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DEVELOPMENT OF A PROCESS TO MANUFACTURE ONE PIECE WIND TURBINE BLADES WITHOUT BONDINGS.

Objective

THIS RESEARCH PROJECT AIMS TO DEVELOP A NEW MANUFACTURING SYSTEM FOR WIND TURBINE BLADES OF FIBREGLASS REINFORCED POLYESTER. THE RESULTING PRODUCT HAS BEEN A 6 M. LONG BLADE CONSTRUCTED BY THE METHOD DEVELOPED, THAT IS TO SAY OF A SINGLE PIECE WITHOUT JOINTS BETWEEN THE TWO HALVES. THE BLADE IS CONSTRUCTED IN A SINGLE OPERATION INCLUDING BOTH THE EXTERNAL AND INTERNAL STRUCTURES.
A new manufacturing system for wind turbine blades of fibreglass reinforced polyester has been developed. The resulting product is a 6 m long blade of a single piece without joints between the 2 halves. The blade is constructed in a single operation including both the external and internal structures.
The noteworthy aspect of the manufacturing process is the absence of any joint on the blade, either on the leading edge or on the trailing edge. As a result, any critical points on the blade are removed and thus also problems of adhesion along the edges are eliminated. The considerable reduction in weight is also an important aspect of this manufacturing process.

A new manufacturing system for wind turbine blades using fibreglass reinforced polyester has been developed. There is no joint on the blade, on either the leading or the trailing edge. As a result, critical points on the blade and problems of adhesion along the edges are eliminated. The blade has been subjected to a short ageing process which has not produced any damage to the mechanical structure of the blade. Statically, the blade has been loaded with forces of approximately 1.7 times the maximum design load, and optical and mechanical analysis of the material have not revealed any damage. The total weight of the blade is less than that of blades made by other processes and its surface properties are good. The catalysation of the polyester resin is optimal and no cases of delamination have been observed as the blade is a single piece.
THE OBJECT OF THIS RESEARCH WORK HAS BEEN FULLY REACHED.
THE MECHANIC CHARACTERISTICS ARE EXCELLENT, COMPLYING THE STANDARD SPECIFICATIONS OF THE RISO.
WITH THE FINAL TEST OF THE MECHANICAL CHARACTERISTICS OF THE BLADE PRODUCED BY THE METHOD OF MANUFACTURE WHICH IS THE SUBJECT OF THE PRESENT PROJECT, THE QUALITY OF THE MATERIAL ACHIEVED FOR ITS CONSTRUCTION HAS BEEN ESTABLISHED, AS HAS THE FAVOURABLE DISTRIBUTION OF EFFORTS IN ITS STRUCTURE FOR STATIC LOADS.
THE BLADE HAS BEEN SUBJECTED TO A SHORT AGEING PROCESS WITH THE INTENTION OF DETECTING POSSIBLE STRUCTURAL DESIGN DEFECTS WITH VARIABLE LOADS, AND THIS PROCESS HAS NOT PRODUCED ANY DAMAGE WHATSOEVER IN ITS MECHANICAL PROPERTIES. IN RELATION TO STATIC CHARGES, THE BLADE HAS BEEN LOADED WITH FORCES OF APPROXIMATELY 1,7 TIMES THE MAXIMUM DESIGN LOAD, AND OPTICAL AND MECHANICAL ANALYSIS OF THE MATERIAL HAVE NOT REVEALED ANY DAMAGE. THE OWN RESONANCE FREQUENCIES ALLOW THE STRUCTURE TO OPERATE AT TURNING FREQUENCIES AT WHICH ITS PERFORMANCE IS OPTIMAL.
THE TOTAL WEIGHT OF THE BLADE IS LESS THAN FOR BLADES MADE BY OTHER PROCESSES, AND ITS SURFACE PROPERTIES ARE GOOD. THE CATALYSATION OF THE POLYESTER RESIN IS OPTIMAL, AND NO CASES OF DELAMINATION HAVE BEEN OBSERVED AS THE BLADE IS A SINGLE PIECE.
THE WORKS HAVE BEEN MADE IN THE FORSIGHTED PERIOD AND WITH THE BUDGET ESTABLISHED.
AT PRESENT, ECOTECNIA IS MANUFACTURING, WITH THIS PROCESS, THE 6M. BLADES OF ITS 30 KW. WINDMILL.
THE RESULTS IS VERY SATISFACTORY AND THE COST IS LOWER THAN FOR OTHER EUROPEAN COMPANIES.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Ecotecnia Sociedad Cooperativa Catalana Ltd.
Address
23 1,Cl. Amistad
08005 Barcelona
Spain