4/24/20141The University of Iowa Intelligent Systems LaboratoryTurbine ManufacturingAndrew KusiakIntelligent Systems Laboratory2139 Seamans CenterThe University of Iowa Iowa City, Iowa 52242 - [email protected]: 319-335-5934 Fax: 319-335-5669http://www.icaen.uiowa.edu/~ankusiakThe University of Iowa Intelligent Systems LaboratoryMajor Turbine ComponentsThe University of Iowa Intelligent Systems LaboratoryRotor Blade Materials 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 http://web.mit.edu/windenergy/windweek/Presentations/Nolet_Blades.pdfThe University of Iowa Intelligent Systems LaboratoryModern Blade DesignLaminated shell design with spar box and spar websE. Hau (2006), p. 2384/24/20142The University of Iowa Intelligent Systems LaboratoryRotor Blade Cross-sectionE. Hau (2006), p. 230GFRP = Glass fiber reinforced polyesterThe University of Iowa Intelligent Systems LaboratoryNew Blade DesignE. Hau (2006), p. 239Mixed glass fiber/carbon fiber with cross-bolt joining at the rotor hubThe University of Iowa Intelligent Systems LaboratoryWinding MachineE. Hau (2006), p. 237 The University of Iowa Intelligent Systems LaboratoryAutomated Manufacturing1. Winding with D-spar2. Placing the cones for the rear box3. Winding the complete bladeE. Hau (2006), p. 2374/24/20143The University of Iowa Intelligent Systems LaboratoryBlade Manufacturing FacilityE. Hau (2006), p. 239 The University of Iowa Intelligent Systems LaboratoryTower SectionE. Hau (2006), p. 430The University of Iowa Intelligent Systems LaboratoryConcrete Tower ManufacturingE. Hau (2006), p. 441 The University of Iowa Intelligent Systems LaboratoryBlade Testing4/24/20144The University of Iowa Intelligent Systems LaboratoryThe Purpose of Testing Rotor 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 LaboratoryNacelle on the RoadE. Hau (2006), p. 558The University of Iowa Intelligent Systems LaboratoryTower TransportationE. Hau (2006), p. 659 The University of Iowa Intelligent Systems LaboratoryTower TransportationE. Hau (2006), p. 6594/24/20145The University of Iowa Intelligent Systems LaboratoryTower BaseE. Hau (2006), p. 660 The University of Iowa Intelligent Systems LaboratoryFoundation for a Tabular Tower E. Hau (2006), p. 431The University of Iowa Intelligent Systems LaboratoryAssembly of ThreeTower SectionsE. Hau (2006), p. 662 The University of Iowa Intelligent Systems LaboratoryPuling up a NacelleE. Hau (2006), p. 6624/24/20146The University of Iowa Intelligent Systems LaboratoryMounting the Complete RotorE. Hau (2006), p. 662 The University of Iowa Intelligent Systems LaboratoryHelicopter UseE. Hau (2006), p. 664The University of Iowa Intelligent Systems LaboratoryPortalCraneE. Hau (2006), p. 665The University of Iowa Intelligent Systems LaboratorySwingingCraneE. Hau (2006), p. 6664/24/20147The University of Iowa Intelligent Systems LaboratoryTop CraneE. Hau (2006), p. 670 The University of Iowa Intelligent Systems LaboratoryTwo CranesMounting a GeneratorE. Hau (2006), p. 672The University of Iowa Intelligent Systems LaboratoryConcrete Tower ConstructionE. Hau (2006), p. 439 The University of Iowa Intelligent Systems LaboratoryTurbine Supply Chain Supply chain of importance due to global production of turbine components Product (wind turbine) assembled in the field Mix of mechanical, electrical, and civil engineering activities Different assembly equipment (e.g., cranes) and different assemblies (e.g., high power electricity, mechanical assembly) Energy cost to manufacture and transport components and assemblies is an issue4/24/20148The University of Iowa Intelligent Systems LaboratoryTurbine Supply Chain Overlapping supply chain with the number of sinks equal to the number of wind turbines at a park Transportation distance (time) a significant component of the network Modeling such a network is challenging due to new network architecture (intertwined networks) CharacteristicsThe University of Iowa Intelligent Systems LaboratoryTurbine Supply ChainExamples of supply chain modeling methodologies Network flow models Petri nets Neural networks Data-driven models (data mining)Important to consider in modeling supply chains: Evolving network architecture Risks CostsThe University of Iowa Intelligent Systems LaboratoryTurbine Supply Chain Single supply source Ease of quality control High risk of delivery disruption  Low control relative to the cost of components, and assemblies Multiple supply sources More involved quality control Lower risk of delivery disruption Management of cost and quality is neededSupplier optionsThe University of Iowa Intelligent Systems LaboratoryTurbine Supply Chain4/24/20149The University of Iowa Intelligent Systems LaboratoryTurbine 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 suppliersThe University of Iowa Intelligent Systems