Introduction to Types of CNC Machining Applications in the Green Energy Industry

The energy industry is the lifeblood of modern society, providing constant power for all of our devices and industries. As such, this constant, vigilant energy production requires a wide range of advanced equipment, from hydraulic valves in the oil and gas industry to solar cells to wind turbine components. CNC plays a key role in the manufacturing of these complex devices.

Aside from aerospace and automotive, energy production is one of the biggest uses for CNC machining. However, the energy industry is at a tipping point where it may have to make room for newer, greener forms of energy alongside traditional energy sources, or (more radically) abandon oil and gas altogether in favor of renewable energy sources. After all, the renewable energy industry grew 5% annually from 2007 to 2017, and there are growing initiatives and global support.

Overall, CNC parts and advanced machining technologies will improve the quality and efficiency of power generation tools and parts. This article will look at some of the main ways CNC plays a key role in this shift.

1.Wind Power

Wind energy production requires durable, long-lasting components that can withstand tremendous pressure while maintaining precision. Manufacturers must produce precise blades that can handle wind pressure with minimal wear. Metal and carbon fiber machining is crucial not only in the production of blades, but also in components such as giant bearings that adjust the angle. By using CNC, giant bearings in the adjustment mechanism of wind turbines can be manufactured with the precision usually reserved for smaller components. Since these are large components whose mobility seriously affects their performance, they (just like aircraft engine blades) need to be very precise.

In general, multi-purpose lathes are used to machine gears, gearbox housings, and rotors. Considering the size of an average wind turbine, it requires large and heavy machines, and about 90% of gear manufacturing involves metal cutting. Today, gear milling mainly uses hobs or disc milling cutters. Similarly, CNC drilling machines are often used to machine holes in shell and tube heat exchangers for various energy systems.

For wind turbines and windmills, CNC machines are needed to process reinforced carbon fiber plastic or fiberglass materials. In terms of materials, hollow fiberglass, aluminum, and lightweight wood can also be used for rotor blades. The blade profile of most rotor blades is very similar to that of aircraft blades, so these machines require quite high precision.

2.Solar

In addition to the solar panels themselves, there are various parts that require precision manufacturing, such as frames, back rails, and bracket rails. Milling and drilling machines are ideal for such projects, and many companies market their CNC machines as being specifically designed for producing solar panel parts. Even large solar panel production lines contain multiple types of CNC processes, such as cutting and drilling, but also require multiple non-CNC processes to work simultaneously with operators.

Because production lines can be very large and fancy, companies such as Fanuc have been offering versatile robotic arms that can handle a variety of shapes with more flexibility and workspace efficiency. Similarly, companies such as Beam cut are offering software specifically designed for solar panel manufacturing that streamlines the process so that only one person can operate it. This is one of the ways CNC frees up space and labor utilization.

Solar panel manufacturers often use turning centers and wire EDM machines to create frames and housings. Plasma and fiber laser cutting machines are often specialized for solar panel manufacturing, and various lasers are often used to segment the panels themselves. Similarly, companies like Protolabs combine CNC machining and 3D printing to produce solar panels. This does suggest there may be room for hybrid manufacturing in the solar industry.

3.Hydropower

Hydro turbines and generators are more than just big machines. They also need to be resistant to pressure and water damage, and made from metals with the same qualities, often using carbon and stainless steel parts. Companies around the world use CNC technology to produce a variety of components, from simple shafts and bushings to hydro turbine casings, impellers, and covers.

It involves the usual turning, line boring, and milling, but is often done on a massive scale, depending on the needs of the factory. For reference, Canyon Hydro in North America uses a 7-axis CNC milling machine capable of manufacturing Pelton and Francis hydro turbines up to 16 feet in diameter and weighing up to 25 tons. The CNC machine can correct small (but potentially impactful) imperfections in the turbines. It’s one of many machines in their manufacturing center. On a larger scale, Voith Hydro’s York plant machines workpieces up to 42 feet (12.80 meters) in diameter and weighing more than 350 tons (317.5 tons).

In addition to turbines, CNC milling and other machining techniques are used to develop gates for dams and hydroelectric plants. In some cases, the development of various CNC machine tools has allowed these parts to be produced on-site rather than shipped from distant factories.

The green energy sector in general has benefited greatly from CNC machining and modern technology. We have only scratched the surface of their capabilities, but there are already many applications, benefits, and use cases.