Towards tURbine Blade production with zero waste

2019年，欧洲安装了10000个风力涡轮机叶片，其中最大的长达100米。然而，自20世纪70年代以来，制造方法没有显著变化，几乎没有或根本没有无损检测或在线控制，导致了高缺陷、高维修和高废品率。TURB0将减少WTB复合材料和涂层中的缺陷并改进修复策略。-改进的复合材料生产工艺：通过使用最新的模拟技术来避免缺陷形成，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)，首次实现大规模在线复合材料生产监控。-次表面WTB涂层检查：目前，涂层仅接受目视表面检查或破坏性测试。TURB0将结合超声波和中红外OCT，进行有史以来最详细的涂层评估。-数字孪生和数据仓库：生产设备、监测和在线无损检测数据将结合在一起，建立用于生产实时分析的数字孪生。对于大型复合材料零件，这是从未尝试过的。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：使用数字孪生算法，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形成和浪费，并优化过程效率。-自动修复策略：数字TWIN能够对复合材料中的缺陷严重程度进行ML分析，并采用自动化策略将修复减少90%，并增加下料的回收。-全尺寸演示：将在位于奥尔堡的SGRE工厂进行全尺寸80米WTB的演示。-量化的可持续性改进：包括生命周期分析、社会生命周期分析和循环经济评估，以量化环境和社会经济效益。-传播和利用活动：包括一个强大的咨询委员会、培训、标准和业务计划。

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.