SAMPE Journal - May/June 2021 - 30
FEATURE / AIRBORNE WIND ENERGY SYSTEM
into a number of equally spaced segments in the
span-wise direction (S0-S8), to capture the varying
thickness profile (t0-t7). The surface area (SA) of the
part is then calculated. The surface area of all of the
plies (PSA) is found by multiplying the surface area
of each segment by the number of plies through the
thickness and summing the values along the part.
A number of studies in the literature use a similar
methodology to deconstruct a part into geometric
variables to assess the material and labour costs
8,10,11,13
.
the structure breakdown module. In these cases,
the labour hours for the step are calculated by
multiplying the relevant geometric scaling variable
(e.g. length of plies in metres) by a " production
rate " variable (e.g. hand layup rate in m/hr).
The equipment costs are related to the
production methods for each part. The
equipment cost is calculated from the number
of parts produced per annum, the lifetime of the
equipment, the depreciation rate and the auxiliary
equipment and installation costs.
Materials, Labour and Equipment Costs
The materials database has a general hierarchy
defined by the following seven categories: fabrics,
resins, hardeners, prepregs, cores and adhesives.
Within each category, individual materials are
defined with a number of associated properties
(such as unit cost, fibre volume fraction and areal
weight) that are used in the cost model calculations.
To determine the total labour costs for wing
manufacture, the major steps in each of the
production methods are defined in a production
methods database. For some production steps,
the numbers of labour hours are defined, however,
for many steps, the labour hours are related to
the geometric scaling variables determined by
Analysis Inputs
The wing for the concept AWES is approximately
40 m long and made up of two elements, a primary
wing element and control surfaces (flaps, flaperons,
ailerons, etc.). The present work focuses on the
primary wing element. The cross-section of the
wing is shown in Figure 5 (a). The wing is supported
by a single torsion-box spar (upper and lower
spar cap with two webs). Figure 5 (b) shows the
thickness distribution of the UD, biaxial and foam
core materials for the wing. Table 1 summarises
the input data for the manufacturing database,
defining the materials and production methods for
each part. Table 2 lists the input material data.
Figure 4. The part is split into span-wise segments to account for ply drops [top]. The part is also split
into sections based on the width of material (i.e. the width of a roll of fabric or prepreg) [bottom].
30
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May June 2021 Journal.indd 30
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SAMPE Journal - May/June 2021
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