENTS


» Company Profile




» Summary

» Questions

Automation Manufacturing Benefit • Less man hours • Quicker cycle time

Design Impact • Less intricate parts that can be made

by machine

MANUFACTURING IMPROVEMENTS


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


» 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


CONTENTS

» Company Profile




» Summary

» Questions

DESIGN IMPROVEMENTS (1 OF 2)


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)


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


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


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.



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


SUMMARY


» 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


HARMONISING DESIGN & MANUFACTURING OF ROTOR BLADES · HARMONISING DESIGN & MANUFACTURING OF ROTOR...

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