Automated Production for Wind Turbines

Split-shaft wind turbines decouple the turbines shaft from generators shaft, enabling several modifications in drivetrain. One of significant achievements a split-shaft drivetrain is reduction size excitation circuit. The grid-side converter eliminated, and rotor-side can safely reduce its to fraction full-size excitation. Therefore, this low-power-rated operates at low voltage handles regular operations well. However, fault conditions may expose weaknesses push it limits. This paper investigates effects reduced-size on ride-through capabilities required all turbines. Four different protection circuits, including active crowbar, crowbar along resistorinductor circuit (C-RL), series dynamic resistor (SDR), new-bridge current limiter (NBFCL), are employed, their investigated compared. Wind turbine controllers also utilized impact faults power electronic converters. effective method store excess energy rotor. proposed low-voltage strategies simulated MATLAB Simulink (2022b) validate results demonstrate effectiveness functionality.

Source

System and method for manufacturing large scale composite structures like wind turbine blades that ensures precise placement and bonding of internal components like spar caps during assembly. It uses pins, studs, cams and actuators to provide high precision positioning of spar caps within the mold throughout the layup process. The pins extend through the mold and composite layers to engage the spar caps. Cam actuators measure spar cap midpoints. This provides accurate spar cap placement without relying on mold closing forces or user skill. The pins also prevent spar cap movement during mold closing. This ensures proper spar cap positioning and bonding for optimal blade strength and tolerance compliance.

Source

Cutting plies for wind turbine blades to reduce wrinkling and voids at blade edges. The plies are cut with angled cuts that shorten some fibers at the edges. This creates a chamfered edge instead of a sharp termination. The cutting is done using specialized tools that make angled cuts along lines parallel to the fiber direction. After cutting, the shortened fibers are mixed with uncut fibers to avoid voids. The modified plies are then stacked to make the blade laminate. The chamfered edges prevent wrinkles and voids at the blade terminations.

Source

A device and method to facilitate assembling of wind turbines in a more efficient and weather-independent way, whether onshore or offshore. The device is a tall structure with an enclosed space to assemble the tower and nacelle separately. A hoisting device lifts the tower into the space, supports it below, then disconnects and lifts the nacelle onto the tower. A rotor blade manipulator brings blades from storage. This allows independent assembly steps not affected by weather. The tower and nacelle are then lifted out as a complete turbine. The device can be a fixed onshore building or a floating vessel.

Source

Abstract: One essential component of contemporary renewable energy solutions is wind systems. To maximize performance and reduce downtime, these systems must be efficiently controlled monitored in real time. With an emphasis on control architectures, fault diagnostics, grid synchronization, SCADA integration, this paper investigates the use PLCs automation technologies The suggested framework extremely relevant for deployment industrial farms since it improves turbine efficiency, guarantees safe operation, facilitates grid-friendly power delivery.

Source

Method to manufacture thick preform building elements for wind turbine blades that avoids issues like binder diffusion during curing. The method involves laying out fiber mats in sections with overlapping edges on a mold. A separate component is placed on the mold first. As each fiber mat is laid, the edge contacts the subcomponent. Binder is applied to the edge beforehand. Pressure is applied to the edge to secure the mat. This prevents binder diffusion into the core of thick preforms. The components are then cured.

Source

This paper details the development of a full turbine model and ensuing aero-servo-elastic analysis International Energy Agencys 15MW Reference Wind Turbine. provides means to obtain realistic performance data, which normal tangential blade loads are extracted applied simplified drivetrain developed expressly quantify shaft eccentricities caused by aerodynamic loading, thus determining impact loading on generator structure. During this process, method determine main bearing stiffness values is presented, for IEA-15MW-RWT obtained. It was found that wind speeds in region cut-out induce as high 56%, has significant contribution eccentricities, increasing deflection at area much 106% windspeeds, necessitating its inclusion. subsequent structure optimisation, scenarios examined were increase necessary mass rotor 40%, meet reduced airgap clearance.

Source

Automated manufacturing method for wind turbine towers using additive printing to build the tower layer by layer, with integrated reinforcement. The method involves using a movable frame assembly with platforms that are raised vertically. As the platforms move, reinforcement bars are dispensed automatically from a separate assembly under tension. Then, cementitious material is printed onto the platforms to embed the bars. This allows continuous reinforcement as the tower grows. The printed layers are repeated to build the tower. The additive printing assembly has multiple printer heads for outer/inner walls and filler material.

Source

Wind turbine component design for towers and blades that allows prefabrication, easier transportation, and faster assembly compared to traditional towers. The component has a wall element with a corrugated structural element attached to it. The corrugated shape reduces weight and allows compression during transportation. The component segments can be prefabricated and connected together at the tower or blade site. This allows preassembly of larger sections offsite, simplifies transportation, and speeds up installation compared to traditional tower assembly. The corrugated shape also provides strength and stiffness.

Source

Fiber reinforcement fabric for wind turbine components like blades and spar caps that allows easier and more efficient impregnation of resin during manufacturing. The fabric has tapered edges where the thickness gradually reduces towards the edge. This eliminates dry spots and air pockets by providing a smooth transition of resin fill as the fabric conforms to the tapered mold shapes. The fabric also enables easier layup of tapered fiber layers for components like spar caps by stitching together layers with terminated edges instead of manually arranging terminated plies.

Source

Abstract. Hollow forging and air hardening ductile (AHD) steels are a novel manufacturing process steel grade for the wind energy sector. Together they enable new rotor shaft design possibilities turbines. combines high material strength of solid forged with direct inner contour similar to casting. To compare an AHD hollow state-of-the-art cast shaft, case study is carried out, focusing on power density, costs (manufacturing) global warming potential (GWP). ensure comparability between two predesigns main bearing unit (MBU, bearings, housings) generated via structural integrity assessment calculation lifetime according ISO 76 / 281. The resulting has 37 % less mass than corresponding 16.5 lower MBU mass. For be comparable casting regarding costs, surcharges need greatly reduced. Due shortened heat treatment use green steel, GWP

Source

Additive manufacturing (3D printing) technique for reinforcing large-scale structures like wind turbine towers using coiled polymer reinforcement members instead of conventional steel rings. The method involves printing the tower structure layers, unwinding continuous rolls of pultruded polymer reinforcement material into coils, placing the coils on the printed layers, and then printing more layers on top. This allows reinforcing the structure with lightweight, corrosion-resistant polymer instead of heavy steel rings. The coiled polymer members are wound and secured using fixtures to maintain shape during printing.

Source

The geometric structure design of three-layer hollow fan blades is extremely complex, which not only directly related to the blade quality and manufacturing cost but also has a significant impact on engine performance. Based algorithms combined with rules process constraints, an intelligent method for proposed: A new cross-section curve based non-equidistant offset presented enable rapid wall plate structure. An innovative parametric corrugation in cross-sections driven by constraints such as diffusion bonding angle thresholds put forward. spanwise rib smoothing optimization realized minimum energy change term. densification carried out improve accuracy wireframe achieve solid modeling blades. Finally, proposed methods are seamlessly integrated into NX software (version 12), system developed, enables automated complex under aerodynamic shape large number constraints.

Source

Digital 3D measurement of bondline thickness during wind turbine blade assembly using a 3D laser scanner to accurately determine the gaps between blade components where bonding paste is applied. This involves scanning the blade shell, shear webs, and mold flanges before and after paste application, aligning the scans, and measuring the bondline thickness. Retroreflective targets are used for registration and volume extension accelerates scanning large parts. This provides high precision component positioning to avoid quality issues from incorrect paste thickness.

Source

A lifting device for rotating and moving preform building elements used in wind turbine blade manufacturing. The lifting device is a yoke with pivoting attachment points that can rotate a building element between top and bottom attachment positions. This allows the preform to be flipped over without manual rotation, reducing damage. The yoke has multiple pivoting attachment devices mounted on a beam that can all be pivoted simultaneously by an actuator. The beam can be clamped onto the building element using a bracket that pivots underneath to secure it. This enables rotating and moving multiple preforms at once. The yoke can also have adjustable counterweights to keep the center of gravity constant during rotation.

Source

Method to manufacture wind turbine blades faster by tailoring the cure time of the resin during infusion based on process parameters. The method involves using two hardeners, one faster than the other, to create a resin mixture. The hardener speed is adjusted by varying the relative proportions of the fast and slow hardeners during infusion. This allows optimizing the cure time and open time of the resin as it infuses the blade layup. By speeding up the hardener as infusion progresses, the cure time and open time can be reduced compared to using just a single hardener. This enables faster infusion cycles with less risk of defects.

Source

Manufacturing wind turbine rotor blades with segmented upper molds that can be assembled around the lower mold without needing excessive overhead clearance. The rotor blade molds consist of a lower mold and a segmented upper mold. The segmented upper mold has a root end section and multiple airfoil sections. The root end section is placed next to an airfoil section, then slid into position at the root. The airfoil sections are then positioned. This allows the upper mold to be assembled around the lower mold without needing the entire height of the blade length. The segmented upper mold sections can be handled sideways for assembly/disassembly.

Source

A cost-effective and rapid method for forming large-diameter, thick-walled tubular structures like wind turbine towers using thinner material. The method involves winding thin strips of material around a curved base and joining them together in spirals. This allows forming thick-walled tubes without the need for expensive rolling and welding of thick steel plates. The spirally wound layers provide structural strength similar to solid-walled tubes while being faster and cheaper to manufacture.

Source

Method to manufacture large wind turbine blades with improved curing uniformity to reduce defects. The method involves impregnating the reinforcement preform with a curing promoter before placing it in the mold. This allows the promoter concentration to vary spatially in the preform, with lower amounts near the edges and higher in the center. This helps prevent overcure and shrinkage differences when curing thicker areas versus the edges. The promoter can be a curing accelerator like a transition metal salt.

Source

A method to manufacture wind turbine blades that improves alignment and bonding of shear webs between the inner shell surfaces. The method involves attaching the shear web to one shell half, then bringing the other half together while guiding the shear web over pairs of angled guide members on the inner surface of the second shell half. This prevents rotation and twisting during bonding. The guide members form a funnel shape that aligns the shear web as it's inserted into the other shell half. The guide members are removable spacers during assembly that are later removed. The guide members can be extruded or injection molded parts with hollow bodies and angled surfaces.

Source