The TURBO consortium has made significant strides in real-time resin monitoring and in-line process control for wind turbine blade infusion, marking a pivotal moment in the industry's pursuit of sustainable and efficient manufacturing. This groundbreaking project, funded by Horizon Europe, is a testament to the power of collaboration, bringing together seven beneficiary organizations and associated partners to tackle the complex challenges of composite wind turbine blade production.
One of the key innovations lies in the wireless sensing platform developed by the Centre for Process Innovation (CPI). This platform, fabricated on a flexible substrate, plays a crucial role in tracking resin flow and temperature during the infusion process. By broadcasting monitoring data in real-time, it enables adaptive process control, a game-changer in improving manufacturing consistency and reducing defects. This real-time monitoring capability is a significant advancement, allowing for immediate adjustments to manufacturing parameters, which is essential for achieving the project's goal of minimizing waste and defects.
The consortium's technical scope is comprehensive, covering process simulation, in-line and post-manufacture nondestructive testing (NDT), and digital twin-based process control. DTU, a key player in the project, is leading the charge on process simulation, employing advanced AI techniques such as model order reduction and machine learning (ML) to generate physics-based predictions. This real-time decision support system is a powerful tool, enabling the adjustment of manufacturing parameters based on sensor data, a critical aspect of defect prevention.
In the realm of in-process monitoring, Synthesites' system takes center stage, measuring resin arrival at up to 56 points during infusion and calculating online resin viscosity and gelation time. This system, combined with CPI's wireless sensor platform, provides a comprehensive view of the resin's behavior, allowing for precise control signals. The integration of these technologies is a significant step towards achieving the project's objectives.
The NDT front is equally impressive, with Norblis ApS developing an industrial-scale combined thermography and mid-infrared optical coherence tomography (OCT) scanner for sub-surface defect detection in blade coatings. DTU's supercontinuum light source, extending to mid-infrared wavelengths, and Universitat Politecnica de Valencia's ML-based defect detection algorithms using YOLO object detection techniques, further enhance the project's capabilities. These advancements ensure that defects are identified and addressed promptly, contributing to the overall quality of the manufacturing process.
NCC takes the lead in developing the project's digital twin framework, which is a cornerstone of the TURBO approach. By combining live process and sensor data with ML and physics-based simulation, this framework provides manufacturing quality insights and corrective feedback loop control. Siemens Gamesa Renewable Energy's integration of TURBO advances into its infusion and control systems at its Aalborg factory will serve as a full-scale project demonstrator, showcasing the practical application of these innovations.
The sustainability assessment activities, led by Arditec, are a crucial aspect of the project. By using standardized life cycle assessment methodologies, including LCA per ISO 14040/14044, Life Cycle Costing, and Social LCA, the consortium evaluates the environmental, economic, and social benefits of the TURBO approach. This comprehensive assessment ensures that the project not only focuses on technical advancements but also on the long-term sustainability and impact of wind turbine blade manufacturing.
In conclusion, the TURBO consortium's progress in real-time resin monitoring and in-line process control is a significant milestone in the wind energy industry. By combining cutting-edge technologies, advanced AI, and a focus on sustainability, the project is paving the way for a more efficient and environmentally friendly production process. As the project continues to unfold, the industry can anticipate a more sustainable and reliable approach to manufacturing composite wind turbine blades, a crucial step towards a greener future.
