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Four processed for producing blades are examined. Two use filament winding techniques and two involve filling a mold or form to produce all or part of a blade. The processes are described and a comparison is made of cost, material properties, design and free vibration characteristics. Conclusions are made regarding the feasibility of each process to produce low cost, structurally adequate blades.
Pressure measurements covering a range of wind velocities were made at one span location on a blade of the Mod-2 Wind Turbine. The data show the existence of higher pressure coefficients than would be expected from wind tunnel data. These high pressure coefficients may be the result of three-dimensional flow over the blade that delays flow separations. Data is presented showing the repetitiveness and abrupt changes in the pressure distribution that occurs as the blade rotates. Calculated values of suction and flap coefficients are also presented.
The primary objective of this project was to demonstrate the potential to significantly reduce the cost of wind turbine blades with carbon fiber reinforced polymer (CFRP) structure. Applicability of textile carbon fibers (TCF) were evaluated for use in pultruded spar cap (SC) elements as a path to cost reduction for utility scale wind turbine blades. In earlier work for the Department of Energy (DOE) Wind Energy Technologies Office (WETO), a collaboration of Sandia National Laboratory (SNL), Oak Ridge National Laboratory (ORNL), and Montana State University has demonstrated potential for pultruded TCF to compete with infused fiberglass and commercially available carbon fiber pultruded sections for spar cap construction. In the design cases evaluated, the TCF sections fared well when compared on cost per unit composite stiffness and cost per unit composite compressive strength for those designs [1]. Both stiffness and compressive strength tend to be key factors in the design of blade composite Spar Cap which carry the bulk of the blade structural loads in bending. Spar Cap design tends to distribute largely symmetric tensile and compressive stresses to opposite sides of the spar structure, but since carbon fiber composite compressive strength is typically 20-50% lower than tensile strength, the compressive loading reaches failure levels well before the tensile loading. Stiffness is critical in containing the large tip deflection in high wind loading situations. However, materials and process development were very limited in the earlier study and the work in this project was expanded to make the comparative information more representative of what will be required in order to make further inroads towards implementation. Similar to that study, this project team confirmed that the primary materials of interest for pultruded spar cap elements should be thermoset (TS) resins reinforced by carbon fibers, utilizing as high a percentage of TCF as practical to benchmark cost and performance against commercial carbon fibers. To make the closest comparison possible and eliminate specific test article size, resin selection, and equipment/operational nuance effects, the team planned to pultrude sections with 100% commercially available carbon fiber (Panex 35 carbon fiber from Zoltek) as well as samples utilizing high fractions of TCF. The resin system chosen was based on formulations recommended by large wind industry supplier Hexion and consisted of Hexion resin RSL-4597, curing agent CCA-138, and internal mold release additive 117, along with common kaolin filler ASP400P from BASF. As commonly deployed in spar cap configurations, the team had a mold built to pultrude a rectangular spar cap element of 100mm width and 3mm thickness. The extremely limited number of samples produced for the earlier study were produced with a “generic” epoxy utilized for a variety of applications by the pultruder contracted to produce test articles for demonstration purposes. More importantly, those samples were produced at a fiber fraction only slightly over 50%. Based on feedback from our industrial advisory team for that project and strongly recommended by this project team, the consensus is that it is highly desirable to obtain fiber fractions of 65-68% for significant penetration in wind blade spar cap. Although this requirement has yet to be exhaustively confirmed in readily available information, this was established as a project goal and informally decided we needed to exceed 60% fiber fraction to gain serious industry consideration. Previous TCF pultrusion trials have been challenged by the lack of robust TCF packages, resulting in non-uniform tension across and between tows, as well as excess labor and waste for removal of interleaved paper. The non-uniform tension and associated intermingling of tows in textile acrylic fiber tows and associated difficulties created from broken filaments in carbon fiber conversion inhibit the ordered packing necessary to enhance fiber fraction elevation. (These “cross-overs” are not considered undesirable for textile applications and there is some sense that they might be advantageous for those applications). In addition to work that is ongoing at the acrylic fiber manufacturers to improve their formats, The Institute of Advanced Composites Manufacturing Innovation (IACMI) Project 6.12 (report PA16-0349-6.12-01) [2] has developed and demonstrated a more robust packaging and creeling approach that at least partially addresses these issues, thus improving control of the TCF feed into the pultrusion unit. It was hoped that these and other improvements currently being implemented would allow us to achieve fiber fractions at least approaching these fiber fraction targets. During this project, sections utilizing 100% commercially available carbon fiber reinforcement were produced as a baseline, as well as sections reinforced with about 94% TCF and the balance being commercially available fiber for comparison. The most important finding was that similar to results reported in the earlier WETO-funded project and results from tests of TCF reported at IACMI meetings, this work demonstrated that sections pultruded with TCF in an epoxy resin frequently utilized in actual spar cap production had stiffness and compressive strengths largely comparable to similar sections pultruded with a commercially available carbon fiber also frequently utilized in the wind industry. Although the amount of that data is limited, some of the tensile strength results were actually closer than would have been expected based on fiber strength results provided by the TCF and commercial fiber producers. The actual test data are reported and discussed in detail in Section 5. The pultruded sections dominated by TCF reinforcement were approximately 8-10% lower in fiber fraction than for the sections produced using commercial fiber alone, making direct comparison difficult. The COVID-19 project has provided significant insight into the current state-of-the-art with various TCF product forms. The data obtained in this project will guide the planned improvements at the precursor level, especially in attaining uniform tensioning and payout to facilitate enhanced fiber fractions and overall processability of the TCF composites. The project team is providing guidance to stakeholders concerning the attributes, needs, and potential demand for TCF in wind blade spar caps. Results achieved in this project are consistent with findings in the related work cited [1] and support this guidance and the high potential for this product type. TCF precursor-producing partners continue to express interest in enhancing their product forms and the team looks forward to working with these improved materials as they become available.
Wind turbine blades are highly engineered structures designed to face temperature extremes and high winds. However, erosion of the blade's leading edge and subsequent repair remains a significant and costly challenge for the wind energy industry. Repair of these leading edges can lead to large amounts of downtime for the turbine and significant operational inefficiencies. In this work, the strength of adhesion and healing ability of a commercially available vitrimer (Mallinda's VITRIMAX) was compared to that of a thermoplastic resin, which has previously been demonstrated in wind energy applications (Arkema's Elium) to evaluate their efficacy as surface coatings for wind turbine blades, particularly their leading edges. Vitrimers are a class of inherently reprocessable thermosets, and it was theorized that vitrimer-based leading edge coatings could enable more robust and efficient wind turbine blades with decreased operational downtime and safer maintenance practices. It was found that the VITRIMAX adhered better to the wind blades' surfaces than both the manufacturer's paint and Elium, with increases in pull-off strength of adhesion ranging from 24% to 83% above that of the original paint. Furthermore, the VITRIMAX adhered strongly to the underlying composite of each blade with strength of adhesion values increasing in ranges from 42% to 97% above that of the original paint. Finally, the vitrimer coating showed an 88% decrease in surface roughness compared to end-of-life blade materials, and initial healing demonstrations in which coatings were manually scratched and subsequently healed exhibited an ~84.5% decrease in scratch depths.
Dynamic blade loads, including aerodynamic, gravitational, and inertial effects, are presented for two large horizontal-axis wind turbines: the ERDA-NASA 100 kW Mod-0 and 200 kw Mod-0A wind power systems. Calculated and measured loads are compared for an experimental Mod-0 machine in operation. Predicted blade loads are also given for the higher power Mod-0A wind turbine now being assembled for operation as part of a municipal power plant. Two major structural modifications have been made to the Mod-0 wind turbine for the purpose of reducing blade loads. A stairway within the truss tower was removed to reduce the impulsive aerodynamic loading caused by the tower wake on the downwind rotor blades. Also, the torsional stiffness of the yaw drive mechanism connecting the turbine nacelle to the tower was doubled to reduce rotor-tower interaction loads. Measured reductions in load obtained by means of these two modifications equaled or exceeded predictions.
Two 60 foot long aluminum wind turbine blades were operated for over 3000 hours on the MOD-OA wind turbine. The first signs of blade structural damage were observed after 400 hours of operation. Details of the blade design, loads, cost, structural damage, and repair are discussed.
Leading edge erosion (LEE) of wind turbine blades has been identified as a major factor in decreased wind turbine blade lifetimes and energy output over time. Accordingly, the International Energy Agency Wind Technology Collaboration Programme (IEA Wind TCP) has created the Task 46 to undertake cooperative research in the key topic of blade erosion. Participants in the task are given in Table 1.
A wind tunnel investigation was conducted to determine the 2-D aerodynamic characteristics of two new rotorcraft airfoils designed especially for application to the inboard region of a helicopter main rotor blade. The two new airfoils, the RC(4)-10 and RC(5)-10, and a baseline airfoil, the VR-7, were all studied in the Langley Transonic Tunnel at Mach nos. from about 0.34 to 0.84 and at Reynolds nos. from about 4.7 to 9.3 x 10 (exp 6). The VR-7 airfoil had a trailing edge tab which is deflected upwards 4.6 degs. In addition, the RC(4)-10 airfoil was studied in the Langley Low Turbulence Pressure Tunnel at Mach nos. from 0.10 to 0.44 and at Reynolds nos. from 1.4 to 5.4 x 10 (exp 6) respectively. Some comparisons were made of the experimental data for the new airfoils and the predictions of two different theories. The results of this study indicates that both of the new airfoils offer advantages over the baseline airfoil. These advantages are discussed.
To test the ability of WEST-1 to predict blade fatigue load distribution, actual wind signals were fed into the simulator and the response data were recorded and processed in the same manner as actual wind turbine data. The WEST-1 simulator was operated in a stable, unattended mode for six hours. The probability distribution of the cyclic flatwise bending moment for the blade was comparable to that for an actual wind turbine in winds with low turbulence. The input from a stationary anemometer was found to be inadequate for use in the prediction of fatigue load distribution for blade design purposes and modifications are necessary.
Wind-tunnel tests on the British Experimental Rotor Programme (BERP) tip are described, and the results are compared with computational fluid dynamics (CFD) results. The test model was molded using the Lynx-BERP blade tooling to provide a semispan, cantilever wing comprising the outboard 30 percent of the rotor blade. The tests included both surface-pressure measurements and flow visualization to obtain detailed information of the flow over the BERP tip for a range of angles of attack. It was observed that, outboard of the notch, favorable pressure gradients exist which ensure attached flow, and that the tip vortex also remains stable to large angles of attack. On the rotor, these features yield a very gradual break in control loads when the retreating-blade limit is eventually reached. Computational and experimental results were generally found to be in good agreement.
In October 2018, the International Energy Agency Wind Task 34 - Working Together to Resolve the Environmental Effects of Wind Energy (WREN) - organized a virtual forum to discuss the likelihood of bats experiencing barotrauma when flying near moving wind turbine blades. The forum included experts in bat biology and physiology, bat and wind turbine interactions, wind turbine technology, and atmospheric sciences. This educational brief summarizes the discussion during the forum and written comments from those who could not attend. Relevant literature was used to provide additional context when needed. Possible explanations regarding the direct cause of bat mortality at operating wind turbines are (1) blunt force trauma caused by turbine blades striking individual bats, often referred to as collisions, and (2) barotrauma, resulting from exposure to pressure changes located near the surface of moving wind turbine blades. While collision- related mortality is easily understood, the mechanism causing barotrauma is more complex. Fast-moving wind turbine blades create regions of high- and low-pressure variations along the blade surfaces. If bats fly within these regions, the rapid change in pressure may cause internal bleeding, damage to lungs or other organs, and damage to the inner ear. However, sufficient data demonstrating barotrauma as a common cause of bat mortality at wind turbines are lacking. Moreover, the pressure variation necessary to cause barotrauma in bats is so close to the surface of turbine blades that there is a higher probability of direct contact with the blades than of solely experiencing barotrauma. Regardless of the cause, bats are interacting with fast-moving wind turbine blades, and these interactions are resulting in fatalities. Resolving this issue will require a better understanding of bat behavior and cost-effective measures to reduce interactions between bats and wind turbines. This is the Spanish translation of NREL/FS-5000-84749, "The Likelihood of Bats Experiencing Barotrauma Near Moving Wind Turbine Blades."
A wind tunnel investigation was conducted to determine the 2-D aerodynamic characteristics of a new rotorcraft airfoil designed for application to the tip region (stations outboard of 85 pct. radius) of a helicopter main rotor blade. The new airfoil, the RC(6)-08, and a baseline airfoil, the RC(3)-08, were investigated in the Langley 6- by 28-inch transonic tunnel at Mach numbers from 0.37 to 0.90. The Reynolds number varied from 5.2 x 10(exp 6) at the lowest Mach number to 9.6 x 10(exp 6) at the highest Mach number. Some comparisons were made of the experimental data for the new airfoil and the predictions of a transonic, viscous analysis code. The results of the investigation indicate that the RC(6)-08 airfoil met the design goals of attaining higher maximum lift coefficients than the baseline airfoil while maintaining drag divergence characteristics at low lift and pitching moment characteristics nearly the same as those of the baseline airfoil. The maximum lift coefficients of the RC(6)-08 varied from 1.07 at M=0.37 to 0.94 at M=0.52 while those of the RC(3)-08 varied from 0.91 to 0.85 over the same Mach number range. At lift coefficients of -0.1 and 0, the drag divergence Mach number of both the RC(6)-08 and the RC(3)-08 was 0.86. The pitching moment coefficients of the RC(6)-08 were less negative than those of the RC(3)-08 for Mach numbers and lift coefficients typical of those that would occur on a main rotor blade tip at high forward speeds on the advancing side of the rotor disk.
The National Wind Technology Center (NWTC), located at the U.S. Department of Energy's (DOE's) National Renewable Energy Laboratory (NREL) Flatirons Campus, has been a driving force in advancing wind energy technology research worldwide since its designation as a DOE national research center in 1992. Enabled by the Flatirons Campus's world-class facilities, scientists, engineers, analysts, and researchers are pushing the frontiers of science to pursue wind energy innovation. In Fiscal Year (FY) 2021, NREL continued to provide the technical expertise, research capabilities, and industry understanding to support DOE's ambitious climate action and research goals by advancing technology, addressing market and deployment barriers, and driving down costs with more efficient, reliable, and predictable wind energy systems. One of several highlights, NREL received an R&D 100 Special Recognition Award for its Thermoplastic Resin System for Wind Turbine Blades. This breakthrough in the wind turbine manufacturing process will enable the production of recyclable blades that are stronger, longer, and less expensive, while increasing energy capture, decreasing energy and transportation costs, and increasing blade reliability. In a year when the entire U.S. economy struggled to address workforce gaps, an NREL study compared wind industry needs, training programs, and hiring practices with perspectives from students and recent college graduates. Researchers hope that, by pinpointing areas of disconnect, the expectations of employers who have difficulty filling entry-level jobs can better align with the preparation of the potential applicants who find it hard to break into the field. The lab also made numerous new data and modeling resources available in FY 2021. Recent NREL releases include a modeling tool for predicting the power performance and structural loads of wind turbines within a wind farm (FAST.Farm), a computational framework for modeling golden eagle behavior near wind farms, and 20 years of offshore wind data. Updates were also made to the widely used Wind Plant Integrated Systems Design and Engineering Model (WISDEM), which couples engineering and cost models to examine system-level trade-offs. Now, bolstered by a renewed national commitment to tackle climate change and revitalize the U.S. economy through increased investment in clean energy - particularly in offshore wind energy - NREL stands poised to lead the way to a sustainable future that powers the United States with significant levels of reliable, low-cost, accessible wind energy. This report provides an overview of the achievements NREL made on behalf of DOE's Wind Energy Technologies Office (WETO) and other partners during FY 2021 (between Oct. 1, 2020, and Sept. 30, 2021).
Abstract. Increasing growth in land-based wind turbine blades to enable higher machine capacities and capacity factors is creating challenges in design, manufacturing, logistics, and operation. Enabling further blade growth will require technology innovation. An emerging solution to overcome logistics constraints is to segment the blades spanwise and chordwise, which is effective, but the additional field-assembled joints result in added mass and loads, as well as increased reliability concerns in operation. An alternative to this methodology is to design slender flexible blades that can be shipped on rail lines by flexing during transport. However, the increased flexibility is challenging to accommodate with a typical glass-fiber, upwind design. In a two-part paper series, several design options are evaluated to enable slender flexible blades: downwind machines, optimized carbon fiber, and active aerodynamic controls. Part 1 presents the system-level optimization of the rotor variants as compared to conventional and segmented baselines, with a low-fidelity representation of the blades. The present work, Part 2, supplements the system-level optimization in Part 1 with high-fidelity blade structural optimization to ensure that the designs are at feasible optima with respect to material strength and fatigue limits, as well as global stability and structural dynamics constraints. To accommodate the requirements of the design process, a new version of the Numerical Manufacturing And Design (NuMAD) code has been developed and released. The code now supports laminate-level blade optimization and an interface to the International Energy Agency Wind Task 37 blade ontology. Transporting long, flexible blades via controlled flapwise bending is found to be a viable approach for blades of up to 100 m. The results confirm that blade mass can be substantially reduced by going either to a downwind design or to a highly coned and tilted upwind design. A discussion of active and inactive constraints consisting of material rupture, fatigue damage, buckling, deflection, and resonant frequencies is presented. An analysis of driving load cases revealed that the downwind designs are dominated by loads from sudden, abrupt events like gusts rather than fatigue. Finally, an analysis of carbon fiber spar caps for downwind machines finds that, compared to typical carbon fibers, the use of a new heavy-tow carbon fiber in the spar caps is found to yield between 9 % and 13 % cost savings.
Unintended consequences of increasing wind energy production include bat mortalities from wind turbine blade strikes. Ultrasonic deterrents (UDs) have been developed to reduce bat mortalities at wind turbines. Our goal was to experimentally assess the species-specific effectiveness of three emission treatments from the UD developed by NRG Systems. We conducted trials in a flight cage measuring approximately 60 m × 10 m × 4.4 m (length × width × height) from July 2020 to May 2021 in San Marcos, Texas, USA. A single UD was placed at either end of the flight cage, and we randomly selected one for each night of field trials. Trials focused on a red bat species group (Lasiurus borealis and Lasiurus blossevillii; n = 46) and four species: cave myotis (Myotis velifer; n = 57), Brazilian free-tailed bats (Tadarida brasiliensis; n = 73), evening bats (Nycteceius humeralis; n = 53), and tricolored bats (Perimyotis subflavus; n = 17). The trials occurred during three treatment emissions: low (emissions from subarrays at 20, 26, and 32 kHz), high (emissions from subarrays at 38, 44, and 50 kHz), and combined (all six emission frequencies). We placed one wild-captured bat into the flight cage for each trial, which consisted of an acclimation period, a control period with the UD powered off, and the three emission treatments (order randomly selected), each interspersed with a control period. We tracked bat flight using four thermal cameras placed outside the flight cage. We quantified the effectiveness of each treatment by comparing the distances each bat flew from the UD during each treatment vs. the control period using quantile regression. Additionally, we conducted an exploratory analysis of differences between sex and season and sex within season using analysis of variance. Broadly, UDs were effective at altering the bats’ flight paths as they flew farther from the UD during treatments than during controls; however, results varied by species, sex, season, and sex within season. For the red bat group, bats flew farther from the UD during all treatments than during the control period at all percentiles (p < 0.001), and treatments were comparable in effectiveness. For cave myotis, all percentile distances were farther from the UD during each of the treatments than during the control, except the 90th percentile distance during high, and low was most effective. For evening bats and Brazilian free-tailed bats, results were inconsistent, but high and low were most effective, respectively. For tricolored bats, combined and low were significant at the 10th–75th percentiles, high was significant at all percentiles, and combined was most effective. Results suggest UDs may be an effective means of reducing bat mortalities due to wind turbine blade strikes. We recommend that continued research on UDs focus on low emission treatments, which have decreased sound attenuation and demonstrated effectiveness across the bat species evaluated in this study.
Laminated wood blades were designed, fabricated, and installed on a 200-KW wind turbine (Mod-OA). The machine uses a two-blade rotor with a diameter of 38.1 m (125 ft). Each blade weights less than 1361 kg (3000 lb). After operating in the field, two blade sets were returned for inspection. One set had been in Hawaii for 17 months (7844 hr of operation) and the other had been at Block Island, Rhode Island, for 26 months (22 months operating - 7564 hr). The Hawaii set was returned because of one of the studs that holds the blade to the hub had failed. This was found to be caused by a combination of improper installation and inadequate corrosion protection. No other problems were found. The broken stud (along with four others that were badly corroded) was replaced and the blades are now in storage. The Block Island set of blades was returned at the completion of the test program, but one blade was found to have developed a crack in the leading edge along the entire span. This crack was found to be the result of a manufacturing process problem but was not structurally critical. When a load-deflection test was conducted on the cracked blade, the response was identical to that measured before installation. In general, the laminate quality of both blade sets was excellent. No significant internal delamination or structural defects were found in any blade. The stud bonding process requires close tolerance control and adequate corrosion protection, but studs can be removed and replaced without major problems. Moisture content stabilization does not appear to be a problem, and laminated wood blades are satisfactory for long-term operation on Mod-OA wind turbines.
Wind tunnel measurements, blade motions, and blade air loads for tandem-rotor helicopters
G2Aero is a Python package for the design and deformation of discrete planar curves and tubular surfaces using a geometric data-driven approach. G2Aero utilizes a topology of product manifolds: the Grassmannian, $\mathcal{G}$($\mathcal{n}$, 2) - the set of 2-dimensional subspaces in $\mathbb{R}$ $\mathcal{n}$ - and the symmetric positive-definite (SPD) manifold, $\mathcal{S}^{2}_{++}$ - the set of 2x2 SPD matrices. The package provides a novel framework for representing separable deformations to shapes, which consist of stretching, scaling, rotating, and translating - also known as affine deformations - and a set of complementary deformations - which we refer to as undulation-type deformations. We focus on airfoil and blade design applications to emphasize the utility of the methods in an environment where the separation of affine and undulation-type deformations is critical. Notable functionalities of the framework for blade design include: 1) generating novel 2D (airfoil) shapes informed by a database of physically relevant airfoils, 2) building 3D blades by interpolating sequences of 2D airfoil cross-sections, and 3) generating blades with consistent perturbations along the blade span. We discuss the framework and provide examples in the context of wind energy applications, specifically wind turbine blade design. Figure 1 shows the wire frame obtained by interpolating airfoils defining the IEA 15-MW wind turbine blade and applying affine transformations corresponding to twist, chordal scaling, and bending. This, and all other figures in the paper, can be reproduced following examples and referencing supporting documentation provided in the G2Aero package.