Kootstra pontis trends in rotorblade manufacturing (sandia 2016)

1. 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

2. |
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

3. 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

4. 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
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

5. 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
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

6. 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
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

7. |
CONTENTS
» Company Profile
» Challenges with Large Rotorblades
» Logistics
- Segmented Blades
» Manufacturing improvements
- Material layup
» Summary
» Questions
7 TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

8. |
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.
8 TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

9. |
CONTENTS
» Company Profile
» Challenges with Large Rotorblades
» Logistics
- Segmented Blades
» Manufacturing improvements
- Material layup
» Summary
» Questions
9 TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

10. |
LOGISTICS - CHALLENGES
10
» Even offshore blades have to be transported.
» Trailer transport very challenging.
» Larger trailers – weight, stiffness
» Handling – blades are vulnerable
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

11. |
SEGMENTED BLADES
Segmented blades look like a good solution:
» Joints (bolted or glued)
» Segmentation has manufacturing challenges.
» Costs – remain within cost profile
» Structural challenges
11 TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

12. |
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
12 TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

13. |
ROTORBLADE EXTENSION
13
GOAL:
» Extension of existing blades
SEGMENTED CHALLENGES:
» 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
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

14. |
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.
SEGMENTED CHALLENGES:
» 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
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

15. |
BOLTED SEGMENTATION
15
GOALS:
» Segmentation of blade through bolted solution
SEGMENTED CHALLENGES:
» 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

16. |
PATENTS FILES
16
Vestas
General Electric
General Electric
Modular Wind
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

17. |
CONTENTS
» Company Profile
» Challenges with Large Rotorblades
» Logistics
- Segmented Blades
» Manufacturing
- Material lay-up & Process control
» Summary
» Questions
17 TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

18. |
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
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

19. |
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.
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

20. |
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
Materialin[kg] Blade lenght [m]
MATERIAL FLOW IN KG/HR
(PER MOULD LOADING)
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
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

21. |
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
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

22. |
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
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
35% inmould cycle time reduction achieved
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

23. |
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)
23 TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

24. |
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
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

25. |
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)
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

26. |
INFUSION OF RESIN
26
Automation
Manufacturing Benefit
• Less critical – operator assisted
• Controlled cycle time
Design Impact
• Controlled material property.
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15 Fully injected visually
10
5
0
Estemated time manual1 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 PLCor 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
Temp(̊C)
Vacuumcheck
Temperaturecheck
DegassingResin
(mix)
Resinmixcheck
Mixcalculation
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
TGsensor
(material green
L
 Most critical step – failure gives unrepairable error
 “Black Box“ approach with most manufacturers
 Material Quality and Properties mostly defined here.
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

27. |
FIRST STEPS
27
Automation
Manufacturing Benefit
• Less critical – operator assisted
• Controlled cycle time
Design Impact
• Controlled material property.
• Return on Investment ?
 Support the operator and make him responsible!
Photo: Hedrich
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

28. |
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
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

29. Summary

30. |
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
TRENDS IN ROTORBLADE MANUFACTURING – SANDIA 31 AUG 2016

31. THANK YOU
djk@pontis-engineering.com
www.pontis-engineering.com