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4/1/2010

Major Turbine Components


Turbine Manufacturing

Andrew Kusiak
Intelligent Systems Laboratory
2139 Seamans Center
The University of Iowa
Iowa City, Iowa 52242 - 1527
andrew-kusiak@uiowa.edu
Tel: 319-335-5934 Fax: 319-335-5669
http://www.icaen.uiowa.edu/~ankusiak

The University of Iowa Intelligent Systems Laboratory The University of Iowa Intelligent Systems Laboratory

Rotor Blade Materials Modern Blade Design


 Rotor blades are usually made using a matrix of fiber glass
that is impregnated with a material such as polyester
(GFRP = Glass fiber reinforced polyester)
 The polyester is hardened after it has impregnated the
fiber glass
 Epoxy may be used instead of polyester
 Likewise the basic matrix may be made entirely or partially
from carbon fiber, which is lighter, but more expensive
material
 Wood-epoxy laminates were also being used for some rotor
blades Laminated shell design with spar box and spar webs

The University of Iowa Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 238 Intelligent Systems Laboratory

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Rotor Blade Cross-section New Blade Design

Mixed glass fiber/carbon fiber with cross-bolt joining at the rotor hub
GFRP = Glass fiber reinforced polyester

The University of Iowa E. Hau (2006), p. 230 Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 239 Intelligent Systems Laboratory

Winding Machine Automated Manufacturing

1. Winding with D-spar


2. Placing the cones for the rear box
3. Winding the complete blade

The University of Iowa E. Hau (2006), p. 237 Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 237 Intelligent Systems Laboratory

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Blade Manufacturing Facility Tower Section

The University of Iowa E. Hau (2006), p. 239 Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 430 Intelligent Systems Laboratory

Concrete Tower Manufacturing Blade Testing

The University of Iowa E. Hau (2006), p. 441 Intelligent Systems Laboratory The University of Iowa Intelligent Systems Laboratory

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The Purpose of Testing Rotor Nacelle on the Road


Blades

 The purpose of rotor blade testing is to verify that


laminations in the blade are, safe, i.e., that the layers
of the rotor blade do not separate (delamination)
 Also, the test verifies that the fibers do not break
under repeated stress

The University of Iowa Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 558 Intelligent Systems Laboratory

Tower Transportation Tower Transportation

The University of Iowa E. Hau (2006), p. 659 Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 659 Intelligent Systems Laboratory

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Tower Base Foundation for a Tabular Tower

The University of Iowa E. Hau (2006), p. 660 Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 431 Intelligent Systems Laboratory

Assembly of Three Puling up


Tower Sections a Nacelle

The University of Iowa E. Hau (2006), p. 662 Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 662 Intelligent Systems Laboratory

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Mounting the Helicopter Use


Complete
Rotor

The University of Iowa E. Hau (2006), p. 662 Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 664 Intelligent Systems Laboratory

Portal
Swinging
Crane
Crane

The University of Iowa Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 666 Intelligent Systems Laboratory
E. Hau (2006), p. 665

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Two Cranes
Top Crane Mounting
a Generator

The University of Iowa E. Hau (2006), p. 670 Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 672 Intelligent Systems Laboratory

Concrete Cost Breakdown


Tower
Construction

The University of Iowa E. Hau (2006), p. 439 Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 711 Intelligent Systems Laboratory

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Mfg Cost Cost Breakdown


Breakdown

200 MW turbine with 25m rotor diameter


E. Hau (2006), p. 712
The University of Iowa Intelligent Systems Laboratory The University of Iowa E. Hau (2006), p. 713 Intelligent Systems Laboratory

Turbine Supply Chain Turbine Supply Chain

 Supply chain of importance due to global production of Characteristics


turbine components
 Product (wind turbine) assembled in the field  Overlapping supply chain with the number of sinks equal
 Mix of mechanical,, electrical,, and civil engineering
g g activities to the number of wind turbines at a park
 Different assembly equipment (e.g., cranes) and different  Transportation distance (time) a significant component
assemblies (e.g., high power electricity, mechanical assembly) of the network
 Energy cost to manufacture and transport components  Modeling such a network is challenging due to new network
and assemblies is an issue architecture (intertwined networks)

The University of Iowa Intelligent Systems Laboratory The University of Iowa Intelligent Systems Laboratory

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Turbine Supply Chain


Turbine Supply Chain
Supplier options
Examples of supply chain modeling methodologies
 Single supply source
 Ease of quality control
 Network flow models
 High risk of delivery disruption
 Petri nets
 Low control relative to the cost of
 Neural
N l networks
t k
components, and assemblies
 Data-driven models (data mining)
Important to consider in modeling supply chains:  Multiple supply sources
 Evolving network architecture  More involved quality control
 Risks  Lower risk of delivery disruption
 Costs  Management of cost and quality is
needed
The University of Iowa Intelligent Systems Laboratory The University of Iowa Intelligent Systems Laboratory

Turbine Supply Chain Turbine Supply Chain

 Many to many relationships prevail


 A supplier may work with many primes,
and a prime may be supplied with components,
assemblies, and services offered by many suppliers

The University of Iowa Intelligent Systems Laboratory The University of Iowa Intelligent Systems Laboratory

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Reference

http://books.google.com/books?id=Z4bhObd65IAC&printsec=frontcover&dq#PPP1,M1

The University of Iowa Intelligent Systems Laboratory

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