Composite Blade Production & Quality Control

Process control for blade production excellence

Producing composite blades is a challenging process that involves controlling variables and understanding the correlation between them. Preventing production defects from unexplained voids, wrinkles, delamination, and other defects is complex. Many companies experience very high rejection rates during blade production, some even greater than 25 percent. Even a small improvement in the rejection rate can save millions of dollars per year.

Dassault Systèmes Sustainable Wind Turbines provides a unique, data-driven, rule-based continuous process improvement methodology for blade manufacturing. The analysis of shop floor data enables you to discover hidden root causes of defects. Describing best practices in natural language rules enables you to capitalize and reuse acquired knowledge. By monitoring shop floor data, the risk of defects can be quantified and you can develop “agile process control”, enabling experts to extract, optimize, and validate a robust set of easy-to-read operational best practices.

Key Capabilities and Benefits:

  • Discover and edit rules with experts (knowledge capture)
  • Quickly identify root causes of failure
  • Understand quantified influence of process variables
  • Obtain advance warning of potential problems
  • Adjust process in real-time to changing conditions
  • Monitor rule compliance and receive notification when new rules may be needed

After 6 months of project, our team already managed to cut by half the number of blades with 'dry glass' defect that required a lot of rework. We now look forward to deploy real-time alerts and recommendations to reach 95% parts right the first time.

Maciej Grzybowski Engineering Manager, LM Windpower