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ENERGIX-Stort program energi

Adaptive control for robotic prefabrication

Alternativ tittel: Adaptiv styring av robotisert prefabrikasjon

Tildelt: kr 14,4 mill.

Prosjektnummer:

337019

Prosjektperiode:

2022 - 2025

Midlene er mottatt fra:

The European Commission (EU) proposes to increase Europe’s offshore wind capacity from its current level of 25 GW to between 230 and 450 GW by 2050 (approx. 21 250 new turbines of 20 MW capacity and 750 turbines annually) as one of the strategies to meet the EU’s goal of climate neutrality by 2050. To reach this goal, rapid and large-scale deployment of offshore wind farms (e.g., 50-150 turbines) has become an undeniable need. In addition, the highest energy potential lies far from shore at deep waters where large bottom fixed (e.g., jacket type) and floating substructures are needed. However, the daunting reality is that Europe lacks sufficient production capacity for such structures, and the cost of production is high. The AdaPfab project aims to develop a sustainable and cost-effective prefabrication process, enabling the mass production of offshore wind substructures. The project aims to quickly implement the planned innovation considering the urgent need to increase renewable energy production, accelerate the energy transition, and achieve the national and global climate goals. The project partners have been collaborating closely to identify the key technical challenges related to prefabrication of substructures, i.e., adaptive control of cutting, welding, and automated non-destructive testing (NDT). When the project starts, a detailed mapping of the existing solutions will be performed to identify the technology gap and viable solutions. In addition, the project will also define two industrial demonstrators as the driver of the R&D activities in the project.

Rapid and large-scale deployment of offshore wind farms (e.g., 50-100 turbines) has become an undeniable need to increase renewable energy production to accelerate the energy transition and achieve the national and global climate goals. However, a high levelized cost of electricity (LCOE) hinders the accelerated development of offshore wind farms, and a significant cost reduction is urgently needed. In addition, the highest energy potential lies far from shore at deep waters where large bottom fixed (e.g., jacket type) and floating substructures are needed. Today, Europe lacks sufficient production capacity for such substructures, and in addition, fabrication has been identified as one of the areas with the largest potential for cost reduction. The AdaPfab project aims to shift the paradigm of the current production technology: from one-off production to mass production. The AdaPfab project gathers Norwegian stakeholders to revolutionize the current production process and solve key technical challenges related to the prefabrication process, i.e., cutting, welding and automated NDT, which are crucial for building the future World Class Production Line (WCPL), representing a flexible, fully automated, resource-efficient, and digitalized production system. The R&D challenges that will be addressed in this project include developing: 1) predictive welding and cutting planning methods to integrate physics and structural performance into the process planning; 2) technology, methods, and algorithms for automated and adaptive process control and 3) automated NDT methods with the support of modelling and AI-enhanced signal processing and defect detect method. The new prefabrication process developed in AdaPfab will result in 1) increased production capacity and efficiency, 2) improved product quality and decreased cost and 3) enhanced sustainability through reducing production-related CO2 emission and promoting local production.

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ENERGIX-Stort program energi