Dimensional metrology for wind energy systems

The mechanical components of Wind Energy Systems (WES) are exposed to the highest loads. Torques of up to 20 MN⋅m act on the blades and are transmitted to the drivetrain components. This defines the high requirements on such parts often resulting in tight manufacturing tolerances related to their size and mass. Reliable verification of manufacturing tolerances by means of measurements is a critical part of quality assurance.

This project will improve industrial measurement capabilities for the mechanical parts of WES following the Manufacturing Metrology Roadmap 2020 and accelerate the Energy Transition by enhancing the efficiency of WES technology.

The specific objectives of the project are:

1. Fast optical and multi-sensor measurement methods for the determination of dimension, shape and roughness are to be investigated with regard to their applicability for mechanical components of wind turbines and the achievable measurement uncertainties are to be determined. This includes coordinate measuring machines with different sensor systems as well as imaging sensors, which are used by means of drones for wear measurement directly on WES
2. Functionally appropriate measurement and evaluation methods for assessing the surfaces of drivetrain components are to be developed. This includes the use of both tactile and non-contact sensors. In particular, a comparison between tactile scanning and single-point measurements is to quantify the influences of the essential measurement parameters. Various approaches for holistic evaluation methods for machine elements are to be investigated and extended to include waviness analysis.
3. The use of digital twins to predict wear and loss of efficiency of wind turbine components is investigated using the example of rotor blades. Here, erosion at the leading edge of the rotor blade plays an essential role, which will be investigated using different measurement techniques. Experiments carried out by DTU in Copenhagen in the wind tunnel serve as a reference.
4. Measuring systems integrated on machine tools for fast and flexible measurement during production shall be qualified and improved. In particular, practical calibration strategies shall be developed for these systems, which, for example, use error separation methods and thus ensure traceability without the use of substitution standards.

The consortium comprises a total of 16 partners, seven of whom are industrial companies. This is intended to ensure rapid implementation of the processes developed and knowledge gained in the project in the manufacturing industry.