Towards tURbine Blade production with zero waste (TURBO)

2019年，欧洲安装了1万个风力涡轮机叶片（WTBs），最大的叶片长100米。然而，自20世纪70年代以来，制造方法并没有发生重大变化，很少或没有无损检测或在线控制，导致高缺陷，维修和报废率。tur0将减少WTB复合材料和涂层的缺陷和改进修复策略。-改进复合材料生产工艺：通过使用最新的模拟技术来避免缺陷的形成，并了解缺陷如何影响结构完整性。-在线无损检测：结合三种尖端无损检测技术（介电、无线、无传感器），首次进行大规模在线原位复合材料生产监测。-表面下WTB涂层检测：目前涂层仅进行目视表面检测或破坏性检测。TURB0将结合超声和中红外OCT进行最详细的涂层评估。-数字孪生和数据仓库：生产设备、监控和在线无损检测数据将结合起来，建立一个数字孪生，用于实时分析生产。这在大型复合材料部件上从未尝试过。它将填充可从多个生产站点访问的数据仓库。在线系统控制：使用数字孪生，基于ml的算法将提供闭环过程控制，以最大限度地减少缺陷的形成和浪费，并优化过程效率。-自动修复策略：数字孪生能够对复合材料的缺陷严重程度进行机器学习分析，采用自动化策略减少90%的修复，并增加边材的回收利用。-全尺寸演示：将在奥尔堡的SGRE工厂进行全尺寸bbb80米WTB部分的演示。-量化的可持续性改进：包括生命周期分析（LCA）、社会LCA和循环经济评估，以量化环境和社会经济效益。-传播和开发活动：包括一个强大的咨询委员会、培训、标准和商业计划。

10000 wind turbine blades (WTBs) were installed in Europe in 2019, and the largest are >100 m long. Yet the manufacturing methods have not changed significantly since the 1970s, with little or no NDT or in-line control, leading to high defect, repair and scrap rates. TURB0 will reduce defects and improve repair strategies in WTB composites and coatings. -Improved composite production processes: By using the latest simulation techniques to avoid defect formation and understand how defects affect structural integrity. -In-line NDT: Combining three cutting-edge NDT technologies (dielectric, wireless, sensor-less) for the first large scale in-line in situ composite production monitoring. -Sub-surface WTB coating inspection: Currently coatings only undergo visual surface inspection or destructive testing. TURB0 will combine ultrasound and mid-IR OCT for the most detailed coating assessment ever performed. -Digital twin and data warehouse: Production equipment, monitoring and in-line NDT data will be combined to establish a digital twin for real-time analysis of production. This has never been attempted for a large-scale composite part. It will populate a data warehouse accessible from multiple production sites. -In-line system control: Using the digital twin, a ML-based algorithm will provide closed-loop process control to minimise defect formation and waste and optimise process efficiency. -Automated repair strategy: The digital twin enables a ML analysis of defect severity in composites, with automated strategies to reduce repairs by 90 % and increase recycling of off-cuts. -Full-scale demo: A demo on a full size >80 m WTB section will be performed at the SGRE factory in Aalborg. -Quantified sustainability improvements: including life cycle analysis (LCA), social LCA and circular economy assessments to quantify environmental and socioeconomic benefits. -Dissemination and exploitation activity: includes a powerful Advisory Board, training, standards and business plan.