Application of combined analytical/FEA coupled aero-structure simulation in design of wind turbine adaptive blades

This paper demonstrates the application of combined analytical/FEA coupled aero-structure simulation in design of bend-twist adaptive blades. A genetic algorithm based design tool, in which the power curve is predicted through a combined coupled aero-structure simulation, has been developed. A bend-twist adaptive blade has been designed to be used on the rotor of a constant speed stall regulated wind turbine. The bend-twist adaptive blade is assumed to be made out of anisotropic composite materials. The designed blade has the same aerofoil and chord distribution as the original blade used on the wind turbine, but with a different pre-twist distribution. The simulated results show a significant improvement in the average power of the studied stall regulated wind turbine when employing the designed adaptive blades.     

WTAB, a computer program for predicting the performance of horizontal axis wind turbines with adaptive blades

An aero-structure code has been developed to predict the performance of a horizontal axis wind turbine (HAWT) with adaptive blades. The code is a combination of an aerodynamic code, an adaptive mesh generator and a finite element code, all developed especially for this purpose. It has been shown that for a high elastic coupling, a coupled aero-structure simulation approach is necessary to have acceptable results while a single step simulation approach can only be used to estimate the blade loading and wind turbine power.     

Decoupled aerodynamic and structural design of wind turbine adaptive blades

This paper presents a method for decoupled design of bend-twist adaptive blades (BTABs) in which the aerodynamic and structural designs take place separately. In this approach the induced twist is considered as an aerodynamic design parameter, whilst its dependency on the structural characteristics of the blade is taken into account by imposing a proper constraint on the structure design. The main advantage of this method is the significant reduction in evaluation time by replacing a finite element analysis (FEA)-based coupled-aero-structure (CAS) simulation in the aerodynamic objective evaluation by a non-FEA-based CAS simulation. Through a re-design case study an ordinary blade has been converted to a BTAB and the efficiency of the method in performing decoupled design of BTABs has been illustrated.     

Efficient meshing of a wind turbine blade using force adaptive mesh sizing functions

This paper describes mesh sizing functions for discretization of a wind turbine blade as a shell structure. Two different functions, one along the blade span and the other chord-wise, are presented. The effect of the magnitude of the aerodynamic force has been considered in a span-wise mesh sizing function to obtain a force-adaptive mesh generator, applicable when the blade needs to be analysed as a part of an aero-structure problem. The direction of the aerodynamic force has been considered in the chord-wise mesh sizing function to improve the mesh efficiency. Results show a large improvement in the rate of convergence when the direction of the external force contributes towards the chord-wise mesh size.     

Bend‐bend‐twist vibrations of a wind turbine blade

Dynamics of a wind turbine blade under bend‐bend‐twist coupled vibrations is investigated. The potential and kinetic energy expressions for a straight nonuniform blade are written in terms of beam parameters. Then, the energies are expressed in terms of modal coordinates by using the assumed mode method, and the equations of motion are found by applying Lagrange's formula. The bend‐bend‐twist equations are coupled with each other and have stiffness variations due to centrifugal effects and gravitational parametric terms, which vary cyclicly with the hub angle. To determine the natural frequencies and mode shapes of the system, a modal analysis is applied on the linearized coupled equations of constant angle snapshots of a blade with effects of constant speed rotation. Lower modes of the coupled bend‐bend‐twist model are dominantly in‐plane or out‐of‐plane modes. To investigate the parametric effects, several blade models are analyzed at different angular positions. The stiffness terms involving centrifugal and gravitational effects can be significant for long blades. To further see the effect of blade length on relative parametric stiffness change, the blade models are scaled in size and analyzed at constant rotational speeds, at horizontal and vertical orientations. These studies show that the parametric stiffness effects should be taken into account when designing long blades.     

Optimization‐based study of bend–twist coupled rotor blades for passive and integrated passive/active load alleviation

This work is concerned with the design of wind turbine blades with bend‐twist‐to‐feather coupling that self‐react to wind fluctuations by reducing the angle of attack, thereby inducing a load mitigation effect. This behavior is obtained here by exploiting the orthotropic properties of composite materials by rotating the fibers away from the pitch axis. The first part of this study investigates the possible configurations for achieving bend‐twist coupling. At first, fully coupled blades are designed by rotating the fibers for the whole blade span, and a best compromise solution is found to limit weight increase by rotations both in the spar caps and in the skin. Next, partially coupled blades are designed where fibers are rotated only on the outboard part of the blade, this way achieving good load mitigation capabilities together with weight savings. All blades are designed with a multilevel constrained optimization procedure, on the basis of combined cross‐sectional, multibody aero‐servo‐elastic and three‐dimensional finite element models. Finally, the best configuration of the passive coupled blade is combined with an active individual pitch controller. The synergistic use of passive and active load mitigation technologies is shown to allow for significant load reductions while limiting the increase in actuator duty cycle, thanks to the opposite effects on this performance metric of the passive and active control solutions. Copyright © 2012 John Wiley & Sons, Ltd.     

Study of damage and repair of blades of a 300 kW wind turbine

The inspection of damages detected in some blades of 300 kW wind turbines revealed that the nature of these damages was probably due to a fatigue mechanism. The causes that had originated the failure (superficial cracks, geometric concentrator, abrupt change of thickness) have been studied, verifying, by means of the simplified evaluation procedure of fatigue life of the “Germanischer Lloyd” (GL) standard, that these causes can explain the failure detected in the period of time in which it happened.     

Aero-elastic behavior of a flexible blade for wind turbine application: A 2D computational study

This paper presents a computational study into the static aeroelastic response of a 2D wind turbine airfoil under varying wind conditions. An efficient and accurate code that couples the X-Foil software for computation of airfoil aerodynamics and the MATLAB PDE toolbox for computation of the airfoil deformation is developed for the aero-elastic computations. The code is validated qualitatively against computational results in literature. The impact of a flexibility of the airfoil is studied for a range of design parameters including the free stream velocity, pitch angle, airfoil thickness, and airfoil camber. Static aero-elastic effects have the potential to improve lift and the lift over drag ratio at off-design wind speed conditions. Flexibility delays stall to a large pitch angle, increasing the operating range of a flexible blade airfoil. With increased thickness the airfoil deformation decrease only linearly.     

Aerodynamic characteristics of wind turbine blades with a sinusoidal leading edge

The aerodynamic characteristics of a kind of bionic wind turbine blades with a sinusoidal leading edge have been investigated in this paper based on a three‐dimensional Reynolds‐averaged Navier–Stokes simulation. The calculated results show that compared with a straight leading‐edge blade, the new‐type blade has a great improvement in shaft torque at high wind speeds. The localized vortices shedding from the leading‐edge tubercles, which can generate a much greater peak of the leading‐edge suction pressure than that from the straight leading‐edge case, are the physical essentials to enhance the wavy blade's aerodynamic performances as the blade goes into stall. In particular, the outboard segment from the 60%R station to the blade tip is the key region for wavy leading‐edge blades to improve the aerodynamic characteristics at high‐speed inflows. In this key region, a wavy blade can obtain a greater power output as the wavelength l and the waveheight δ increase. The present numerical results also show that the wavy leading‐edge shape is unfavorable for a wind turbine blade under the design conditions (e.g., at the rated wind speed). At these conditions, an early boundary‐layer separation as a result of the geometric disturbances of the leading‐edge tubercles will inevitably result in a visible shaft‐torque reduction in the wavy‐blade cases. Anyway, the wavy blades still tend to generate a more robust power output as a whole from 10 to 20 m s ^?1 than the original NREL phase‐VI blade. Copyright © 2011 John Wiley & Sons, Ltd.     

The effect of delaminations on local buckling in wind turbine blades

In this article the effect of delaminations on the load carrying capacity of a large wind turbine blade is studied numerically. For this purpose an 8.65 m long blade section with different initial delaminations in the main spar was subjected to a flapwise dominated bending moment. The model was setup in Abaqus and cohesive elements were chosen for modelling delamination growth.For initial delaminations with a width of 30–50% of the cap width the study showed that delamination close to the surface started to grow in load ranges of normal operation conditions and led to local buckling modes. The local buckling caused high strains and stresses in the surrounding of the delamination, which exceeded the material design properties and therefore should be considered as dangerous.Delaminations placed near the mid-surface of the cap did not have a significant effect on the blade response under normal operation conditions. In the simulations the static load exceeded the design load by more than 40% before delamination growth or cap buckling occurred.It could be concluded that delamination induced near-surface buckling modes have to be considered critical due to an onset of local sublaminate buckling below the design load level.     

The concept of a smart wind turbine system

A smart wind turbine concept with variable length blades and an innovative hybrid mechanical-electrical power conversion system was analyzed. The variable length blade concept uses the idea of extending the turbine blades when wind speeds fall below rated level, hence increasing the swept area, and thus maintaining a relatively high power output. It is shown for a typical site, that the annual energy output of such a wind turbine that could double its blade length, could be twice that of a corresponding turbine with fixed length blades. From a cost analysis, it is shown that the concept would be feasible if the cost of the rotor could be kept less than 4.3 times the cost of a standard rotor with fixed length blades. Given the variable length blade turbine system exhibits a more-or-less linear maximum power curve, as opposed to a non-linear curve for the standard turbine, an innovative hybrid mechanical-electrical power conversion system was proposed and tested proving the feasibility of the concept.     

Numerical simulation on effect of pressure distribution of wind turbine blade with a tip vane

It is important to study the pressure distribution on the blade and in the adjacent area while searching the power augmentation theory with adding a tip vane to the wind turbine. This paper shows the CFD simulation relationship of the pressure distribution on the rotor blade and in the adjacent area, after calculating the pressure of the different chordwise and spanwise point on the blade with the tip vane-V(8.8×8) and without the tip vane under tip speed ratio λ 4.5. Combining the isobaric section figure in certain location, it can be seen that the tip vane improve the pressure difference between pressure and suction surface. The most influenced zone is found and these can further display the power augmentation theory of the wind turbine using the tip vane. The simulation calculation was based on N-S equations. 3-D, steady, implicit solver was chosen. Turbulence model was k-ω SST. Discretization scheme is SECOND ORDER UPWIND. Pressure-velocity coupling was a typical SIMPLE scheme. In the whole grid system, two-divided grid formation was adopted, that is, inner region and outer region. Inner region including rectangular solid blade and neighboring, outer region is semi-cylinder. There were together 720,000 nodes with tetra-prism unstructured mesh.     

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.     

Integrated free‐form method for aerostructural optimization of wind turbine blades

A typical approach to optimize wind turbine blades separates the airfoil shape design from the blade planform design. This approach is sequential, where the airfoils along the blade span are preselected or optimized and then held constant during the blade planform optimization. In contrast, integrated blade design optimizes the airfoils and the blade planform concurrently and thereby has the potential to reduce cost of energy (COE) more than sequential design. Nevertheless, sequential design is commonly performed because of the ease of precomputation, or the ability to compute the airfoil analyses prior to the blade optimization. This research compares 2 integrated blade design approaches. The precomputational method combines precomputation with the ability to change the airfoil shapes in limited ways during the optimization. The free‐form method allows for a complete range of airfoil shapes, but without precomputation. The airfoils are analyzed with a panel method (XFOIL) and a Reynolds‐averaged Navier‐Stokes computational fluid dynamics method (RANS CFD). Optimizing the NREL 5‐MW reference turbine showed COE reductions of 2.0%, 4.2%, and 4.7% when using XFOIL and 2.7%, 6.0%, and 6.7% when using RANS CFD for the sequential, precomputational, and free‐form methods, respectively. The precomputational method captures most of the benefits of integrated design for minimal additional computational cost and complexity, but the free‐form method provides modest additional benefits if the extra effort is made in computational cost and development time.     

Design of a new urban wind turbine airfoil using a pressure-load inverse method

This paper presents the design methodology of a new wind turbine airfoil that achieves high performance in urban environment by increasing the maximum lift. For this purpose, an inverse method was applied to obtain a new wind turbine blade section with constant pressure-load along the chord, at the design inlet angle. In comparison with conventional blade section designs, the new airfoil has increased maximum lift, reduced leading edge suction peak and controlled soft-stall behaviour, due to a reduction of the adverse pressure gradient on the suction side. Wind tunnel experimental results confirmed the computational results.     

Performance enhancement and load reduction of a 5 MW wind turbine blade

A wind turbine rotor blade, based on the U.S. National Renewable Energy Laboratory (NREL) 5 MW reference turbine, is optimized for minimum cost of energy through simultaneous consideration of aerodynamics and bend-twist coupling. Eighty-three total design variables are considered, encompassing airfoil shapes, chord and twist distributions, and the degree of bend-twist coupling in the blade. A recently developed method requiring significantly less computation than finite element analysis is used for planning and predicting the bend-twist coupling behavior of the rotor. Airfoil performance is computed using XFOIL, while the wind turbine loads and performance are computed using the NREL FAST code. The objective function is annual cost of energy (COE), where reductions in flapwise bending loads and blade surface area are assumed to decrease rotor cost through reduced material requirements. The developed optimization process projects decreased blade loads while maintaining wind turbine performance.     

Numerical study of a concept for major repair and replacement of offshore wind turbine blades

Repair and replacement of offshore wind turbine blades are necessary for current and future offshore wind turbines. To date, repair activities are often conducted using huge jack‐up crane vessels and by applying a reverse installation procedure. Because of the high costs associated with installation and removal of offshore wind turbine components and the low profit margin of the offshore wind industry, alternative methods for installation and removal are needed. This paper introduces a novel concept for replacement or installation of offshore wind turbine blades. The concept involves a medium‐sized jack‐up crane vessel and a tower climbing mechanism. This mechanism provides a stable platform for clamping, lowering, and lifting of a blade. A case study of a 5‐MW offshore wind turbine is shown, where common engineering practices were applied and numerical simulations of the marine operations were carried out using finite element and multibody simulation tools. Operational limits for wave and wind actions were established to demonstrate the technical feasibility of the proposed concept.     

Modal re‐analysis of rotary wind turbine blades in refinement design

A modal re‐analysis approach is proposed for refinement designs of rotary wind turbine blades on the basis of matrix perturbation methods. The approach entails effects of stress stiffening, spin softening, uncertainty of material properties and structural modifications of blades. Three perturbation methods are used to conduct the re‐analysis approach, including the standard perturbation method and two improvements proposed by H. C. Hu and S. H. Chen, respectively. Numerical results of a typical wind turbine blade indicate that the two improved methods deliver better accuracy than the standard perturbation method in terms of eigenpairs. In application to blade designs, Chen's method is suitable for a multi‐step modal re‐analysis with explicit small parameters and cultivates the first‐order and second‐order perturbations of eigenpairs as well. In contrast, Hu's method is a better choice for a single‐step modal re‐analysis without determining any small parameter explicitly and directly offers approximate eigenpairs instead of somehow tedious perturbation processes. Copyright © 2012 John Wiley & Sons, Ltd.     

Development of a 20 kW wind turbine simulator with similarities to a 3 MW wind turbine

As the use of wind power has steadily increased, the importance of a condition monitoring and fault diagnosis system is being emphasized to maximize the availability and reliability of wind turbines. To develop novel algorithms for fault detection and lifespan estimation, a wind turbine simulator is indispensible for verification of the proposed algorithms before introducing them into a health monitoring and integrity diagnosis system. In this paper, a new type of simulator is proposed to develop and verify advanced diagnosis algorithms. The simulator adopts a torque control method for a motor and inverter to realize variable speed-variable pitch control strategies. Unlike conventional motor–generator configurations, the simulator includes several kinds of components and a variety of sensors. Specifically, it has similarity to a 3 MW wind turbine, thereby being able to acquire a state of operation that closely resembles that of the actual 3 MW wind turbine operated at various wind conditions. This paper presents the design method for the simulator and its control logic. The experimental comparison between the behavior of the simulator and that of a wind turbine shows that the proposed control logic performs successfully and the dynamic behaviors of the simulator have similar trends as those of the wind turbine.     

On‐site inspection of potential defects in wind turbine rotor blades with thermography

Recurrent non‐destructive testing inspections are necessary to prevent damages in wind turbine rotor blades, but so far, there is no established method that detects defects in blades from greater distances – although this becomes increasingly important in the context of hardly accessible offshore wind parks. Thermography is a promising method for detecting subsurface defects, but various challenges arise when this method is applied on‐site to turbine blades in operation. Disturbing influences from the environment easily lead to a misinterpretation of thermograms (i.e. thermographic images), such as thermal signatures caused by reflections, dirt and other superficial inhomogeneities. This study explores several problems and effects that arise, when (rotating) blades are monitored with thermography. It will then be demonstrated that a meaningful defect inspection in this scenario is essentially restricted to a procedure following three steps: Firstly, calculating the so‐called difference thermograms of all blade pairs for eliminating disturbing reflections. Secondly, identifying potentially relevant signals, which are associated neither with structural features nor with dynamical effects, and the identification of these signals' allocations (through comparison of all difference thermograms with each other). And thirdly, comparing these signals with (processed) photos for excluding incorrect indications by surface effects. Unlike common thermographic analysis methods, which typically only include an aspect of this procedure, the composition presented in this contribution constitutes an advanced technique for minimizing disturbing influences in thermograms. The proposed thermographic technique enables the detection of potential subsurface defects within rotating rotor blades from greater distances – such as from the ground, air crafts or vessels. Copyright © 2015 John Wiley & Sons, Ltd.