FabLab EDP projects

Objective: The design and manufacture of a reduced hydraulic model of the Fixed Ichthyofauna Capture Device (DFCI) for the Foz Tua hydroelectric power plant.

Destination: Technical study of the implementation of DFCI for EDP Gestão da Produção de Energia SA using a 1:10 reduced scale model tested at LNEC.

Process: Parametric 3D CAD design, rapid prototyping/digital manufacturing using additive/subtractive manufacturing techniques.

Development: 3D modeling in Solidworks and Rhinoceros CAD; 3D printing of modular thermoplastic ABS parts; CNC machining of DFCI walls and partitions in a transparent acrylic and polyethylene base; CNC machining of high density expanded polystyrene to replicate a river; cutting of PVC plates to replicate the dissipation basin of the dam; assembly of the various components of the reduced hydraulic model in the LNEC.

EDP Produção and LNEC turned to FabLab EDP to build the reduced hydraulic model of the Fixed Ichthyofauna Capture Device (DFCI) planned for the AH Foz Tua. For that, a physical model was developed at a 1:10 by 100 m2 using new methodologies for the construction of hydraulic structures through rapid prototyping and digital fabrication available at the EDP Group Lab. .

In the construction of this model, innovative materials and techniques such as CNC machining of polyethylene, acrylic and 3D printing in ABS plastic used in DFCI model and the CNC machinery of about a ½ ton of Styrofoam - high density expanded polystyrene - used to partially reproduce the topography of the river with rigor were used.

The design and construction of the DFCI model was made to be modular to allow for the analysis of the hydraulic behavior of different configurations. The laser-cut grids and transparent walls allow the inside flow to be visualized.

At the beginning of 2018, the first DFCI model test was carried out at LNEC in the presence of a specialized team of biologists from the University of Évora and EDP Production.

This test revealed the overall good performance of the DFCI model; for that reason, this partnership is a pioneering experience in performing hydraulic tests on models related to EDP works.