4/14/20101Turbine Life Cycle EngineeringAndrew KusiakIntelligent Systems Laboratory2139SeamansCenterThe University of Iowa Intelligent Systems Laboratory2139 SeamansCenterThe University of Iowa Iowa City, Iowa 52242 - [email protected]: 319-335-5934 Fax: 319-335-5669http://www.icaen.uiowa.edu/~ankusiakLife Cycle Engineering Where it all begins? All resources are limited, including ability of the earth and atmosphere to clean itself Major water and atmosphere pollutants, e.g., CO2, NOx, dSOThe University of Iowa Intelligent Systems LaboratoryandSOx CO2 emissions in the energy production process (in particular the wind energy equipment production)  Water contamination by industry, e.g., waste disposal, etc.  Waste and disposal of contaminants and resources, e.g., electronics, mercury, cellulose (paper) Sustainable DevelopmentMain goal Meeting our needs without negative impact on the ability of future generations to meet their needsThe University of Iowa Intelligent Systems Laboratory Most disputes evolve around who is going to pay for making the world clean and healthy Is it natural to be sustainable (responsible, no debt, …)Sustainability Chain in Wind Energy Extraction of natural resources, e.g., iron ore, chemicals, cellulose Transportation of natural resourcesEnergy usage and environmental impact perspectiveThe University of Iowa Intelligent Systems Laboratory Production of raw materials, e.g., iron, fiber glass Fabrication and machining – material processing Assembly of subsystems  Transportation Final assembly Service (operations and maintenance) Product end of life4/14/20102Sustainable Manufacturing Sustainability is of paramount importance in wind energy industry due to high material (energy) content, e.g., gearbox, tower, cablesS t i bilit h t b ffi i tl dd d t thi tiThe University of Iowa Intelligent Systems LaboratorySustainability has not been sufficiently addressed at this time by the wind energy industry due to the wind energy “rush”  Now is the very last opportunity (somewhat late) to address turbine life-cycle engineering issues in wind industryThe Four-Criteria Dilemma Maximization of turbine performance Maximization of turbine life-cycleThe University of Iowa Intelligent Systems Laboratory Minimization of energy used to built a turbine Minimization of environmental impactsEmerging solution: Predictive engineeringSource of Decreased Wind Turbine Life Time? Problem: Variable loadsKey issue: Torque management is a viable solution to The University of Iowa Intelligent Systems Laboratoryreduction of extreme stressesSolution: Anticipation of the extreme loads (wind conditions)Implementation: Predictive engineeringWhat to Do With an Old Wind Farm Equipment?The University of Iowa Intelligent Systems Laboratory Reuse (most preferred) Remanufacture Recycle  Disposal (should disappear)Life cycle engineeringRestored 1949 VW Bug4/14/20103Life Cycle Engineering Fuji-Xerox CaterpillarBest industrial practicesThe University of Iowa Intelligent Systems Laboratoryp Appliance industry, e.g., washers UI’s “Wind Turbine Corporation”Design, process, and mfg engineers: Kevin LanganR bbiLtThe University of Iowa Intelligent Systems LaboratoryRobbie Lovstuen Dan Rogge Matt ZankerUI engineeringstudentsTurbineComponentsHubThe University of Iowa Intelligent Systems LaboratoryCoilmanufacturingGenerator componentsdesigned for reuseand remanufacturingTurbine ComponentsThe University of Iowa Intelligent Systems LaboratoryVa neYaw mechanismRated power: 750 WTotal cost: $3544/14/20104Predictive Engineeringand Residual LifeThe University of Iowa Intelligent Systems LaboratoryPredictive Engineeringand Power EstimationThe University of Iowa Intelligent Systems LaboratorySustainable ManufacturingLife Cycle Engineering covers issues ranging from product (component) conceptual design to its retirement Basic ways of assembly (component) retirement:The University of Iowa Intelligent Systems LaboratoryBasic ways of assembly (component) retirement: Reuse (most preferred) Remanufacture Recycle  Disposal (should disappear)Sustainable ManufacturingWhy reuse?How long does it take to decompose when disposed in a landfill? Paper: 2 – 5 months Orange peels: 6 months Milk cartoons: 5 yearsThe University of Iowa Intelligent Systems Laboratory Plastic bags: 10 – 20 years Leather shoes: 24 – 40 years Plastic containers: 50 – 80 years  Disposable diapers: 75 years  Tin cans: 100 years  Aluminum cans: 200 – 500 years4/14/20105Life Cycle EngineeringAssembly (component) reuse Products involve components and assemblies with different useful life timeThe University of Iowa Intelligent Systems Laboratory Estimating (predicting) residual life time of components and assemblies is of importance to their reuse A component (assembly) designed for sustainability may be reused a number of times and serve different productgenerations Life Cycle EngineeringAssembly (component) remanufacture Components (assemblies) that can not be reused in “as is” form could be remanufactured and then usedThe University of Iowa Intelligent Systems Laboratoryin the current or next product generationsLife Cycle EngineeringAssembly (component) recycle Components (assemblies) that can not be reused and remanufactured should be recycled in most The University of Iowa Intelligent Systems Laboratoryenvironmentally conscious way Components (assemblies) disposal should meetthe highest standards of the societal scrutiny  The long-term goal should be elimination ofthe product disposal as the life cycle alternative Benign Manufacturing and Transportation The turbine manufacturing process itself and transportation should not adversely impact the natural environmentM f t i ith i i l d i tThe University of Iowa Intelligent Systems LaboratoryManufacturing processes with minimal adverse impact on the environment should be developed Supply chain logistics should focus on minimizing transportation energy during the wind farm construction as well as operations and maintenance4/14/20106Ubiquitous Manufacturing and Wind Farm Operations A ubiquitous system involves many sensors,including RFIDsChiittififtiThe University of Iowa Intelligent Systems LaboratoryComprehensive integration of information among physical