Robotic assistance in the manufacturing of wind turbine blades has recently been a significant breakthrough at the U.S. Department of Energy’s National Renewable Energy Laboratory (NREL). The utilization of robots in this process not only eliminates challenging working conditions for humans but also has the potential to enhance product consistency. Although the wind energy industry has used robots for tasks like painting and polishing blades, automation has not been widely adopted. However, the research conducted at NREL showcases the capabilities of robots in trimming, grinding, and sanding wind turbine blades, marking a significant milestone in the industry.
The post-molding operations involved in manufacturing wind turbine blades often require workers to work in precarious positions on scaffolding while wearing protective suits. By incorporating automation in these processes, the safety and well-being of employees are improved, and manufacturers can retain skilled labor more effectively. This shift towards automation is crucial for the growth of U.S.-based blade manufacturing in the domestic wind turbine market, as highlighted by Daniel Laird, director of the National Wind Technology Center at NREL. The automation of labor-intensive processes can lead to a more robust domestic blade manufacturing industry, thereby creating more job opportunities in the U.S. and reducing the reliance on imported blades.
The primary objective of the research conducted at the Composites Manufacturing Education and Technology (CoMET) facility at NREL was to develop automation methods that would enhance the cost-competitiveness of domestically manufactured blades in the global market. Offshore blades are currently not produced in the U.S. due to high labor costs and the labor-intensive nature of the finishing process. Automation in these finishing processes can make domestic offshore blade manufacturing more economically viable, paving the way for increased competitiveness on a global scale.
During the research, a robot was employed to work on a 5-meter-long blade segment, showcasing the potential of automation in the field. While wind turbine blades are typically much longer, the flexibility of the robot programming allows for the work to be done section by section. The use of 3D scans enabled precise identification of the blade’s front and rear sections, facilitating accurate task programming for the robot. The researchers identified areas for improvement, especially in tasks like grinding, where the robot exhibited inconsistencies. Despite these challenges, the research highlights the potential for robots to provide unparalleled consistency in blade manufacturing, outperforming human capabilities in precision and efficiency.
The integration of robotics in wind turbine blade manufacturing represents a significant step forward for the industry. By leveraging automation technology, manufacturers can enhance product quality, improve worker safety, and boost the competitiveness of domestically produced blades in the global market. As further advancements are made in robotic assistance and programming, the future of wind turbine blade manufacturing looks promising, offering a glimpse into a more efficient, sustainable, and economically viable industry.
Leave a Reply