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The design of large wind power systems in Germany is reviewed with attention given to elaboration of the total wind energy system, aerodynamic design of the rotor blade, and wind loading effects. Particular consideration is given to the development of composite glass fiber/plastic or carbon fiber/plastic rotor blades for such installations.
NASA has a significant maintenance challenge with the aging wind tunnel infrastructure across the Agency. Some wind tunnel fan blades, such as those in the National Transonic Facility at NASA Langley Research Center, have been in use for far longer than their planned 10-year lifetime. No detailed analytical models of the fan blades from their initial fabrication were created. To support the fabrication of either new, nominally identical fan blades or newly designed fan blades, accurate analytical models of the existing fan blades are necessary to demonstrate an understanding of the capabilities of the existing fan blades. Additionally, the existing documentation of the testing of the existing fan blades has gaps. In this report, a process for improving test-analysis correlation for these wind tunnel fan blades is discussed. This process involved a detailed study of unknown parameters in test fixture parameters from the old and incomplete test documentation. To improve correlation, these unknown parameters were used as design variables in an optimization study to minimize the error between test data and computed structural responses. Legacy strain gage data from tests conducted in 1981 were compared with results from a finite element model created in 2019. The use of test data from 1981 was necessary because none of the existing fan blades could be spared for use in destructive structural testing. While this process was demonstrated for wind tunnel fan blades, this process could be utilized for evaluating unknowns in test fixtures for other structural test configurations.
Work performed by GE Aircraft on advanced counterrotation blade configuration concepts for high speed turboprop system is described. Primary emphasis was placed on theoretically and experimentally evaluating the aerodynamic, aeromechanical, and acoustic performance of GE-defined counterrotating blade concepts. Several blade design concepts were considered. Feasibility studies were conducted to evaluate a forward-swept versus an aft-swept blade application and how the given blade design would affect interaction between rotors. Two blade designs were initially selected. Both designs involved in-depth aerodynamic, aeromechanical, mechanical, and acoustic analyses followed by the fabrication of forward-swept, forward rotor blade sets to be wind tunnel tested with an aft-swept, aft rotor blade set. A third blade set was later produced from a NASA design that was based on wind tunnel test results from the first two blade sets. This blade set had a stiffer outer ply material added to the original blade design, in order to reach the design point operating line. Detailed analyses, feasibility studies, and fabrication procedures for all blade sets are presented.
The aerodynamic design, structural design, fabrication, and structural testing is described for a 60 foot long filament wound, fiberglass/epoxy resin matrix wind turbine rotor blade for a 125 foot diameter, 100 kW wind energy conversion system. One blade was fabricated which met all aerodynamic shape requirements and was structurally capable of operating under all specified design conditions. The feasibility of filament winding large rotor blades was demonstrated.
Most present wind, wave, and tidal energy systems require expensive power conditioning systems that reduce overall efficiency. This new design eliminates power conditioning all, or nearly all, of the time. Wind, wave, and tidal energy systems can transmit their energy to pumps that send high-pressure fluid to a central power production area. The central power production area can consist of a series of hydraulic generators. The hydraulic generators can be variable displacement generators such that the RPM, and thus the voltage, remains constant, eliminating the need for further power conditioning. A series of wind blades is attached to a series of radial piston pumps, which pump fluid to a series of axial piston motors attached to generators. As the wind is reduced, the amount of energy is reduced, and the number of active hydraulic generators can be reduced to maintain a nearly constant RPM. If the axial piston motors have variable displacement, an exact RPM can be maintained for all, or nearly all, wind speeds. Analyses have been performed that show over 20% performance improvements with this technique over conventional wind turbines
Design of mass-efficient composite structures intended for Automated Fiber Placement (AFP) requires close interaction between structural analysis and manufacturing process planning. Tools exist for each of these disciplines, but software interplay has been insufficient for rapid and efficient design iteration. Within the NASA Advanced Composites Consortium (ACC), the Design for Manufacturing (DFM) task has made significant progress towards linking these disciplines and respective software – HyperX (design), CAPP (process planning), and VCP (tool path generation). The initial focus in previous work was on data exchange between disciplines. The ability to both export and consume composite design and manufacturing data to and from each tool. This paper focuses on the effort to automate and streamline the connection between the tools listed above, with the goal of being able to automatically generate a composite AFP design that is mass-efficient and manufacturable. The optimization method being pursued is a bi-level approach, where each tool performs optimization within its discipline. The optimization in HyperX is focused on mass and laminate strength, while CAPP is focused on maximizing manufacturability. VCP is used to generate fiber paths for each design iteration. These sub-processes are wrapped with a global level optimization, driven by HyperX, used to converge the design. This paper describes the current state of this effort, which is a completed HyperX-VCP iteration loop and initial work on the HyperX-CAPP iteration loop. Additionally, example results are shown for a wind blade structure with double curvature.
A failure analysis was performed to establish the cause of a 2014-T6 aluminum compressor rotor blade failure in a large NASA-Ames wind tunnel. Metallurgical failure analysis by light photography, fractographic SEM examinations, and fatigue experiments showed that a 0.13-mm-deep scratch in the shank of the blade had acted as an initiation site for a fatigue crack, which subsequently grew by Stage II fatigue before occurrence of the final fracture by unstable crack growth. Studies of modal deformation plots and blade FEM analysis indicated that Mode-3 was the most likely mode responsible for the resonance condition which produced the vibration loading that effected crack growth. Tunnel measurements data showed that the crack growth was controlled by both the tunnel resonance and the dampening from the crack itself.
The development and evaluation of a low cost blade concept based on the NASA-Lewis specifications is discussed. A blade structure was designed and construction methods and materials were selected. Complete blade tooling concepts, various technical and economic analysis, and evaluations of the blade design were performed. A comprehensive fatigue test program was conducted to provide data and to verify the design. A test specimen of the spar assembly, including the root end attachment, was fabricated. This is a full-scale specimen of the root end configuration, 20 ft long. A blade design for the Mod '0' system was completed.
Pressure measurements covering a range of wind velocities were made at one span location on the surface of an operating Mod-2, 2500 kW, wind turbine blade. The data, which were taken with and without vortex generators installed on the leading edge, show the existence of higher pressure coefficients than would be expected from two-dimensional wind tunnel data. These high pressure ratios may be the result of three-dimensional flow over the blade, which delays flow separation. Data are presented showing the repetitiveness of abrupt changes in the pressure distribution that occur as the blade rotates. Calculated values of suction and flap coefficients are also presented.
A computer program is presented which numerically solves an exact, full potential equation (FPE) for three dimensional, steady, inviscid flow through an isolated wind turbine rotor. The program automatically generates a three dimensional, boundary conforming grid and iteratively solves the FPE while fully accounting for both the rotating cascade and Coriolis effects. The numerical techniques incorporated involve rotated, type dependent finite differencing, a finite volume method, artificial viscosity in conservative form, and a successive line overrelaxation combined with the sequential grid refinement procedure to accelerate the iterative convergence rate. Consequently, the WIND program is capable of accurately analyzing incompressible and compressible flows, including those that are locally transonic and terminated by weak shocks. The program can also be used to analyze the flow around isolated aircraft propellers and helicopter rotors in hover as long as the total relative Mach number of the oncoming flow is subsonic.
Information is presented which was compiled by the NASA Inter-Center Committee on Structural Integrity of Wooden Fan Blades and is intended for use as a guide in design, fabrication, evaluation, and assurance of fan systems using wooden blades. A risk assessment approach for existing NASA wind tunnels with wooden fan blades is provided. Also, state of the art information is provided for wooden fan blade design, drive system considerations, inspection and monitoring methods, and fan blade repair. Proposed research and development activities are discussed, and recommendations are provided which are aimed at future wooden fan blade design activities and safely maintaining existing NASA wind tunnel fan blades. Information is presented that will be of value to wooden fan blade designers, fabricators, inspectors, and wind tunnel operations personnel.
A mechanical drive system for oscillating blades in a wind tunnel at frequencies up to 767 hertz and amplitudes of + or - 1.2 deg is described. High-speed motion pictures of schlieren images of the flow over a double-circular arc blade oscillating in harmonic motion about the midchord revealed extensive shock patterns at a nominal free stream Mach number of 0.7, a mean angle of attack of 4 deg, and reduced frequency of about 0.7. A phase lag resulting from the slow response of the flow to the motion of the blade increased with increasing reduced frequency. This phase lag, based on the difference between the time the blade attained its maximum angle of attack and the time required for the normal shock to reach its extreme downstream position, was nominally 100 deg at the above conditions.
This manual describes the organization and flow of data and analysis in the computer code, COBSTRAN (COmposite Blade STRuctural ANalyzer). This code combines composite mechanics and laminate theory with an internal data base of fiber and matrix properties and was developed for the design and analysis of composite turbofan and turboprop blades and composite wind turbine blades. Inputs to the code are constituent fiber and matrix material properties, factors reflecting the fabrication process, composite geometry and blade geometry. COBSTRAN performs the micromechanics and laminate analyses of these fiber composites and generates a NASTRAN finite element model of the blade. This manual describes the equations formulated and solved in the code and the function of each of the seventy-two subroutines. COBSTRAN is written in FORTRAN 77.
The existing 40- by 80-Foot Wind Tunnel at Ames Research Center is being modified to upgrade and expand the research capabilty of the facility. The modification project includes an enhancement of the wind-tunnel drive power capability by installing large capacity electric motors and new drive fans to attain higher airspeeds in the existing 40- by 80-ft test section. It also involves the constructin of a new tunnel leg which includes a larger 80-- by 120-ft test section. The 40-by 80-ft test section will have a maximum airspeed approaching 300 knots. It was previously limited to about 200 knots. The maximum airspeed of the 80- by 120-ft test section will be about 100 knots. Becaue of the critical nature of the drive fans in the operation of the facility, an extensive effort was undertaken to verify, for each blade-retention system, its structural integrity and its dynamic characteristics.
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.
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.