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Development of advanced blades for integration into wind turbine systems

Objective

The aim of this study is to increase the performance of wind turbines and reduce costs by developing blades of advanced design.
The expected results are the following :
To demonstrate that advanced structural design can be incorporated into blades with advanced airfoil shape '("structural design").
To show that advanced manufacturing methods can be used to fabricate spar/shell blades of advanced design ("manufacturing methods").
To show that alternative wood and resin types can be used to improve the performance and reduce the cost of blades made of wood
("wood-composites").
To demonstrate that glass-epoxy composites can be used to develop large wind turbine blades ("glass-epoxy composites").
To validate and verify design rules and recommendations for standards by calculation and testing ("norms and standards").

Results from the fatigue testing of the materials have enabled 'stiffness-controlled fatigue curves' for glass fibre composites and glass/carbon fibre composites to be established, allowing designers to make better choices between materials. Results of component testing showed that degradation was difficult to detect in the studs and blade, until the loads became much higher than the design loads.

Results from the blade tests were used to improve the earlier prototype blade, whilst the blade root review showed the most cost-effective construction to be the 'post-bonding' stud concept. Finally, the project proposed a methodology to allow turbine manufacturers to conform with the EU machinery directive and label turbines with the CE mark.
Recent advances in our knowledge of materials, structural response to load, aerodynamics and manufacturing techniques will be utilised combined with the necessary supporting research. The results of the project will permit the verification of the design, manufacture, performance and replication of the principal advanced blade types. Each type is related to projects for full-size turbines. A subsidiary aim is to develop recommendations concerning design rules and norms. The work will be performed by institutes and blade manufacturers to make the best use of expertise, manufacturing and test facilities.

The situation in Europe is the following :
Materials : There now exists an expanded understanding of the response of materials to fluctuating loads incorporating both a larger set of data and a wider spectrum of materials, developed with the aid of JOULE I funding.
Design : blade manufacturers have improved their design capability both by recruiting staff and the development of know-how. Aerodynamic design has advanced in Europe through work carried out by two of the partners on low lift profiles and profiles with good stall characteristics. Manufacture : New materials have been incorporated as they have become available - though they have not yet been fully characterized; process techniques have concentrated on improving quality.
Testing : Existing methods have been developed to permit the extensive testing of coupons, spars and blades and the monitoring of damage accumulation. Non-destructive evaluation shows promise of being able to monitor the state of the blade during testing.

The expected results are the following :
To demonstrate that advanced structural design can be incorporated into blades with advanced airfoil shape ("structural design").
To show that advanced manufacturing methods can be used to fabricate spar/shell blades of advanced design ("manufacturing methods").
To show that alternative wood and resin types can be used to improve the performance and reduce the cost of blades made of wood ("wood-composites").
To demonstrate that glass-epoxy composites can be used to develop large wind turbine blades ("glass-epoxy composites").
To validate and verify design rules and recommendations for standards by calculation and testing ("norms and standards").

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

RISOE NATIONAL LABORATORY
Address
Frederiksborgvej 399
Roskilde
Denmark

Participants (11)

Aerpac Holding BV
Netherlands
Address

7550 AN Hengelo
ENERGY RESEARCH CENTRE OF THE NETHERLANDS
Netherlands
Address
Westerduinweg 3
Petten
FFA - THE AERONAUTICAL RESEARCH INSTITUTE OF SWEDEN
Sweden
Address
12-14,Ranhammarsvaegen 12-14
161 11 Bromma
GERMAN AEROSPACE CENTRE
Germany
Address
Pfaffenwaldring 38-40
70569 Stuttgart
LM Glasfiber A/S
Denmark
Address
1,Rolles Moellevej
6640 Lunderskov
POLYMARIN BEHEER BV
Netherlands
Address
Nijverheidsweg 7
1671 GC Medemblik
Sciotech
United Kingdom
Address
9 Heathwood Yateley
GU17 7TP Camberley
University of Bath
United Kingdom
Address
Claverton Down
BA2 7AY Bath - Avon
University of the West of England, Bristol
United Kingdom
Address
Coldharbour Lane Frenchay
BS16 1QY Bristol
Veritas Offshore Technology and Services A/S
Norway
Address

1322 Høvik
Wind Energy Group Ltd
United Kingdom
Address
Phoenix Centre Totton
SO4 3SH Southampton