Advanced Technology Developed by We4Ce and CNC Onsite for the Reconstruction of Blade Roots
In a groundbreaking collaboration, Dutch rotor blade expert We4Ce and Danish precision machining specialist CNC Onsite have transferred blade repair expertise to a wind park in South Asia. This joint project marks a significant milestone in the wind energy industry, offering a cost-effective, sustainable, and efficient solution for blade repairs.
The customer, Suzlon, will restore more than 1,000 bushings in their wind turbines, thanks to the adoption of the innovative remanufacturing technology. This technology provides several advantages, including up to 60% in cost savings, reduced downtime, and environmental benefits from eliminating potential blade waste and blade transportation.
The remanufacturing method offers a viable alternative to full blade replacement. It combines precision milling, a specialized fixing method, and the installation of replacement bushings to produce a like-new component engineered for reliable performance over a lifespan of up to 20 years.
The blade root bushing, or insert, is a safety-critical component that connects the rotor blade to the turbine hub. If during the original manufacturing process this material shrinks or is unevenly distributed, microcracks can arise. These cracks reduce the bonding surface and increase the risk of the bushing loosening, potentially leading to blade failure.
To address this issue, the technicians were trained at We4Ce's laboratory in the Netherlands and at CNC Onsite in Denmark. The training equipped them with the skills to independently repair loose blade root bushings on 26 turbines.
CNC Onsite designed and built a custom machine for drilling out defective bushings in rotor blades' composite laminate. Soren Kellenberger, partner and sales director at CNC Onsite, explained the use of special drills for high precision and efficiency. We4Ce then applied its patented infusion technology to fasten the new replacement bushing in place, ensuring exact centering.
This partnership between We4Ce and CNC Onsite is not limited to this project. They are currently preparing for upcoming projects with significant potential, including Brazil and the US. Their collaboration aims to revolutionize the wind energy industry, making blade repairs more accessible, sustainable, and cost-effective.
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