JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 20

MANUFACTURlNG wind

Fig. 4: Configuration of a
tape laying operation

Fig. 5: Simulation of an
ATL operation via CAESA®

Fig 6: Sticking feature from the CAESA® software

on the overall process.
Individually-adjustable process parameters
are one of the most important features
in CAM software because they allow the
entire processes to be mapped digitally and
optimized accordingly. Over several years
of development, CAESA® has established a
distinctive process configuration for the ATL
and AFP environment. Figures 4 and 5 show
how ATL/AFP processes can be configured
in a virtual environment and how this is
simulated.
For instance, after two shells have cured,
any potential defect cannot be reversed. The

bonding process can illustrate this problem.
When the two shells are bonded together, it
is important that the correct amount of adhesive is applied to the right place. Otherwise,
residual stresses or insufficient bonding of
the individual shell components in the rotor
blade may occur, which subsequently render
it unusable and result in a rejected component. With automation, the process parameters are specially controlled and precisely
dimensioned. This results in fewer defective
products. The costs for defect processing are
still very high. Figure 6 shows the process
configuration for an adhesive application

jec composites magazine / N°136 September - October 2020

operation. The user can divide the job into
separate sections and configure them as
required. This feature helps to optimize time
and resources.
The benefit of this is not only the optimization of cycle times but also the reduction
of rework times. A further advantage that
results from fewer defective products is
the conservation of resources. Thus, the
improved process quality and reliability
contribute to the fact that fewer plastic raw
materials are wasted, which significantly
reduces the environmental impact.
Contribution to an improved
environmental impact
Obviously, the wind power industry has
declined sharply in recent years, although
wind power is still one of the most important
sources of renewable energy. This is not
due to technological failure, but to political
and bureaucratic causes. It can take several
years from finding a location to the start of
construction. Finding a location for a wind
farm has become very difficult. The distance
to residential areas often triggers discussions
due to concerns from the residents. When a
suitable location for a wind farm is found, the
procedure begins that decides who may build
it. Clarifying the financing, finding investors
and obtaining permits also takes time. Even if
it is financially possible for some countries to
switch to wind power or something similar,
bureaucracy is a constant impediment.
The project was designed to strengthen the
competitiveness of wind power. Since it is
one of the most effective renewable energies,
the BladeFactory project leads the way to
rethinking energy production. Processes
are also being researched that could be
worthwhile for other industries. The targeted three-dimensional depositing of fibre
structures is also of particular interest in the
aerospace industry, for example.
In conclusion, this research project presents
opportunities for wind power to further develop composite manufacturing technology
in general and can also be used to support
today's climate issues.

More information:
www.swms.de

http://www.swms.de

JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020