Coordinators

• H2 (Magdeburg-Stendal University of Applied Sciences), Kitemill

Topics and objectives

This is a new WP which addresses the challenges of AWE companies to manufacture their systems and scale up production capacity towards mass production. Requirements for the design tools are defined handled in WP2.

Today, the pilot and demonstration AWE systems are manufactured in single or very low quantities. AWE systems have the potential advantage to be able to be mass-produced similar to trucks or agricultural machinery as the components are comparably small. Some AWE OEMs have already started to define manufacturing processes, such as SkySails, EnerKíte, Kitepower and Twingtec/Mozaero. Their designs already consider future mass-production requirements, also by using off-the-shelf components where possible.

Industrialised manufacturing of AWES is still below TRL6. However, certain AWE systems are already at TRL7 or even higher which will make the step to reach TRL 6 for AWE manufacturing realistic.

In order to quickly upscale AWE manufacturing and to reduce costs, knowledge sharing among AWE technology developers is key. EU funding will help to build up sharable knowledge that is eventually required by all OEMs. Countries involved are at least: DE, NL, NO, ES

The project will consider the following aspects:

– Materials & Design

• Design for Circularity: Lightweight design, long-term use, reduction of material consumption
  through repairability, re-use, recycling, etc.
  o Specifying circular designs for shared components of the different kite technologies
  o Second markets for specific parts
  o Use of natural/recyclable components
  o Material evaluation besides the traditional engineering criteria
  o Considering social impact, CO2 impact, environmental footprint
• Design for mass production and deployment:
  o Cost reduction due to scaled production of shared components of the different kite technologies
  o Equal parts for easier automation
• Deliverables:
  • Catalogue for shared components for efficient AWE manufacturing
  • Creation of an open data source and a standardized material parameter template

– Life-Cycle Analysis (LCA)

Extending analysis towards improved and/or advanced systems regarding carbon and environmental footprint of AWE systems and components

• Establish a frontend with uniform material categories for the most common AWE concepts based on LCA publications.
• Address this by harmonizing key assumptions (e.g., recycling rates, manufacturing energy mix) so results are comparable with other technologies. WP2 or AWE OEMs need to supply load cases relative for LCA analysis.
• Include a supply-chain resilience assessment, covering material criticality, regional concentration, substitution/recycling pathways, and disruption scenarios.
• Provide suitable data for such analysis for models in WP 2
• Evaluate of designs, materials in these designs and manufacturing processes
• Compile research status and AWE-specific LCA guidelines, in line with ISO 14040 and ISO 14044 (PSI)
• Deliverables:
  • Material catalogue with AWE-specific requirements
  • LCA of AWE – status of research and guidelines (paper – PSI)

– Definition of test strategies for material and critical components

• Inspired V&V test pyramid from aerospace standards
  • Definition of testing standardization
  • In future allowing the introduction of some form of certificate, helping investors and reducing the risk for them.
  • Tether testing and proof of reliability (potential use of tether testing machine built under the Interreg NWE MegaAWE project)
• Deliverable:
  • AWE-specific standards (on testing)

– Manufacturing

• Manufacturing: Design for mass production, production floor layout, machinery, tools, location of manufacturing plants
• Manufacturing processes of core components
• Scaling and economies of scale: Production output increase, cost decreases, learning rates
• Quality assurance (non-destructive inspection, manufacturing process certification for critical parts, etc.)
• Definition and use of economic metrics: Levelized costs/profit/revenue of energy (LCOE, LPOE, LROE) etc.
• Reduction of waste

– Supply chain

• Logistics, supply chain analysis and supplier mapping
• Supplier selection / joint purchasing criteria / Definition of requirements for key suppliers
• Make-or-buy decision evaluation
• Supply chain resilience
• Data handling required to provide proof of circular economy compliance

– Standardization & certification

• Introduction of AWE-specific standards in IEC 61400 and other relevant standards related to manufacturing and components
• Electrical system safety: How to deal with ground station and grid connection related components and related safety expected.

– Deliverables

• D1.1. Catalogue for shared components for efficient AWE manufacturing
  D1.2 Material catalogue with AWE-specific requirements
  D1.3 LCA of AWE – status of research and guidelines (papers – PSI & TU Delft) and LCA repository
  D1.4 AWE-specific standards on testing

– Milestones

M1.1. WP kick-off meeting and potentially subsequent scope adjustment
M1.2 Review of status of deliverables
M1.3 Determine outstanding work for finalisation of Task