WINDBOX: Advanced Manufacturing Centre to improve competitiveness in the Basque Country Wind Power supply chain

Introduction

WINDBOX initiative was launched in 2014 and promoted by the Basque Government as part of the Basque Country's Advanced Manufacturing Strategy. It aims to develop the capabilities of Basque companies in the wind power sector and help them to improve their position in the international market.
A consortium of Basque companies composed by wind turbine manufacturers (GAMESA, ADWEN) and component manufacturers (HINE, LAULAGUN, GLUAL, GAMESA EOLICA, WEC, ANTEC, MATZ-ERREKA), coordinated by the Basque Energy Cluster, are developing a Wind Power Advanced Manufacturing Centre aimed to integrate and validate subsystems for multi-megawatt wind turbines by means of advanced testing.



Approach

WINDBOX main objectives are the following:
• Reduce the wind power CoE (Cost of Energy) through improved critical wind turbine components and sub-products fully developed by Basque manufacturers.
• Provide these manufacturers with access to cutting-edge testing facilities, thus improving their competitiveness in the global market and their positioning towards the OEMs.
• Achieve higher added value in validation processes: operating conditions close to reality (loads, temperatura, humidity, vibrations), validation of integrated systems from different providers, independent assessment carried out by third party.
• Conduct component testing for all kinds of wind turbines, with particular focus on the new offshore wind turbine models up to 8 MW.
• Boost the potential and development capabilities of the Basque wind power supply chain.

Main body of abstract

For that purpose, WINDBOX will design and start up five state-of-the-art test benches in which critical components for wind power systems will be tested and validated: 1. the pitch system, 2. the generator, 3. the blade and hub bearings, 4. the yaw system and 5. the bolted joints.
The first is a pitch test bench in which component manufacturers will be able to test and optimise the pitch systems of their wind turbines and their components in conditions that are similar to those of a wind farm. The pitch system reliability is key to ensure the turbine's maximum production, integrity and safety. These tests will help to validate highly reliable products with an optimised design that reduce the cost of energy and of the system's design and manufacturing processes. The bench is up and running since November 2015 and tests are being conducted on a pitch cylinder and a hydraulic group, both components supplied by Basque manufacturers and part of a brand-new 8MW offshore wind turbine model.
The second test bench, targeted to test and validate wind power generator components, is being currently assembled and will be soon put into operation, thus allowing first tests to be conducted.
The third test bench, still at an engineering stage, will allow to conduct tests on the hub, the blade bearings and the blade-bearing and bearing-hub joints. Results from these tests will be key to validate such components, which will be part of a brand-new 8MW offshore wind turbine model. First tests on this bench are foreseen in Q1 2017.
The fourth test bench, currently under design, is aimed to test and validate the yaw system and is expected to start working on 2017. Last but not least, the fifth bench will be focused on testing and validation of bolted joints, although it is still at a concept design phase.

Conclusion

WINDBOX is fully aligned with the Basque Government Industrialisation Plan and Smart Specialisation Strategy, and will enable the Basque Country to build specific added-value infrastructure, with which companies will be able to develop industrial products, test systems and validate advanced manufacturing techniques, combining two of the specialisation priorities established to improve the competitiveness of the Basque industry - Advanced Manufacturing and Energy.


Learning objectives
WINDBOX is a clear example of fruitful regional cooperation between the Public Administration and the whole wind power supply chain to boost the creation of advanced manufacturing and validation infrastructures, thus improving the competitiveness of the industry.