In recent developments at the U.S. Department of Energy’s National Renewable Energy Laboratory (NREL), researchers have made significant strides in the use of robotics for the manufacturing of wind turbine blades. This cutting-edge approach aims to alleviate the arduous working conditions faced by human workers and enhance the overall quality and consistency of the final product.
Traditionally, robots have been employed in the wind energy industry for tasks such as painting and polishing blades. However, the widespread adoption of automation in the manufacturing process has been limited. The latest research at NREL showcases the capabilities of a robot in trimming, grinding, and sanding wind turbine blades – crucial steps following the fabrication of the two sides of the blade and their bonding.
Hunter Huth, a robotics engineer at NREL and the lead author of the research paper published in the journal Wind Energy, expressed satisfaction with the outcomes of the study. While acknowledging some areas where improvements are needed, Huth emphasized the valuable lessons learned that will enable the technology to meet or even surpass expectations. The co-authors of the paper, all affiliated with NREL, contributed to the comprehensive exploration of robotic automation in wind turbine blade finishing operations.
The post-molding operations involved in wind turbine blade manufacturing often require workers to endure challenging conditions, including perching on scaffolding and wearing protective gear. By implementing automation, not only can the safety and well-being of employees be enhanced, but it can also contribute to retaining skilled labor in the industry. Daniel Laird, the director of the National Wind Technology Center at NREL, emphasized the importance of automating labor-intensive processes to promote U.S.-based blade manufacturing and improve economic competitiveness.
The primary goal of the research was to develop automation methods that could drive domestically manufactured blades to be cost-competitive on a global scale. Offshore blades currently face challenges in the U.S. due to high labor costs associated with the finishing process. Through automation, domestic offshore blade manufacturing can become more economically viable, potentially leading to increased job opportunities in the industry.
The research was conducted at the Composites Manufacturing Education and Technology (CoMET) facility at NREL’s Flatirons Campus, where a robot was employed to work on a 5-meter-long blade segment. While full-scale wind turbine blades are significantly longer, the researchers demonstrated that robots can effectively handle the manufacturing process in sections. By utilizing 3D scanning technology, the team precisely identified the sections of the airfoil and programmed the robot to execute various tasks with a focus on accuracy and efficiency.
Throughout the research, areas for improvement were identified, particularly in the grinding process, where the robot exhibited inconsistencies in material removal. Despite these challenges, the research team remains optimistic about the potential of robotic automation in enhancing the quality and consistency of wind turbine blade manufacturing. By addressing the shortcomings and refining the technology, the industry can embrace automation as a means to achieve superior results compared to manual labor.
The integration of robotics in wind turbine blade manufacturing represents a significant advancement with far-reaching implications for the industry. As researchers continue to innovate and refine the technology, the future of automated manufacturing holds promise for enhancing efficiency, safety, and economic competitiveness in the renewable energy sector.