The use of robotics in wind turbine blade manufacturing has shown promising results according to a recent study conducted by researchers at the U.S. Department of Energy’s National Renewable Energy Laboratory (NREL). The research aimed to explore the potential benefits of leveraging robotic assistance in the manufacturing process, with the goal of improving product consistency and eliminating challenging working conditions for human workers.
Automation in Wind Energy Industry
While robots have been previously employed in tasks such as painting and polishing wind turbine blades, overall automation in the industry has been limited. However, the study at NREL showcased the capability of a robot to handle complex operations such as trimming, grinding, and sanding blades. These crucial steps occur after the blade sides are manufactured and bonded together, highlighting the significance of automation in streamlining the production process.
Enhanced Safety and Efficiency
The traditional post-molding operations for wind turbine blade manufacturing often involve workers working in difficult conditions, including wearing protective gear and balancing on scaffolding. By introducing automation, the researchers observed potential improvements in employee safety, well-being, and retention of skilled labor. This transformation not only fosters a safer working environment but also enhances the efficiency and quality of blade manufacturing.
Daniel Laird, the director of the National Wind Technology Center at NREL, emphasized the economic implications of automating blade manufacturing processes. He highlighted that by making domestic blade production more cost-competitive globally, the U.S. can potentially foster growth in the wind energy sector and create more job opportunities. The research aimed to address the challenges posed by high labor rates and labor-intensive finishing processes that hinder offshore blade manufacturing in the U.S.
The research was conducted at the Composites Manufacturing Education and Technology (CoMET) facility at NREL’s Flatirons Campus, where a robot was tasked with working on a 5-meter-long blade segment. Although full-length wind turbine blades are substantially longer, the researchers noted that robots could be programmed to handle larger blades in sections due to their flexibility. By utilizing advanced scanning technology to map the position of the blade and program the robot accordingly, the team assessed the robot’s performance based on accuracy and speed.
Throughout the study, researchers identified areas for improvement, particularly in the grinding process where inconsistencies were observed. Despite these challenges, the study highlighted the potential for robots to enhance manufacturing consistency, a feat that is difficult to achieve with human labor. Additionally, the researchers noted that robots could use more aggressive abrasives, thereby improving efficiency and precision in the finishing process.
The research conducted at NREL signifies a significant step towards revolutionizing wind turbine blade manufacturing through robotics. By addressing key challenges and unlocking the potential for automation, the industry can pave the way for safer, more efficient, and cost-effective blade production methods. With further advancements and refinements, the integration of robotics in wind energy manufacturing holds promise for sustainable growth and innovation in the renewable energy sector.
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