Fraunhofer Institute for Wind Energy SystemsAt a glance
- Pultrusion-based rotor blade spar caps are seeing increasing use in rotor blade manufacturing. However, potential savings – for example in material consumption and transport – have yet to be fully exploited.
- In the PulFer24 research project, a manufacturing concept will be developed that offers higher flexibility and reduces transport distances among other things.
- In addition to coordinating the project, Fraunhofer IWES is also responsible for the development of process technologies as well as process and quality control.
The challenge
The manufacturing of rotor blades for wind turbines is associated with considerable cost pressure. Pultrusion-based rotor blade spar caps offer high process stability in manufacturing and good mechanical properties. As such, they are being used increasingly often.
Nevertheless, there is still potential for savings, for example in transportation and the avoidance of auxiliary materials that become waste at the end of the process. In addition, the replacement of carbon fibers with state-of-the-art high-modulus glass fibers in the pultrusion process can also lower costs. As rotor blade lengths and masses increase, even small percentage changes can have significant effects on the absolute amount of material required.
The solution
In the PulFer24 joint project, the project partners are developing an innovative manufacturing concept with new processes and new machine technology for the production of rotor blade spar caps close to the final manufacturing site. The aim is to reduce production costs for rotor blades and their spar caps while simultaneously increasing the security of supply for rotor blade production. The new manufacturing process should be taken into consideration for new rotor blade designs and render the production of the rotor blades more efficient.
At Fraunhofer IWES, the available technology is being expanded and modified to permit pultrusion close to the rotor blade molds and further processing of the pultruded components without intermediate transport. In addition, adapted manufacturing and measuring technologies are being employed for improved process control and monitoring.
Fraunhofer IWES is also responsible for the development of process technologies as well as process and quality control among other things. The testing and validation of the manufacturing concept will take place in the institute’s DemoCenter in Bremerhaven.
The added value
PulFer24 will contribute not only to lowering the costs of rotor blade production but also to reducing the carbon footprint of wind turbines. Furthermore, the use of state-of-the-art materials makes it possible to increase material availability. Thanks to the compact process chain, it will also be possible to plan material usage more efficiently.
