Transforming Wind Turbine Blade Mold Manufacturing
TRANSFORMING WIND TURBINEBLADE MOLD MANUFACTURINGWITH 3D PRINTING
WIND POWERTHE FASTEST GROWING FORM OFRENEWABLE ENERGY IN THE UNITED STATESWind energy provides more than 5% of the nation’stotal electricity generation. U.S. wind generates enoughelectricity to power more than 24 million averageU.S. homes. With an increase in generation, the windindustry must meet the challenges of a growingsector. Larger wind turbine blades and more efficientwind farm configurations set the stage for industrialinnovation and advancements. Collaborationbetween the public and private sectors providesa forum for addressing these challenges andopportunities for the future of wind power.
The U.S. Department of Energy’s (DOE’s) Office of Energy Efficiencyand Renewable Energy (EERE) plays a strategic role in promoting cleanand secure energy by increasing our nation’s competitiveness throughmanufacturing clean energy technologies. Investments in the researchand development of cross-cutting platform technologies have theability to revolutionize the delivery of clean energy. Wind componentmanufacturing provides opportunities to grow domestic jobs and leaseand tax revenues in local communities while also strengthening andsupporting our nation’s economy and electricity sector.WORKING TOGETHER TO BUILD A FASTER AND LEANERFUTURE FOR WIND TURBINE MANUFACTURINGInnovation in the design and manufacturing ofwind power generation components continuesto be critical. As a result of this challenge,DOE’s Wind Energy Technologies Office(WETO) and Advanced Manufacturing Office(AMO), both within EERE, are partnering withpublic and private organizations to applyadditive manufacturing, commonly known as3D printing, to the production of wind turbineblade molds. The traditional method of bladedesign requires the creation of a plug, or a fullsize representation of the final blade, which isthen used to make the mold. Creating the plugis one of the most time-intensive and laborintensive processes in wind blade construction,saving time and money.Specific aerodynamic research on wind turbinerotor wakes, funded by WETO, calls for customresearch blades outfitted with special sensors.These research blades would require a uniqueplug, mold, and tooling design, which wouldbe expensive. WETO leveraged AMO’s existingexpertise to develop an innovative solution forcreating the research blade mold. 3D printingthe mold eliminates the need for a plug andprovides the opportunity to pioneer innovativedesign features, such as air heating throughbuilt-in ductwork instead of hand-laid heatingwires embedded in the mold. The groundbreaking project engages Oak Ridge NationalLaboratory’s Big Area Additive Manufacturing,or BAAM, machine developed in collaborationwith Cincinnati Incorporated. BAAM is 500to 1,000 times faster and capable of printingpolymer components more than 10 timeslarger than traditional industrial additivemachines. With research blades measuring13 meters (42 feet) in length, BAAM providesthe necessary scale and foundation for thisground-breaking advancement in wind bladeresearch and manufacturing.
DOE is leading our nation toward a secure energy future and increasingdomestic industry competitiveness through research and developmentof innovative manufacturing technologies such as 3D printing.WHAT IS 3D PRINTING?3D printing, or additiveINNOVATIVE NEW PROCESS USES3D PRINTING TO CREATE MOLDS1.The mold is designed using computer-aideddesign (CAD) and a file is generated for BAAMto follow.2.The BAAM machine extrudes heated compositematerial based on the CAD file design layer bylayer until the component is fully developed.This process occurs for each piece of the mold.3.A layer of fiberglass is applied on top of the mold,and excess material is machined off to achieve thedesired shape and smoothness.4.Heating duct work is installed and the mold piecesare assembled together.5.The research blades are produced from thecompleted mold.manufacturing, is the processof
This process occurs for each piece of the mold. 3. A layer of fiberglass is applied on top of the mold, and excess material is machined off to achieve the desired shape and smoothness. 4. Heating duct work is installed and the mold pieces are assembled together. 5. The research blades are produced from the
which is the mold with availability production hours, including Mold ALC 40, Mold ALC 80, Mold SLDX, Mold ASGR, and Mold PLGD as shown in Fig. 1. Fig. 1. Production Hours of 5 injection molds period April - July 2018 After OEE calculation is applied to the injection mold, and showed that mold SLDX get the OEE values from April- July
2. Brief Wind Turbine Description The wind turbine under study belongs to an onshore wind park located in Poland. It has a power of 2300 kW and a diameter of 101 m. Figure 1 shows its major components. A summary of the wind turbine technical specifications is Fig. 1. Main components of the wind turbine [16]. given in Table I. The wind farm .
Jan 31, 2013 · blades. Horizontal-axis wind turbine was developed a high wind speed location. A hybrid composite structure using glass and carbon fiber was created a light-weight design Structural analysis for wind turbine blades is investigated with the aim of improving their design, minimizing weight. The wind turbine blade was modelled by using Catia.
WE Handbook- 2- Aerodynamics and Loads Wind Turbine Blade Aerodynamics Wind turbine blades are shaped to generate the maximum power from the wind at the minimum cost. Primarily the design is driven by the aerodynamic requirements, but economics mean that the blade shape is a compromise to keep the cost of con-struction reasonable.
Mold design to manufacture Design and machine the mold in NX Not only does NX offer Mold Wizard to design the complete mold assembly, NX also offers an excellent NC programming solution to set up the machining of mold faces and mold structure components. Feature data added to the model by Mold Wiza
Mold design to manufacture Design and machine the mold in NX Not only does NX offer Mold Wizard to design the complete mold assembly, NX also offers an excellent NC programming solution to set up the machining of mold faces and mold structure components. Feature data added to the model by Mold Wiza
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Agile Development in a Medical Device Company Pieter Adriaan Rottier, Victor Rodrigues Cochlear Limited rrottier@cochlear.com.au Abstract This article discuss the experience of the software development group working in Cochlear with introducing Scrum as an Agile methodology. We introduce the unique challenges we faced due to the nature of our product and the medical device industry. These .
