0
Research Papers

Automated Composite Fabric Layup for Wind Turbine Blades

[+] Author and Article Information
Siqi Zhu

The Wind Energy Manufacturing Laboratory,
Department of Industrial and
Manufacturing Systems Engineering,
Iowa State University,
Ames, IA 50010
e-mail: drsiqizhu@gmail.com

Corey J. Magnussen

TPI Composites, Inc.,
8501 N. Scottsdale Rd.,
Gainey Center II, Suite 100,
Scottsdale, AZ 85253
e-mail: CMagnussen@tpicomposites.com

Emily L. Judd

Department of Climate and
Space Sciences and Engineering,
University of Michigan,
Ann Arbor, MI 48104
e-mail: emily.l.judd@gmail.com

Matthew C. Frank

Associate Professor
Department of Industrial and
Manufacturing Systems Engineering,
Iowa State University,
Ames, IA 50010
e-mail: mfrank@iastate.edu

Frank E. Peters

Associate Professor
Department of Industrial and
Manufacturing Systems Engineering,
Iowa State University,
Ames, IA 50010
e-mail: fpeters@iastate.edu

1Corresponding author.

Manuscript received June 19, 2016; final manuscript received October 7, 2016; published online January 11, 2017. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 139(6), 061001 (Jan 11, 2017) (10 pages) Paper No: MANU-16-1342; doi: 10.1115/1.4035004 History: Received June 19, 2016; Revised October 07, 2016

This work presents an automated fabric layup solution based on a new method to deform fiberglass fabric, referred to as shifting, for the layup of noncrimp fabric (NCF) plies. The shifting method is intended for fabric with tows only in 0 deg (warp) and 90 deg (weft) directions, where the fabric is sequentially constrained and then rotated through a deformation angle to approximate curvature. Shifting is conducted in a two-dimensional (2D) plane, making the process easy to control and automate, but can be applied for fabric placement in three-dimensional (3D) models, either directly or after a ply kitting process and then manually placed. Preliminary tests have been conducted to evaluate the physical plausibility of the shifting method. Layup tests show that shifting can deposit fabric accurately and repeatedly while avoiding out-of-plane deformation.

Copyright © 2017 by ASME
Topics: Textiles , Machinery , Blades
Your Session has timed out. Please sign back in to continue.

References

Figures

Grahic Jump Location
Fig. 1

Shifting process on a unit section of fabric

Grahic Jump Location
Fig. 2

(a) Steering—schematic and actual and (b) shifting—schematic and actual

Grahic Jump Location
Fig. 3

Guide curve and tolerance zones

Grahic Jump Location
Fig. 4

(a) Starting position and (b) fabric variables

Grahic Jump Location
Fig. 5

Path calculation for Tji+1

Grahic Jump Location
Fig. 6

Prototype fabric shifting machine

Grahic Jump Location
Fig. 7

Fabric before (left) and after (right) shifting

Grahic Jump Location
Fig. 8

Working procedure of the shifting machine

Grahic Jump Location
Fig. 9

Mesoscale observation on the shifted fabric

Grahic Jump Location
Fig. 10

The shape of test coupons

Grahic Jump Location
Fig. 11

The effect of discrete shift quantity on fatigue life

Grahic Jump Location
Fig. 12

Two-dimensional sample layout

Grahic Jump Location
Fig. 13

The measurement coordinate system

Grahic Jump Location
Fig. 14

Prescribed and actual position of the shifted fabric in a 2D coordinate system

Grahic Jump Location
Fig. 15

Average position deviation of each section and radius

Grahic Jump Location
Fig. 16

Effect of over-shifting

Grahic Jump Location
Fig. 17

Average positional deviation for over-shifted versus non-over-shifted samples

Grahic Jump Location
Fig. 18

CAD model of trailing edge prefabrication mold

Grahic Jump Location
Fig. 19

Measurement of fabric position along the mold

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In