JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 50

KNOW-HOW
Software

50

L

Four factors drive the development of superior wind blades
DR. OLIVIER GUILLERMIN DIRECTOR OF PRODUCT AND MARKET STRATEGY, VISTAGY

Blades are probably the most complicated and important component of wind turbines. Manufacturers are making substantial investments in developing larger wind turbines in order to enhance efficiency and increase yield among wind farms. However, as the size of blades continues to grow, current materials and design and manufacturing methodologies are reaching their limits. In particular, the need to reduce wind turbine weight is becoming more critical as turbines grow in size.
Automation cuts time and costs
premature blade failure issues and leading to repeat orders from satisfied customers. A prerequisite for developing efficient automated manufacturing is implementing a fully digital product development process in which the definition of the composite product is achieved via a complete and detailed digital master definition within a commercial 3D CAD system, such as CATIA, Pro/ENGINEER or Siemens NX. It is vital that the digital composite model for a blade contain all the necessary engineering information about plies and laminates, fibre orientations, ply thicknesses and materials. Such a model allows a computer-based producibility simulation (i.e. the simulation of the manufacturing process), be it prepreg layup for vacuum-assisted curing, dry layup for resin infusion or some other manufacturing method. Producibility simulations enable the design or manufacturing engineer to predict potential issues – such as composite fabric wrinkles or bridges – that may appear during layup operations due to the

ightweight composites have the demonstrated durability, stiffness and strength to be well suited for wind turbine blades, but new technologies and processes are needed to fully leverage these materials and enhance wind’s viability as a cost-effective source of power. Four elements are necessary to develop high-quality, durable, high-performance composite turbine blades that will enable the industry to meet the challenges of bringing wind turbines to market faster while lowering manufacturing costs, reducing lifecycle costs and premature failure occurrences, and creating larger and lighter blades. These four factors address how to: - Enable automation of the composite blade development process - Improve blade quality and consistency - Increase blade performance with respect to aerodynamics, weight, noise and vibrations - Promote innovation for new and customized blade design

Similar to the experience of the aerospace industry over the last decade, by automating the composites manufacturing process, a wind energy firm can expect dramatic reductions in labour and other manufacturing costs as well as cycle times. Reduced cycle times enable manufacturers to go to market more quickly and capture maximum market share. More automated processes also result in a greater level of consistency and quality, alleviating

jec composites magazine / No61 November - December 2010

This figure shows an example of the details of a wind blade ply layup. VISTAGY’s FiberSIM® composites engineering software is used to create and modify the layup to ensure that no errors are made in the selection of materials, orientations and sequences and that the blade will be manufactured as designed and analyzed.



JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010

Cover
Contents
NEWS WORLDWIDE
Companies
Spirit AeroSystems and GOL Linhas Aereas Inteligentes enter into agreements
CTRM and CTL to commercialize composites testing in Asia
IDI Composites International announces installation of automated BMC production line
Umeco and Shanghai Leadgo Technology form a joint venture in China
SAIC awarded USD 11 million contract to deliver manufacturing facility for composite building materials
Airbus completes allocation of A350 XWB airframe work packages to China
Hexagon Composites signs new major contract with Daimler AG
National Aerospace Laboratories: incisive know-how
Innovations - Twelve companies rewarded by JEC and CCE for their composites innovations
Agenda of events
Equipment: Welding - Increasing bond strength and reducing defects in ultrasonic welding
BUSINESS
Market survey - Aerospace composites in Quebec: a wealth of players and R&D
AN INTERVIEW WITH JACQUES CABANA PRESIDENT & GENERAL MANAGER FDC COMPOSITES Inc.
Niche Market - Tool-side breathing allows BAE Systems to manufacture its new UAV
Trend - Composites and the carbon label
FEATURE - AUTOMOTIVE
Data - World ranking of manufacturers years 2009
Trend -Formula One experience to drive forward other industries
Application - BMW's MCV, the first mass produced car with a carbon passenger cell
An interesting solution for NASCAR race engine alternators
Prepreg materials investigated as a storage battery for future cars
Research & Development - Lamborghini prepares for the future with a new carbon-fibre research development
Environment - How adhesives reduce emissions, minimize waste and improve recycling
FRP recycling in Europe, North America and the Pacific Rim area
USER'S PLATFORM
Composites in the world - Agile as a snake for ice climbing
Recyclable emergency snow shovel
Superbus: an innovative public transport concept
Successful partners - Conseil & Technique, an SME dedicated to the development of new products
Application - Advanced graphite composite bipolar plate for fuel cells
KNOW-HOW
Software - four factors drive the development of superior wind blades
Simulation - Bespoke simulation for thermoplastic composite
Raw material - Latent acid catalysts for process control phenolics
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Cover
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 2
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 3
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 4
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 5
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Contents
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 7
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Hexagon Composites signs new major contract with Daimler AG
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - National Aerospace Laboratories: incisive know-how
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Innovations - Twelve companies rewarded by JEC and CCE for their composites innovations
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Equipment: Welding - Increasing bond strength and reducing defects in ultrasonic welding
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 13
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Market survey - Aerospace composites in Quebec: a wealth of players and R&D
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 15
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - AN INTERVIEW WITH JACQUES CABANA PRESIDENT & GENERAL MANAGER FDC COMPOSITES Inc.
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 17
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Niche Market - Tool-side breathing allows BAE Systems to manufacture its new UAV
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Trend - Composites and the carbon label
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 20
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 21
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 22
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 23
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Data - World ranking of manufacturers years 2009
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 25
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Trend -Formula One experience to drive forward other industries
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 27
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Application - BMW's MCV, the first mass produced car with a carbon passenger cell
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 29
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - An interesting solution for NASCAR race engine alternators
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Prepreg materials investigated as a storage battery for future cars
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Research & Development - Lamborghini prepares for the future with a new carbon-fibre research development
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 33
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Environment - How adhesives reduce emissions, minimize waste and improve recycling
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 35
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 36
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - FRP recycling in Europe, North America and the Pacific Rim area
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 38
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 39
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 40
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 41
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 42
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 43
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Superbus: an innovative public transport concept
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Successful partners - Conseil & Technique, an SME dedicated to the development of new products
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 46
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Application - Advanced graphite composite bipolar plate for fuel cells
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 48
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 49
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Software - four factors drive the development of superior wind blades
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 51
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 52
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Simulation - Bespoke simulation for thermoplastic composite
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 54
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 55
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 56
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Raw material - Latent acid catalysts for process control phenolics
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 58
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 59
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 60
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