API's Dynamic 9D LADAR improves accuracy, safety, and speed in windmill rotor manufacturing inspections

As the demands on the wind energy industry continue to increase as the pressure for greener energy intensifies, manufacturing processes need to continually improve. Specifically, improvements to the accuracy and efficiency levels in the manufacturing processes for windmill rotor components. Manufacturers can achieve these improvements by applying and improving inspection processes, which ensures the quality and performance of components.

This is where API’s Dynamic 9D LADAR (LAser Detection And Ranging) technology comes in. The solution aims to provide improvements in the accuracy, efficiency, safety, and speed, of windmill rotor manufacturing inspections.

About the wind energy industry

While wind energy can be traced back as early as 5,000 BC, it wasn’t until the 1970s that the method was seriously considered as an alternative energy source. During this period, oil shortages and environmental concerns started to gain traction with governments from around the globe trying to find a solution. Today, there are hundreds of thousands of wind turbines installed all around the world, both on-shore and off-shore, as the fight against global warming continues.

How API's Dynamic 9D LADAR is affecting windmill rotor manufacturing

The Dynamic 9D LADAR can be utilised throughout the manufacturing process, from mould verification to flange hole inspection and final assembly inspection. With the Laser Tracker, the technology provides non-contact scanning speed which works to improve accuracy, and throughput while also reducing man-hours.

Moulds are used in windmill rotor manufacturing to shape composite materials. The mould verification process ensures the correct shape and dimensions of the rotor blades. Dynamic 9D LADAR can help manufacturers achieve these levels of accuracy whilst also completing the process quickly, with the system able to scan the mould surface from a rail or moving gantry, capturing precise measurements, and comparing them to the design specifications.

Another crucial step in windmill rotor manufacturing is flange hole inspection. The process involves ensuring the alignment and integrity of the bolt holes in the rotor hub. API’s system aims to make this process quicker, safer, and more accurate. Dynamic 9D LADAR features non-contact scanning capabilities which allows for rapid data capture of the flange surface. This results in the detection of any deviations or misalignments in the hole positions.

During the final assembly inspection process, the positioning and alignment of various components including blade roots, pitch mechanisms, and sensors are all verified. API’s system can perform comprehensive inspections, according to the developers, as it can complete inspections from multiple angles ensuring all components are correctly aligned. This is further enhanced with a 6DoF tracker from a Radian Laser Tracker and i360 sensor.

Key benefits of API's Dynamic 9D LADAR

• Captures data at the rate of 20,000 points per second.
• Provides high-precision measurements and detailed point cloud data.
• Ensures the accuracy of windmill rotor components at 25um per metre.
• Reduces inspection time and increases productivity.
• Minimises the risk of defects.
• Automates the inspection process, streamlining manufacturers' operations and reducing costs.
• Includes improved safety features like non-contact scanning which eliminates the need for physical contact. 

How will API's technology impact the wind energy industry?

The Dynamic 9D LADAR aims to eliminate the need for manual measurements while also speeding up the measurement process and reducing human errors, during mould validation. Similarly, in flange hole inspection API’s technology also reduces inspection time while enhancing accuracy. However, it also eliminates any need for physical contact, which in turn minimises the risk of damage to the delicate rotor components.

During the final assembly inspection process, the high accuracy level and ability to capture detailed point cloud data allows the Dynamic 9D LADAR to provide reliable results. This ensures API’s system can improve a company’s quality control, as it detects deviations and misalignments which could negatively impact the rotor’s performance.

Overall, API claims that its solution is “game-changing” for windmill rotor manufacturing inspections. The Dynamic 9D LADAR can aid in mould verification, flange hole inspection, and final assembly inspection, with the technology claiming to improve the accuracy, efficiency, safety, and speed, of the entire process. By integrating API’s system, wind energy manufacturers can enhance both the quality and performance levels of rotor components. Which can go on to positively impact the future growth of sustainable energy production.