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Corey J. Magnussen
TPI Composites, Inc.,
8501 N. Scottsdale Rd.,
Automated Composite Fabric
Gainey Center II, Suite 100,
Scottsdale, AZ 85253
Layup for Wind Turbine Blades
e-mail: CMagnussen@tpicomposites.com
This work presents an automated fabric layup solution based on a new method to deform
Emily L. Judd fiberglass fabric, referred to as shifting, for the layup of noncrimp fabric (NCF) plies.
Department of Climate and The shifting method is intended for fabric with tows only in 0 deg (warp) and 90 deg
Space Sciences and Engineering, (weft) directions, where the fabric is sequentially constrained and then rotated through a
University of Michigan, deformation angle to approximate curvature. Shifting is conducted in a two-dimensional
Ann Arbor, MI 48104 (2D) plane, making the process easy to control and automate, but can be applied for fab-
e-mail: emily.l.judd@gmail.com ric placement in three-dimensional (3D) models, either directly or after a ply kitting pro-
cess and then manually placed. Preliminary tests have been conducted to evaluate the
Matthew C. Frank physical plausibility of the shifting method. Layup tests show that shifting can deposit
Associate Professor fabric accurately and repeatedly while avoiding out-of-plane deformation.
Department of Industrial and [DOI: 10.1115/1.4035004]
Manufacturing Systems Engineering,
Iowa State University, Keywords: automated composite manufacturing, composite fabric forming, composite
Ames, IA 50010 layup, wind turbine blades, noncrimp Fabric
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
Journal of Manufacturing Science and Engineering JUNE 2017, Vol. 139 / 061001-1
C 2017 by ASME
Copyright V
Fig. 2 (a) Steeringschematic and actual and (b) shiftingschematic and actual
Journal of Manufacturing Science and Engineering JUNE 2017, Vol. 139 / 061001-3
as the rollers feed the fabric. The shifting clamp moves back
to center synchronously. At this point, the cycle is finished
and the next cycle starts from Step 1.
4 Experimentation
To test the performance of the shifting machine, a series of
layup experiments were performed. A preliminary fatigue test was
conducted to test the effect of shifting on the tensile fatigue life of
fiberglass. A 2D layup test was completed to test the accuracy and
repeatability of the machine. Next, a 3D layup test was completed
to test the plausibility of applying the shifting technique to lay up
Fig. 7 Fabric before (left) and after (right) shifting the trailing edge prefabrication of an MW class wind turbine
blade. The fabric used for the layup tests was 200 mm wide Saer-
tex 930 g/m2 unidirectional noncrimp fiberglass.
Initialize: The shifting head moves to start position. Both
rollers close and both clamps open. 4.1 Mesoscale Deformation After Shifting. Preliminary
Step 1: The spacing clamp moves to the corresponding posi- mesoscale observation on the shifted fabric showed that most of
tion according to the length of the shift section. the unidirectional tows were subjected to pure shear, while the
Step 2: Both rollers open and both clamps close to grip the tows adjacent to the clamps were subjected to bending (Fig. 9).
fabric. Next, the gantry moves the entire shifting head to Tow separation in the bent section was observed when the
position the spacing clamp, while the shifting clamp synchro- shift angle was close to shear locking limit. The deformation was
nously moves in the opposite direction to maintain position small enough to be acceptable in industrial wind blade manufac-
relative to the mold. At the same time, the spacing clamp turing, where the shift angle will be kept well below the shear
moves toward the rear roller to compensate for the length locking limit for most commonly used fabrics. The low level
reduction of the shifted fabric. details of the mesoscale measurement analysis is outside the scope
Step 3: Both clamps open and both rollers close. Next, the of this paper, and due to page constraints they will not be pre-
entire shifting head moves forward to the next shift position sented in their entirety.
Journal of Manufacturing Science and Engineering JUNE 2017, Vol. 139 / 061001-5
Group # Radius (mm) Shift angles (deg) Length of each section (mm) Replications Variable
Group # Radius (mm) Shift angles (deg) Length of each section (mm) Replications Variable
Fig. 14 Prescribed and actual position of the shifted fabric in a 2D coordinate system
Journal of Manufacturing Science and Engineering JUNE 2017, Vol. 139 / 061001-7
Journal of Manufacturing Science and Engineering JUNE 2017, Vol. 139 / 061001-9