A group consisting of Siemens Gamesa, Airborne(the Netherlands), the University of Southern Denmark and the Technical University of Denmark has received funding in the ALMA project (2023-2026) to develop an Automatic Preforming robotic system (APRS) for composite layering in the manufacturing of large offshore wind turbine blades. The system will automatically lay the layers of preforms, replacing the current manual process.
As described on the ALMA project page, APRS will reduce the time taken by large, expensive wind blade molds and will improve the quality of the blades. It is expected to reduce 120-140 man-hours per blade, while reducing material waste, which will reduce the production cost per blade by DKK 92,500 (US $13,460).
The ALMA project strengthens a collaboration between Airborne and Siemens Gamesa that began in 2022 for the construction and supply of large-scale automated systems for the manufacturing of offshore blades. The project aims to further accelerate the development of the technology with the addition of new features, advanced sensor systems, and digital twining.
The preformed robot system (APRS) is combined with three key hardware components: a fabric material distribution system, an end-effector, and a robot on the (movable) gantry. Combined with state-of-the-art inspection software, the system can be used with preforming techniques during the lay-up process to accurately detect wrinkles and lay-up positions. The entire process will be simulated in order to pave the way for a digital twin that will allow testing and validation of the production cycle before actual leaf production. The product will be integrated into Siemens Gamesa's wind turbine factory. This will allow Siemens Gamesa to transition to automated blade manufacturing processes, increasing blade output while reducing production costs. Thus, the ALMA project and the proposed solutions will be an enabler of preforms technology for Siemens Gamesa's production sites.
Marcus Kremers, Chief Technology Officer of Airborne, said: This project is an important extension of our collaboration with Siemens Gamesa, one of the leading companies in the wind energy space, and it fits well into the strong trend we are seeing in the wind energy and composites industry more generally to automate the lay-up process while requiring the maintenance of current affordable and qualified fabric materials. This is what we address with our automated lay-up technology, which enables simple, fast and flexible automation without the need for material replacement - it can handle the full range of materials used in industry today.
