The energy transition is not just creating an increased demand for wind turbines, but also the need for greater performance per unit. The resulting challenges are numerous. One answer is to optimise the highly stressed fibre composite components. This not only ensures greater output from the turbine, it also increases its service life. In this way, you can increase your competitiveness and make an important contribution to saving resources. With us, you can implement the technology of fibre composite structures in the best possible way, as we have developed innovative solutions for your challenges.
Our solution competencies
Our formula for success in inspiring solutions is an experienced team that develops components with passion and curiosity using the latest tools and methods – simulating and then optimising their properties.
We do highly stressable components.
Thanks to our experience from over 150 fibre composite projects, we know how to find and exploit potential for increasing the load-bearing capacity of large components. In order to achieve economic results, we not only use our simulation expertise and calculation automation, we also develop our own calculation tools to find the best solution for you.
In this way, we realise the optimisation of your component in terms of its weight, stiffness or strength. In this way, we make the desired increase in performance of the system possible while maintaining the quality and improving the price/performance ratio of the component.
Components optimised by us live longer.
In order to extend the service life of components for you, we realise the optimisation of your structural component, thus enabling the desired service life while simultaneously increasing the load capacity. From the conceptual design through simulation and optimisation of the components to the development of production-optimised manufacturing concepts to meet quality standards, we support you. Since monitoring during the production process also plays an important role in the longevity of rotor blades, for example, we offer you expertise in the quality assurance of FRP parts through on-site production monitoring.
Components realised by us thus reduce your running costs, as these components not only have a longer service life but also allow for longer inspection intervals. As a result, the downtimes of the wind turbines can be reduced and their effectiveness increases.
With us, you’re just in time – and on budget, of course.
We make short development cycles and the highest component safety possible for you while adhering to the budget framework defined by you.
In addition to our many years of expertise in lightweight design and innovative solutions, the professional management of your project makes an important contribution to its fast and successful fulfilment. Close and regular communication with you is the efficient way to react quickly and flexibly to your wishes and to offer expedient solutions.
Our 10-strong team is equipped with all the necessary in-house resources. This guarantees speed and quality. We are constantly developing – state-of-the-art digital engineering is not just applied by us, we also develop it, meaning that unique simulation/calculation tools are available.
Lightweight engineering for wind turbines
Supervising the production of fibre-composite rotor blades for wind turbines
The loads on individual components of ever larger wind turbines are immense. In addition to the structural design of fibre-composite parts - e.g. rotor blades - their flawless production is essential. That is why we monitor the production of rotor blades with a member of staff on site at the customer’s premises and also carry out the final inspection.
In this field, the following competencies at ar engineers lead to success:
- Extensive expertise in production planning and monitoring of complex, highly loaded fibre-composite components.
- In-depth knowledge of production processes in small batches, thanks to extensive experience in boat building
- Identification and evaluation of potential bottlenecks in production and development of
- Coordination between manufacturer (Siemens Gamesa) and operator (Vattenfall), as well as documentation and preparation of reports.
Thanks to our many years of expertise in the production planning and monitoring of complex, highly stressed fibre-composite components, we at ar engineers can enable our customer to produce the rotor blades on schedule while at the same time achieving the highest quality standards.
Lightweight engineering for wind turbines
Development of a wind turbine canopy
A medium-sized German manufacturer asked us to support them in the development of a nacelle for an offshore wind turbine. As the company’s engineering was primarily focused on manufacturing, we were called in. This project required extensive expertise in FE simulation. The aim was to develop an economically manufacturable component from conceptualisation of the complex project to the creation of the production documents. An additional challenge was that the boundary conditions were not clearly defined at the start of the project.
The following competences at ar engineers led to the success of the project:
- Very good knowledge of fibre-composite structures in the field of wind turbines
- Expertise in the production of large fibre-composite structures also from allied industries such as maritime (lifeboats with similar approaches and production processes)
- A lot of experience with the certification of composite structures and dealing with certifiers such as Lloyds Register (LR), Bureau Veritas (BV) or DNV
With our comprehensive expertise in fibre-composite materials and structural design in offshore wind, boat and ship building, we were able to realise the project with our client and hand it over on time and on budget, thanks to our long experience with large load bearing structures requiring certification.
→ Michel’s favourite project:
My passion is working on future technologies like wind energy.
My job in the renewable energy sector allows me to put my specialist skills from my Master’s degree in Wind Engineering into practice. I supervise the production of wind turbine rotor blades on site at the customer’s production facility.