Eine echte Innovation: Rotorblättern aus einem Stück GFK – ONE SHOT – mit allen integrierten Strukturen

Based near Naples, Italy, Cartflow is the market leader in Italy for the production of rotor blades for wind power generators. / Photo: Cartflow
Based near Naples, Italy, Cartflow is the market leader in Italy for the production of rotor blades for wind power generators. / Photo: Cartflow
Based near Naples, Italy, Cartflow is the market leader in Italy for the production of rotor blades for wind power generators. / Photo: Cartflow

Cartflow ist Marktführer in Italien in der Herstellung von Rotorblättern in einem einstufigen Verfahren in einer geschlossenen Form

(WK-intern) – CARTFLOW ONE SHOT Blades

Cartflow is market leader in Italy in manufacturing rotor blades in a one-step process in a closed mould.

Rotor Blades

Trunk, body, outer skin and inner structures of blades are all produced at the same time. The ONE SHOT process technology does away with tolerances that remain an issue with conventional processes which are based on glueing together previously installed cross members or reinforcing elements.

As a closed body is created there is no danger of micro-cracks or leaks. Water cannot get in. Protection against lightning is also enhanced. The Cartflow ONE SHOT technology enables significantly more production cycles per mould to be implemented compared to conventional production.

The Company                                                 

Based near Naples, Italy, Cartflow is the market leader in Italy for the production of rotor blades for wind power generators.

For over 15 years the managing director and owner, Angelo D´Ettore, has established his expertise in the development of products in the composite technology sector. In the past his team was renowned for utilizing composite technology in the manufacturing of boat hulls. Boats up to 110 feet long were built, amongst them two world master vessels in the offshore class. In 2008 Cartflow expanded its field of endeavour to the energy sector, to include rotor blades for wind turbines.

Experience gained in building high-performance motor boats was transferred to the new rotor blade manufacturing activities. The new ONE SHOT process for the production of rotor blades was created in cooperation with the Frederick II University of Naples. In contrast to the conventional production process Cartflow rotor blades are manufactured as a complete unit in a single processing step. This is possible by utilizing a closed mould in which all processing steps take place.

Cartflow advanced to market leadership and carrier of the technology in Italy in a very short period of time. Modern manufacturing processes using robots paired with a passion for experimenting and a readiness for innovation will continue to guarantee the company’s success in the market.

Technology

The Manufacturing Process: Rotor blades manufactured by Cartflow are the product of a single injection. The whole process is carried out in a completely closed mould. Fibre glass or carbon fibre mats are wrapped 360° around the rotor blade profile thus guaranteeing highest possible strength, in particular by means of cross elements integrated by the manufacturing process.

Blades manufactured in this way display no splices or joints. The blades feature highest material quality and ruggedness. Six robots carry out the most critical steps where repetitiveness and precision are called for. Cartflow alone is able to produce rotor blades of any type, any width or length, with or without winglets, and in all cases seamless. The same holds true for turbine casings.

With regard to colour and surface finish, all options are possible. Thus borings and the implementation of any connection variant can be re-alized with the robots.

Laser placement ensures the precise implementation of the lamination process according to the technical specifications. Human error can be excluded to a great extent during the entire lamination process.

The sum of these unique technology steps in combination with the use of robots gives the company a big lead in technology keeping it far ahead of its competitors. Cartflow supplies rotor blades of highest quality internationally. The ONE SHOT process does not require any bonding or expensive reworking.

Green

Quite apart from the fact that wind power represents a green product, Cartflow consciously makes use of processes that are environmentally friendly. As the entire process takes place in a closed system no one-way products such as hoses, vacuum sacks or peelply are left over.

In comparison to conventional production methods far less waste results.

The precision of the blades made by Cartflow also guarantee noise reduction. Their longer durability reduces their environmental footprint.

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