In a groundbreaking study conducted by researchers at the U.S. Department of Energy’s National Renewable Energy Laboratory (NREL), robotic assistance has been successfully integrated into the manufacturing process of wind turbine blades. This revolutionary approach aims to eliminate challenging working conditions for humans while also enhancing the consistency and quality of the end product. While robots have been utilized in the wind energy industry for tasks such as painting and polishing blades, the full potential of automation has yet to be fully realized. This research showcases the ability of robots to perform intricate operations such as trimming, grinding, and sanding blades, ushering in a new era of innovation in blade manufacturing.
The traditional post-molding operations involved in manufacturing wind turbine blades typically require workers to navigate precarious scaffolding and don protective suits, including respiratory gear. By introducing automation into the process, the researchers anticipate a notable improvement in employee safety and well-being, as well as a more efficient utilization of skilled labor. Daniel Laird, director of the National Wind Technology Center at NREL, emphasizes the critical role of this work in enabling the expansion of U.S.-based blade manufacturing for the domestic wind turbine market. He highlights the potential economic benefits of automating labor-intensive tasks, suggesting that it could lead to the creation of more jobs in the United States by enhancing the competitiveness of domestically produced blades against imported alternatives.
The primary objective of this research initiative was to develop automation techniques that could render domestically manufactured blades cost-competitive on a global scale. Currently, offshore blades are not produced in the U.S. due to high labor costs associated with the finishing process. The manual labor involved in blade finishing is physically taxing and often leads to a high turnover rate among workers. By automating these finishing operations, the researchers anticipate a significant reduction in production costs, thereby making domestic offshore blade manufacturing a more economically viable proposition. The ultimate goal is to bridge the gap between domestic and imported blades, positioning U.S.-based manufacturers as formidable players in the global wind energy market.
The research was carried out at the Composites Manufacturing Education and Technology (CoMET) facility located at NREL’s Flatirons Campus. During the study, a robot was tasked with working on a 5-meter-long blade segment, although commercial wind turbine blades are significantly larger. The researchers devised a strategic approach by programming the robot to work on the larger blades in sections since they tend to bend and deflect under their own weight. By utilizing a series of scans to generate a precise 3D representation of the blade’s position and identifying the front and rear sections of the airfoil, the team successfully programmed the robot to undertake a series of intricate tasks with a focus on accuracy and efficiency.
Throughout the research process, the researchers identified areas for enhancement, particularly in the grinding aspect. The robot exhibited variability in its performance, grinding down certain areas of the blade excessively while neglecting others. Despite these challenges, Hunter Huth, a robotics engineer at NREL and the lead author of the study, remains optimistic about the potential of automated systems in blade manufacturing. He emphasizes the importance of consistency in the manufacturing process, a factor that can be significantly enhanced through automation. Additionally, Huth points out the advantage of robots being able to utilize more robust and aggressive abrasives compared to human workers, thereby potentially improving the overall quality of the blades produced.
The integration of robotic assistance in wind turbine blade manufacturing represents a significant step forward in the quest for enhanced efficiency, quality, and cost-competitiveness in the renewable energy sector. As researchers continue to refine and optimize automated systems, the future of blade manufacturing holds immense promise for revolutionizing the global wind energy landscape.
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