In a groundbreaking development, researchers at the U.S. Department of Energy’s National Renewable Energy Laboratory (NREL) have successfully utilized robotic assistance in the manufacturing process of wind turbine blades. This innovation not only eliminates challenging working conditions for humans but also has the potential to enhance the consistency and quality of the final product. While robots have been employed in the wind energy industry for painting and polishing blades, the widespread adoption of automation has been limited. The research conducted at the laboratory showcases the capabilities of a robot in trimming, grinding, and sanding blades, essential steps following the production of blade segments using molds and subsequent bonding.
According to Hunter Huth, a robotics engineer at NREL and the lead author of the research paper, the project has been deemed successful despite some operational challenges. The study, titled “Toolpath Generation for Automated Wind Turbine Blade Finishing Operations,” has been published in the journal Wind Energy with co-authors from NREL. The post-molding operations required in wind turbine blade manufacturing involve workers having to work on scaffolding and don protective suits, including respiratory equipment. The introduction of automation in these processes is expected to enhance employee safety and well-being while aiding manufacturers in retaining skilled labor force.
Economic Impact and Job Creation
Daniel Laird, director of the National Wind Technology Center at NREL, emphasizes the significance of automating labor-intensive tasks in blade manufacturing to enable substantial U.S.-based production for the domestic wind turbine market. Automation not only enhances the economics of domestic blade production compared to imported alternatives but also contributes to creating more jobs within the U.S. As Huth highlights, the research aims to develop automation methods that can make domestically manufactured blades cost-competitive on a global scale. Currently, the high labor costs in the U.S. prevent the local production of offshore blades, making automation a crucial factor in improving economic viability.
Technological Advancements in Blade Manufacturing
Conducted at the Composites Manufacturing Education and Technology (CoMET) facility at NREL’s Flatirons Campus, the research involved a robot working on a 5-meter-long blade segment. Despite wind turbine blades being much longer, the robot’s programming can be adapted to address larger blades section by section, considering their flexibility and deflection. Through a 3D representation of the blade’s position and precise identification of its front and rear sections, the team programmed the robot to execute various tasks, focusing on accuracy and speed. While the researchers identified areas for improvement, particularly in grinding, the automation system aims to provide consistency in blade manufacturing, a feat difficult to achieve with manual labor.
Looking ahead, the integration of robotics in wind turbine blade manufacturing holds promise for increasing efficiency, quality, and safety standards in the industry. As automation technology continues to evolve, manufacturers can leverage these advancements to streamline production processes, reduce costs, and enhance competitiveness in the global market. With a focus on achieving cost-competitiveness and sustainability, the research at NREL paves the way for a new era of innovation in the renewable energy sector.
The utilization of robotics in wind turbine blade manufacturing represents a significant advancement with far-reaching implications for the industry. By harnessing the power of automation, manufacturers can overcome challenges related to manual labor, improve product quality, and drive economic growth in the renewable energy sector. As research and development efforts continue, the future of wind energy looks brighter with the integration of cutting-edge technologies and innovative solutions.
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