CorPower Ocean Delivers First Commercial-Scale Composite WEC Hull
CorPower Ocean has partnered with composite machinery specialist Autonational and composite tank experts CPT Tankwell to successfully develop its first commercial-scale hull in Viana do Castelo, Portugal, using a bespoke machine , housed inside a controlled-environment work cell that will become the future of mobility and scalability for CorPower’s composite manufacturing capabilities.
The composite hull is an integral part of CorPower Ocean’s (WEC) next-generation C4 wave energy converter, which was recently unveiled at a global launch event in Stockholm, Sweden.
Over the past year, process characterization work on quarter-scale models has enabled rapid iterations and continuous tuning to achieve the targeted quality and material properties reviewed by DNV as an organization. certification, paving the way for final construction on a commercial scale.
Completed at CorPower Ocean’s Portuguese base in Viana do Castelo, it marks a milestone in the flagship HiWave-5 project, which will involve an ocean deployment in the nearby town of Aguçadoura.
“It has been a tremendous team effort involving our team of composites specialists in Portugal and Sweden, working closely with our local and global supply chain partners.” said Miguel Silva, General Manager of CorPower Ocean Portugal. “The hull of the C4 has been designed with a low-cost sandwich structure comprising filament-wound composite skins for the inner and outer layer separated by a base material. This approach brings a series of advantages, including high strength, durability and impact resistance combined with lightweight and buoyant properties, which can withstand fatigue, slamming and impact loads.Other important characteristics include excellent bond strength and chemical resistance with a low water absorption.
Hull construction was done in conjunction with dry testing of CorPower Ocean’s PTO (Power Take Off) system, using the largest wave energy test rig in the world.
As a whole, the composite hull development work cell consists of a fully customized filament winding machine located on a 14 meter long base. This includes an automated transport system to apply fibers to a 9 meter diameter mandrel, to wind the shell layer by layer.
Tord Jonsson, Supply Chain and Quality Manager, said: “Based on the R&D cell in Viana do Castelo, future versions of these manufacturing cells can be easily integrated into port facilities or final assembly, which amounts to “mobile factories”. This will enable composite hulls to be built quickly at customer sites, with additive manufacturing dramatically reducing time, cost and carbon footprint by eliminating transportation of the finished product. When delivering wave trusses to our customers, we will move these factory cells from site to site, to produce the hulls needed for a project, and then move the cells to the next customer site. The equipment will be packed and transported in three standard containers, taking only a few days to assemble once delivered to a new site. Our “mobile factory” concept enables high local content in projects and will play a key role in revitalizing local port communities and local supply chains. »
Working in conjunction with several utility companies, CorPower Ocean’s first commercial-scale C4 WEC will be used to become part of a larger network of four systems and one of the world’s first wave farms generating energy. energy for the national grid.
CorPower Ocean CEO Patrik Möller said the overall mission is to successfully introduce certified and guaranteed WEC products to the market, making wave power a bankable technology to attract financing for traditional renewable projects and foster rapid large-scale deployment to combat climate change.
Source: CorPower Ocean