JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 19

lnnovation in wind power through multi-process-capable systems
same time, the computer-aided production
of composites would also expand, creating advantages outside of the wind power industry.

Fig. 2: Process chain of the BladeFactory project 

Fig. 3: Computer-aided manufacturing - Process chain

The use of two gantries has major advantages.
No substitution processes are required and
the set-up times are considerably reduced.
These advantages help achieve the desired
parallelization of the production process.
Enabling new manufacturing
structures through automation
Rotor blades have been made of composite
material for years. The core of this innovation
is therefore not the material used but the
process technology. The production of rotor
blades is still largely manual due to their high
complexity and their large dimensions. The
BladeFactory project is specifically aimed at
automating this manual production.
What is interesting about this research project
is the diversity of process technologies. Not
only are different raw materials used (glass
fibre mats, tapes), but the way in which the
material is applied varies. Simple pick &
place processes, tape laying strategies and
sophisticated draping possibilities are under
research. These processes are also interesting
for general composite manufacturing outside
wind power. It should also be mentioned that

another process is being developed for joining
the two rotor shells. This process is specifically
required for dosing and applying the adhesive
that holds the shells together.
As part of this project, SWMS Systemtechnik
is conducting special research into the possibilities of integrating CAD/CAM solutions.
The CAM chain to be developed includes
the Siemens Fibersim, CAESA® Composites
and NX CAM/VNCK software programs
(process chain shown in Figure 3). The
rotor blade's lifecycle is covered from product
development to virtual manufacturing. The
three-dimensionality of the depositing process is a major challenge as the fibre material
is not deposited in one plane but is directly
oriented according to the mould geometry
during the laying process (deposited close
to the final contour). This requires a six-axis
manufacturing process.
The research project primarily advances
the wind power industry and promotes the
competitiveness of renewable energy. If manual rotor blade production is automated, the
cycle time and labour costs could be reduced
while increasing production quality. At the

Multi-process-capable
systems with CAM support
In automation technology, a machine is often
used to implement a specific production
step or process. These production systems
are then often arranged in a line to perform
their respective process steps according to
the production sequence. The steps for manufacturing the forming tool (e.g. by milling),
laminate production (ATL/AFP and pick &
place processes), the bonding process of the
half-shells and grinding are used here as examples for the wind power sector. By means
of a novel production environment, the
BladeFactory project should make it possible
to implement all value-adding processes on
one single machine.
However, the ability of a system to carry
out different processes using suitable tools
and end effectors is a particular challenge
for automation technology. This increases
complexity but also enables a multitude
of process optimizations. To fully exploit
these possibilities, it is important to handle
the increased difficulty in a controlled and
consistent manner. SWMS is developing a
continuous process-accompanying CAM
environment for multi-process plants. The
CAESA® software can already be used to map
various laying processes from composite
technology. Using the BladeFactory project
results, it should now also be possible to handle and carry out several different processes
one after the other, in sequence, in the same
plant. The processes are not limited to AFP or
ATL technologies but can be extended and
adapted according to process requirements.
It is now necessary that numerous, varied
processes can be consecutively and sequentially integrated independently from the
strategy and tools used. Tool changes and
general set-up times are also being taken into
account. The entire production sequence can
be accompanied and mapped using both the
real-life and CAM process chains.
Since these are largely specially-developed
process technologies, an adaptable software
interface has to be developed. For each
process, specific manufacturing features are
established in which relevant parameters can
be specified that have a corresponding effect

N°136 September - October 2020

/ jec composites magazine

19



JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020

Cover
Edito
“We can change the way we envision global shipping overall”
Contents
NEWS
In brief
Agenda
BUSINESS
Reinforcement - Natural-fibre composites: an overview
Startup - When 3D printing meets sustainability
China - Xinzhou bets on the bamboo-based composites industry
MANUFACTURING
Wind - lnnovation in wind power through multi-process-capable systems
Automation - Higher production capacity thanks to automated manufacturing
FEATURE Sustainability - The path has been plotted
Recycling ecosystem - Composites recycling: in search of the circular economy
Mobility - A new generation of recycled composite materials for sustainable mobility
Preimpregnated textile - Healable composites to improve circularity
Process - New trends in composites and plastics recycling
Raw materials - Innovative composites made from up to 92% reclaimed materials
Construction - Biocomposites and automation: a sustainable future for the building industry
Ressources - Waste-free composite wheel production
Wind energy - From bottle to blade
Durable composites - Upcycling plastic bottles into value-added composite applications
Matrix - Novel thermoset composites for more competitive and sustainable industries
SOLUTIONS
Aerospace - Slinging rockets into space
Aerospace - Composites push back the final frontier
Railway - Composite overhead line catenary system for light rail
TECHNOLOGY
Repair - Developing an eddy current-based sensor system for quality assurance of carbon fibres
Inside the lab - Advanced Composite Materials Facility University of Southampton
Resin - Development of new type of plastics: Polypropylene 2.0
Index
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JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Cover
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 2
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Edito
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - “We can change the way we envision global shipping overall”
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 5
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Contents
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 7
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - In brief
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 9
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 10
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Agenda
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Reinforcement - Natural-fibre composites: an overview
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 13
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Startup - When 3D printing meets sustainability
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 15
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - China - Xinzhou bets on the bamboo-based composites industry
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 17
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Wind - lnnovation in wind power through multi-process-capable systems
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 19
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 20
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 21
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Automation - Higher production capacity thanks to automated manufacturing
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 23
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 24
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 25
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Recycling ecosystem - Composites recycling: in search of the circular economy
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 27
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 28
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 29
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 30
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Mobility - A new generation of recycled composite materials for sustainable mobility
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 32
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Preimpregnated textile - Healable composites to improve circularity
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 34
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 35
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Process - New trends in composites and plastics recycling
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 37
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Raw materials - Innovative composites made from up to 92% reclaimed materials
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 39
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Construction - Biocomposites and automation: a sustainable future for the building industry
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 41
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Ressources - Waste-free composite wheel production
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 43
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Wind energy - From bottle to blade
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 45
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Durable composites - Upcycling plastic bottles into value-added composite applications
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 47
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Matrix - Novel thermoset composites for more competitive and sustainable industries
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 49
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 50
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Aerospace - Slinging rockets into space
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 52
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 53
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Aerospace - Composites push back the final frontier
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 55
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Railway - Composite overhead line catenary system for light rail
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 57
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 58
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Repair - Developing an eddy current-based sensor system for quality assurance of carbon fibres
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 60
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 61
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Inside the lab - Advanced Composite Materials Facility University of Southampton
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 63
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Resin - Development of new type of plastics: Polypropylene 2.0
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 65
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 67
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 68
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