Automated Arc Welding and Sensor Based Quality Assessment for Enhancing Fatigue Strength and Structural Reliability of Offshore Wind Turbine Supports

  • Offshore wind energy plays a crucial role in achieving a carbon dioxide free industrial sector in the coming decades. However, foundation systems for offshore wind turbines significantly impact the overall installation process, posing technical and regulatory challenges. Adopting lightweight design principles in steel construction such as dissolved load bearing structures in jacket foundations offers substantial potential for reducing resource consumption, particularly steel usage. This presentation explores the complete digitalization of welding manufacturing and testing processes, enabling fully automated production and data driven quality assessment of tubular nodes, which are vital components of jacket foundations. The study also investigates the relationship between seam geometry and fatigue strength inspired by bionic design principles. The results demonstrate that tubular nodes can be welded entirely automatically, accommodating geometric tolerances, and that seam geometries caOffshore wind energy plays a crucial role in achieving a carbon dioxide free industrial sector in the coming decades. However, foundation systems for offshore wind turbines significantly impact the overall installation process, posing technical and regulatory challenges. Adopting lightweight design principles in steel construction such as dissolved load bearing structures in jacket foundations offers substantial potential for reducing resource consumption, particularly steel usage. This presentation explores the complete digitalization of welding manufacturing and testing processes, enabling fully automated production and data driven quality assessment of tubular nodes, which are vital components of jacket foundations. The study also investigates the relationship between seam geometry and fatigue strength inspired by bionic design principles. The results demonstrate that tubular nodes can be welded entirely automatically, accommodating geometric tolerances, and that seam geometries ca n be precisely manufactured according to suggestions from e.g. numerical models or other sources . These advancements significantly enhance the fatigue strength and service life of offshore wind turbine support structures.zeige mehrzeige weniger

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Autor*innen:Andreas PittnerORCiD, Cagtay FabryORCiD, Marc ThieleORCiD, Antoni ArtinovORCiD, Michael RethmeierORCiD
Dokumenttyp:Vortrag
Veröffentlichungsform:Präsentation
Sprache:Englisch
Jahr der Erstveröffentlichung:2025
Organisationseinheit der BAM:9 Komponentensicherheit
9 Komponentensicherheit / 9.3 Schweißtechnische Fertigungsverfahren
DDC-Klassifikation:Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Angewandte Physik
Freie Schlagwörter:Automated gas metal arc welding; Fatigue; Quality assessment and control; Support structures
Themenfelder/Aktivitätsfelder der BAM:Energie
Energie / Windenergie
Veranstaltung:IIW Annual Assembly 2025
Veranstaltungsort:Genova, Italy
Beginndatum der Veranstaltung:23.06.2025
Enddatum der Veranstaltung:25.06.2025
Verfügbarkeit des Dokuments:Datei im Netzwerk der BAM verfügbar ("Closed Access")
Datum der Freischaltung:19.12.2025
Referierte Publikation:Nein
Eingeladener Vortrag (wissenschaftliche Konferenzen):Nein
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