The ALMA Project

Preform technology is a game-changer in wind turbine blade manufacturing. By laying up and activating preform plies at specific temperatures and pressures, we create rigid sub-components that can be placed in blade moulds. This technology not only saves valuable production time but also addresses the health and safety concerns that increase with larger blades.

The ALMA project is spearheading the development of an Automatic Preforming Robotics System (APRS) to replace the current manual preform lay-up process. This cutting-edge system will be integrated into Siemens Gamesa (SGRE) wind turbine factories, marking a significant step towards fully automated blade manufacturing.

Key Features of APRS

• End-Effector: Facilitates accurate and fast placement of preform plies.
• Robot system: Uses the end-effector to automatically place plies according to layup plans for preforms.
• Advanced Inspection Software: Detects wrinkles and ensures precise ply placement, paving the way for a digital twin that simulates production cycles before actual manufacturing.

Benefits and Impact

• Reduced Production Time: Significant decrease in manual labour for material lay-up.
• Enhanced Blade Quality: Improved consistency and reduced need for repairs.
• Cost Savings: Expected reduction in production costs and man hours per blade.
• Environmental Incentives: Lower production costs will encourage renewable energy providers to invest in wind turbines, potentially leading to new offshore wind farms.

Demonstration and Implementation

The APRS will be demonstrated and validated at SGRE's production site in Aalborg. SGRE leads the project towards a commercial solution that will be implemented in future operations, ensuring the company's competitiveness in wind farm auctions despite rising inflation and material costs.

Global Climate Action Strategy

In line with the Paris Agreement’s objective to limit global warming to 1.5°C, Denmark has set ambitious goals for emission reduction and climate neutrality, aiming for a 70% reduction by 2030 and full climate neutrality by 2050. The ALMA project supports these objectives in several ways:

• Increasing Global Climate Ambition: Denmark seeks to influence both state and non-state actors to adopt ambitious renewable energy (RE) projects, such as onshore and offshore wind farms. By reducing the production costs of wind blades and accelerating the production process for large blades, the ALMA project enhances the economic viability of wind farms. This aligns with Denmark’s aim to replace fossil fuels with renewable energy.
• Shifting Financial Flows to Green Investments: The strategy includes redirecting global financial flows from fossil fuels to renewable energy and climate-friendly investments. The ALMA project will enable SGRE to increase the output of large wind blades while reducing costs, encouraging both state and private RE producers to invest in offshore wind farms, both in Denmark and internationally.

Contribution to EU Goals

The ALMA project will also support the European Union's targets which aims to reduce greenhouse gas emissions by at least 55% by 2030 and becoming the first climate-neutral continent by 2050.

Alignment with EUDP Strategy

1. More Green Electricity for Various Purposes: By 2030, Denmark aims to generate enough renewable energy to fully cover its electricity consumption, leveraging wind and solar power. The Danish government plans to establish two energy islands by 2030 to harness the wind resources in the North and Baltic Seas, with more offshore wind farm projects expected in the coming decades. The ALMA project will ensure the production of high-quality, cost-effective large-scale wind blades, meeting future demand from both state and private RE producers.
2. Energy Efficiency: Denmark, along with other EU countries, is committed to significant energy efficiency improvements. There is a considerable market for companies that can provide components and solutions for more efficient energy use. By making wind energy investments more attractive, the ALMA project will facilitate the export of wind energy technology, contributing to greater energy efficiency. The ALMA project is pivotal in supporting both Denmark's and the EU's climate and energy goals, ensuring a transition to more sustainable and efficient energy systems.