Electromagnetic energy harvester for monitoring wind turbine blades

The long composite blades on large wind turbines experience tremendous stresses while in operation. There is an interest in implementing structural health monitoring (SHM) systems inside wind turbine blades to alert maintenance teams of damage before serious component failure occurs. This paper proposes using an energy harvesting device inside the blade of a horizontal axis wind turbine to power a SHM system. The harvester is a linear induction energy harvester placed radially along the length of the blade. The rotation of the blade causes a magnet to slide along a tube as the blade axis changes relative to the direction of gravity. The magnet induces a voltage in a coil around the tube, and this voltage powers the SHM system. This paper begins by discussing motivation for this project. Next, a harvester model is developed, which encompasses the mechanics of the magnet, the interaction between the magnet and the coil, and the current in the electrical circuit. A free fall test verifies the electromechanical coupling model, and a rotating test examines the power output of a prototype harvester. Copyright © 2013 John Wiley & Sons, Ltd.     

A computational investigation of airfoil aeroacoustics for structural health monitoring of wind turbine blades

A generalized computational methodology for reduced order acoustic‐structural coupled modeling of the aeroacoustics of a wind turbine blade is presented. This methodology is used to investigate the acoustic pressure distribution in and around airfoils to guide the development of a passive damage detection approach for structural health monitoring of wind turbine blades for the first time. The output of a k ? ε turbulence model computational fluid dynamics simulation is used to calculate simple acoustic sources on the basis of model tuning with published experimental data. The methodology is then applied to a computational case study of a 0.3048‐m chord NACA 0012 airfoil with two internal cavities, each with a microphone placed along the shear web. Five damage locations and four damage sizes are studied and compared with the healthy baseline case for three strategically selected acoustic frequencies: 1, 5, and 10 kHz. In 22 of the 36 cases in which the front cavity is damaged, the front cavity microphone measures an increase in sound pressure level (SPL) above 3 dB, while rear cavity damage only results in six out of 24 cases with a 3‐dB increase in the rear cavity. The 1‐ and 5‐kHz cases show a more consistent increase in SPL than the 10‐kHz case, illustrating the spectral dependency of the model. The case study shows how passive acoustic detection could be used to identify blade damage, while providing a template for application of the methodology to investigate the feasibility of passive detection for any specific turbine blade.     

Wireless monitoring algorithm for wind turbine blades using Piezo‐electric energy harvesters

Wind turbine blade failure can be catastrophic and lead to unexpected power interruptions. In this paper, a Structural Health Monitoring (SHM) algorithm is presented for wireless monitoring of wind turbine blades. The SHM algorithm utilizes accumulated strain energy data, such as would be acquired by piezoelectric materials. The SHM algorithm compares the accumulated strain energy at the same position on the three blades. This exploits the inherent triple redundancy of the blades and avoids the need for a structural model of the blade. The performance of the algorithm is evaluated using probabilistic metrics such as detection probability (True Positive) and false alarm rate (False Positive). The decision time is chosen to be sufficiently long that a particular damage level can be detected even in the presence of system sensor noise and wind variations. Finally, the proposed algorithm is evaluated with a case study of a utility‐scale turbine. The noise level is based on measurements acquired from strain sensors mounted on the blades of a Clipper Liberty C96 turbine. Strain energy changes associated with damage from matrix cracking and delamination are simulated with a finite element model. The case study demonstrates that the proposed algorithm can detect damage with a high probability based on a decision time period of approximately 50–200 days. Copyright © 2016 John Wiley & Sons, Ltd.     

Multicamera measurement system to evaluate the dynamic response of utility‐scale wind turbine blades

Wind turbine blade certification requires static and fatigue testing at a large‐scale facility similar to the Wind Technology Testing Center (WTTC) located in Charlestown, Massachusetts. Usually, these tests are conducted by using wire‐based sensors such as strain gages, accelerometers, and string potentiometers. These systems are expensive, require a time‐consuming installation (e.g., up to 3 weeks and $35 k–$50 k for a strain gage system on a 55‐m‐long blade), are difficult to deploy on large‐sized structures, require additional instrumentations (e.g., power amplifiers and data acquisition systems), and produce results only at a handful of a discrete number of measurement points. In this study, a multicamera measurement system is implemented and experimentally evaluated to obtain full‐field displacement and strain over a ~12‐m‐long portion of a ~60‐m utility‐scale wind turbine blade. The proposed system has the potential to streamline the certification process by reducing the blade's preparation and sensor installation cost and time to a few hundreds of dollars (for painting equipment) and a few days for preparing the surface of the blade for the test. Furthermore, operational modal analysis was used in conjunction with the multicamera system to estimate the natural frequencies and mode shapes of the wind turbine blade. The obtained results have shown that the proposed approach can detect in‐plane displacement as low as 0.2 mm, mechanical strain with an error below 3% when compared with measurement performed using strain gages, and the first five natural frequencies with an error below 2% when compared with data recorded using traditional wire‐based accelerometers. This paper presents these results and provides a summary of the strengths and weaknesses of the proposed optical measurement approach in the context of streamlining the blade certification/testing process and performing vision‐based structural dynamic measurements on large‐scale structures.     

On the integration of lightning protection with stealth coated wind turbine blades

In this paper, we consider the problem of reducing the radar cross section of a wind turbine blade through the application of radar absorbing material (RAM). One problem encountered by these techniques is the integration of the RAM solution with the existing lightning protection system, which is mandatory requirement to protect the blade when in operation. A common form of lightning protection is the use of conducting lightning receptors on the surface of the blade. To ensure the protection system is effective, a clearance area around the receptor may be required before any RAM treatment is applied. The size of the clearance area and the number of lightning receptors therefore potentially reduce the effectiveness of the RAM treatment. Design guidelines are given in this paper for a generic 40 m blade geometry. Some modelling results of the radar cross section and Doppler signature from a RAM treated blade are presented, and a comment is also made on the importance the blade edges have in reducing radar effects. ©2013 The Authors. Wind Energy published by John Wiley & Sons, Ltd.     

Feasibility study on a full-scale wind turbine blade monitoring campaign: Comparing performance and robustness of features extracted from medium-frequency active vibrations

The present work investigates the performance of different features, extracted from vibration-based data, for structural health monitoring of a 52-meter wind turbine blade during fatigue testing. An active vibration monitoring system was used during the test campaign, providing periodic excitation of single frequencies in the medium-frequency range, and using accelerometers to measure the vibration output on different parts of the blade. Based on previous work from the authors, data is available for the wind turbine blade in healthy state, with a manually induced damage, and with progressively increasing damage severity. Using the vibration data, different signal processing methods are used to extract damage-sensitive features. Time series methods and time-frequency domain methods are used to quantify the applied active vibration signal. Using outlier analysis, the health state of the blade is classified, and the classification accuracy through use of the different features is compared. Highest performance is generally obtained by auto-regressive modeling of the vibration outputs, using the auto-regressive parameters as features. Finally, suggestions for future improvements of the present method toward practical implementation are given.     

Aeroelastic design of large wind turbine blades considering damage tolerance

Modern offshore turbine blades can be designed for high fatigue life and damage tolerance to avoid excessive maintenance and therefore significantly reduce the overall cost of offshore wind power. An aeroelastic design strategy for large wind turbine blades is presented and demonstrated for a 100 m blade. High fidelity analysis techniques like 3D finite element modeling are used alongside beam models of wind turbine blades to characterize the resulting designs in terms of their aeroelastic performance as well as their ability to resist damage growth. This study considers a common damage type for wind turbine blades, the bond line failure, and explores the damage tolerance of the designs to gain insight into how to improve bond line failure through aeroelastic design. Flat‐back airfoils are also explored to improve the damage tolerance performance of trailing‐edge bond line failures. Copyright © 2016 John Wiley & Sons, Ltd.     

Accuracy of an efficient framework for structural analysis of wind turbine blades

This paper presents a novel framework for the structural design and analysis of wind turbine blades and establishes its accuracy. The framework is based on a beam model composed of two parts—a 2D finite element‐based cross‐section analysis tool and a 3D beam finite element model. The cross‐section analysis tool is able to capture the effects stemming from material anisotropy and inhomogeneity for sections of arbitrary geometry. The proposed framework is very efficient and therefore ideally suited for integration within wind turbine aeroelastic design and analysis tools. A number of benchmark examples are presented comparing the results from the proposed beam model to 3D shell and solid finite element models. The examples considered include a square prismatic beam, an entire wind turbine rotor blade and a detailed wind turbine blade cross section. Phenomena at both the blade length scale—deformation and eigenfrequencies—and cross section scale—3D material strain and stress fields—are analyzed. Furthermore, the effect of the different assumptions regarding the boundary conditions is discussed in detail. The benchmark examples show excellent agreement suggesting that the proposed framework is a highly efficient alternative to 3D finite element models for structural analysis of wind turbine blades. Copyright © 2015 John Wiley & Sons, Ltd.     

On the structural topology of wind turbine blades

As wind turbines continue to grow in size, it becomes increasingly important to ensure that they are as structurally efficient as possible to ensure that wind energy can be a cost‐effective source of power generation. A way to achieve this is through weight reductions in the blades of the wind turbine. In this study, topology optimization is used to find alternative structural configurations for a 45 m blade from a 3 MW wind turbine. The result of the topology optimization is a layout that varies along the blade length, transitioning from a structure with trailing edge reinforcement to one with offset spar caps. Sizing optimization was then performed on a section with the trailing edge reinforcement and was shown to offer potential weight savings of 13.8% when compared with a more conventional design. These findings indicate that the conventional structural layout of a wind turbine blade is sub‐optimal under the static load conditions that were applied, suggesting an opportunity to reduce blade weight and cost. Copyright © 2012 John Wiley & Sons, Ltd.     

A novel wind turbine health condition monitoring method based on common features distribution adaptation

Aimed at the difficulty of diagnosing the transmission system of wind turbine under variable working conditions, a novel health condition monitoring method based on common features distribution adaptation is proposed in this article. In the method, envelope analysis is first performed on the collected signals, and then the time-frequency features are extracted to be combined as new input samples. The feature set under the working condition similar to target working condition is selected as the auxiliary sample set in source domain through the evaluation of the transferability. The kernel function is used to map the labeled auxiliary samples and unlabeled target samples to a reproduced kernel Hilbert space, which effectively reduces the data distribution discrepancy between source and target domains. The problem of class imbalance in each domain is taken into account when performing fault recognition, which improves the effect of transfer learning. Finally, the adjusted source domain is used to train the classifier, which is applied to the target domain to get the predicted labels of the test data. Experiment shows that the proposed method has better working performance than traditional fault diagnosis methods.     

Flap/lead–lag aeroelastic stability of wind turbine blades

A numerical tool for investigating the aeroelastic stability of a single wind turbine blade subjected to combined flap/lead–lag motion is presented. Its development is motivated by recent concern about destructive edgewise vibrations of modern stall‐controlled blades. The stability tool employs a finite element formulation to discretize in space the structural and aerodynamic governing equations. Unsteady aerodynamics is considered by means of the extended ONERA lift and drag models. The mathematical form of these models allows for a combined treatment of dynamics and aerodynamics through the introduction of a so‐called ‘aeroelastic beam element’. This is an extended two‐node beam element having both deformation and aerodynamic degrees of freedom. Several linear and non‐linear versions of the stability tool are available, differing in the way that instantaneous lift and/or drag is treated. In the linear case, stability is investigated through eigenvalue analysis. Time domain integration is employed for non‐linear stability analysis. Results are presented and discussed for a 17 m stall‐controlled blade. Copyright © 2001 John Wiley & Sons, Ltd.     

Investigation of data fusion applied to health monitoring of wind turbine drivetrain components

The research described was performed with diagnostic tools used to detect damage to dynamic mechanical components in a wind turbine gearbox. Different monitoring technologies were evaluated by collecting vibration and oil‐debris data from tests performed on both a ‘healthy’ gearbox and a damaged gearbox that were mounted on a dynamometer test stand at the National Renewable Energy Laboratory (NREL). The damaged gearbox tested had been removed from the field after it experienced component damage because of two events that resulted in the loss of oil. The gearbox was re‐tested under controlled conditions by using the NREL dynamometer test stand. Preliminary results indicate that oil‐debris and vibration data can be integrated to improve the assessment of the health of the wind turbine gearbox. Copyright © 2012 John Wiley & Sons, Ltd.     

Structural health monitoring of wind turbines: method and application to a HAWT

Structural health monitoring in the context of a Micon 65/13 horizontal axis wind turbine was described in this paper as a process in statistical pattern recognition. Simulation data from a calibrated model with less than 8% error in the first 14 natural frequencies of vibration was used to study the operational response under various wind states as well as the effects of three types of damage in the blade, low speed shaft and yaw joint. It was shown that vertical wind shear and turbulent winds lead to different modal contributions in the operational response of the turbine suggesting that the sensitivity of operational data to damage depends on the wind loads. It is also shown that there is less than a 4% change in the wind turbine natural frequencies given a 25% reduction in the stiffness at the root of one blade. The modal assurance criterion was used to analyse the corresponding changes in modal deflections, and this criterion exhibited nearly orthogonal changes because of the three damage scenarios suggesting that the modal deflection determines which damage is observable at a given frequency for a given wind state. The' modal contribution is calculated as a damage feature, which changes as much as 100% for 50% reductions in blade root stiffness, but only the blade damage is detected using this feature. Operational data was used to study variations in the forced blade response to determine the likelihood that small levels of damage can be detected amidst variations in wind speed across the rotor plane. The standard deviation in measured data was shown to be smallest for the span and edge‐wise measurements at 1P due to gravity, which provides the dominant forcing function at this frequency. A 3% change in the response in the span and edge‐wise directions because of damage is required to detect a change of three standard deviations in contrast to the 90% change in flap direction response that is required to detect a similar change because of damage. The dynamic displacement in the span direction is then used to extract a damage feature from the simulation data that provides the ability to both locate and quantify the reduction in stiffness in the blade root. Copyright © 2011 John Wiley & Sons, Ltd.     

Calculation of effective section stiffness properties for wind turbine blades using homogenization

The structural behavior of wind turbine blades can be accurately modeled using beam models. The accuracy in the predictions using beam models depends on the degree of accuracy in the prediction of the effective section properties. A simple and efficient method compared with full 3D analysis is developed for the prediction of effective section properties for prismatic slender members of any arbitrary cross‐section shape. The technique, which is based on the superposition principle, is developed to include the shear deformation modes in predicting the effective stiffness properties. A homogenization scheme based on strain energy equivalence is employed for calculating the effective properties. The method can accurately predict the full stiffness matrix including the off‐diagonal terms. Also a procedure for finding the locations of the weighted centroid and the shear center is presented. The results for four different cross‐section shapes including a wind turbine blade section are validated using an existing analysis technique, Variational Asymptotic Beam Sectional Analysis. Copyright © 2012 John Wiley & Sons, Ltd.     

The Brazier effect in wind turbine blades and its influence on design

Critical failure was observed in the shear web of a wind turbine blade during a full‐scale testing. This failure occurred immediately before the ultimate failure and was partly caused by buckling and non‐linear cross‐sectional strain. Experimental values had been used to compare and validate both numerical and semi‐analytical results in the analysis of the shear webs in the reinforced wind turbine blade. Only elastic material behaviour was analysed, and attention was primarily focused on the Brazier effect. The complex, geometrically non‐linear and elastic stress–strain behaviour of the shear webs and the cap in compression were analysed using a balance of experimental, numerical and analytical approaches. It was noted that the non‐linear distortion was caused by the crushing pressure derived from the Brazier effect. This Brazier pressure may have a significant impact on the design of new blades, and an optimized box girder had been studied to show the importance of including Brazier pressure in the design process for future wind turbine blades. Copyright © 2011 John Wiley & Sons, Ltd.     

Leading edge erosion of wind turbine blades: Multiaxial critical plane fatigue model of coating degradation under random liquid impacts

A computational model of rain erosion of wind turbine blades is presented. The model is based on the transient fluid–solid coupled finite element (FE) analysis of rain droplet/coating interaction and fatigue degradation analysis. The fatigue analysis of the surface degradation is based on multiaxial fatigue model and critical plane theory. The random rain fields are constructed computationally, and the estimated droplet sizes are included in FE model to acquire a library of load histories. Subsequently, the resulted nonproportional multiaxial high cycle fatigue problem is solved to assess the damage and lifetimes of the coatings. The approach can be used to design new coating systems withstanding longer service times.     

A spinner‐integrated wind lidar for enhanced wind turbine control

A field test with a continuous wave wind lidar (ZephIR) installed in the rotating spinner of a wind turbine for unimpeded preview measurements of the upwind approaching wind conditions is described. The experimental setup with the wind lidar on the tip of the rotating spinner of a large 80 m rotor diameter, 59 m hub height 2.3 MW wind turbine (Vestas NM80), located at Tjæreborg Enge in western Denmark is presented. Preview wind data at two selected upwind measurement distances, acquired during two measurement periods of different wind speed and atmospheric stability conditions, are analyzed. The lidar‐measured speed, shear and direction of the wind field previewed in front of the turbine are compared with reference measurements from an adjacent met mast and also with the speed and direction measurements on top of the nacelle behind the rotor plane used by the wind turbine itself. Yaw alignment of the wind turbine based on the spinner lidar measurements is compared with wind direction measurements from both the nearby reference met mast and the turbine's own yaw alignment wind vane. Furthermore, the ability to detect vertical wind shear and vertical direction veer in the inflow, through the analysis of the spinner lidar data, is investigated. Finally, the potential for enhancing turbine control and performance based on wind lidar preview measurements in combination with feed‐forward enabled turbine controllers is discussed. Copyright © 2012 John Wiley & Sons, Ltd.     

Post‐installation adaptation of offshore wind turbine controls

The cost of offshore wind energy can be reduced by incorporating control strategies to reduce the support structures' load effects into the structural design process. While effective in reducing the cost of support structures, load‐reducing controls produce potentially costly side effects in other wind turbine components and subsystems. This paper proposes a methodology to mitigate these side effects at the wind farm level. The interaction between the foundation and the surrounding soil is a major source of uncertainty in estimating the safety margins of support structures. The safety margins are generally closely correlated with the modal properties (natural frequencies, damping ratios). This admits the possibility of using modal identification techniques to reassess the structural safety after installing and commissioning the wind farm. Since design standards require conservative design margins, the post‐installation safety assessment is likely to reveal better than expected structural safety performance. Thus, if load‐reducing controls have been adopted in the structural design process, it is likely permissible to reduce the use of these during actual operation. Here, the probabilistic outcome of such a two‐stage controls adaptation is analyzed. The analysis considers the structural design of a 10 MW monopile offshore wind turbine under uncertainty in the site‐specific soil conditions. Two control strategies are considered in separate analyses: (a) tower feedback control to increase the support structure's fatigue life and (b) peak shaving to increase the support structure's serviceability capacity. The results show that a post‐installation adaptation can reduce the farm‐level side‐effects of load‐reducing controls by up to an order of magnitude.     

切出风速下风力机变桨故障叶片气动特性及准静态结构响应分析

为探究大型水平轴风力机达到切出风速停机后变桨故障叶片的气动特性及准静态结构响应,基于计算流体力学方法对NREL 5 MW风力机变桨故障/成功叶片气动侧状态进行分析,并利用双向弱流固耦合及曲屈分析对典型方位角下变桨故障叶片展开研究。结果显示：切出风速下变桨故障叶片挥舞力矩平均值为变桨成功叶片的13.8倍,且前者的流场尾迹更为明显。此外,180°方位角变桨故障叶片较之0°方位角变桨故障叶片应力及叶尖位移分别减小29.8%和32.7%,一阶屈曲因子增加20.2%。