Optimization of Automated Manufacturing Process using 3R Enduring Prepregs
Topic(s) : Manufacturing
Co-authors :
Blanco Salgado LOURDES (SPAIN), De La Mano Ferreira RUBÉN , Coto Moretti MARÍA IVETTE (SPAIN), Genua Ferreras ARATZ , Gomes DANIEL (PORTUGAL), Elena RODRÍGUEZ-SENÍN (SPAIN)Abstract :
The enormous size of next generation wind turbine blades makes the manufacturing of them very challenging and the manufacturing of large-scale composite parts is becoming more common need. Also, the requirements towards materials go towards easier processing, through an automated processing where better consistency, higher quality and lower cost of the composite parts could be achieved. In this regard, prepreg composites allow a higher level of automation using Automated Fiber Placement (AFP) technique and high mechanical characteristics have been achieved. The present study focuses on the work being developed in an ongoing European project the H2020 (CARBO4POWER - GA.953192 https://carbo4power.net/project-overview/) where one of the main objective is to develop a new generation of lightweight, high strength, multifunctional, digitalized multi-materials for offshore wind and tidal turbine rotor blades that will increase their operational performance and durability while reducing the cost of energy production (below 10ct€/kWh for wind turbines and 15ct€/kWh for tidal), maintenance, and their environmental impact.
The prepreg used was 3R enduring prepregs. 3R technology is a thermoset composites that are intrinsically Reprocessable, Recyclable and Repairable (3R). The dynamic character of the 3R epoxy resin makes it possible to manufacture the enduring prepregs, which are (semi-)cured, non-perishable prepregs which is possible to process using different techniques, one of them, AFP. This novel prepreg tape was developed using commercial carbon fibre impregnated with 3R liquid resin.
The WTB (Wind Turbine Blade) demonstration prototype was developed at a scale-down to about 1:20 as a modular segmented blade with a total length of 6.8m. The spar cap is the main load carrying structure in the blade as such is very important component. The modular spar caps are manufactured by AFP using the novel 3R prepreg.
This work will display the details of the optimal manufacturing strategy to achieve it. A thorough analysis addressing new smart out of autoclave (OOA) manufacturing processes was performed.
Several automated approaches have been studied. Manufacturing was assisted through different monitoring technologies such as resin arrival sensors and thermography in order to ensure high quality components. AFP technology has been adapted to process these manufacturing trials. Microscopic analysis, thermal and mechanical tests were carried out to achieve the optimal processability and to obtain a reference data on the mechanical behavior of the new materials developed. Finally, several demonstrators have been made. In this manner, the most promising technologies were scaled-up and subsequently tested in the WTB demonstration case.
The prepreg used was 3R enduring prepregs. 3R technology is a thermoset composites that are intrinsically Reprocessable, Recyclable and Repairable (3R). The dynamic character of the 3R epoxy resin makes it possible to manufacture the enduring prepregs, which are (semi-)cured, non-perishable prepregs which is possible to process using different techniques, one of them, AFP. This novel prepreg tape was developed using commercial carbon fibre impregnated with 3R liquid resin.
The WTB (Wind Turbine Blade) demonstration prototype was developed at a scale-down to about 1:20 as a modular segmented blade with a total length of 6.8m. The spar cap is the main load carrying structure in the blade as such is very important component. The modular spar caps are manufactured by AFP using the novel 3R prepreg.
This work will display the details of the optimal manufacturing strategy to achieve it. A thorough analysis addressing new smart out of autoclave (OOA) manufacturing processes was performed.
Several automated approaches have been studied. Manufacturing was assisted through different monitoring technologies such as resin arrival sensors and thermography in order to ensure high quality components. AFP technology has been adapted to process these manufacturing trials. Microscopic analysis, thermal and mechanical tests were carried out to achieve the optimal processability and to obtain a reference data on the mechanical behavior of the new materials developed. Finally, several demonstrators have been made. In this manner, the most promising technologies were scaled-up and subsequently tested in the WTB demonstration case.