CHALLENGES AND RESEARCH OPPORTUNITIES FOR WIND TURBINE BLADE MANUFACTURE

U.I.K. Galappaththi1, A.M. De Silva2, M Macdonald3 Department of Energy Systems Engineering, Glasgow Caledonian University, Glasgow, UK Udayanga.Galappaththi@gcu.ac.uk1, A.Desilva@gcu.ac.uk2 M.Macdonald@gcu.ac.uk3
ABSTRACT Over the years number and size of wind turbines have increase significantly. The number and size of wind turbines has increased significantly in recent years. This development is expected to continue in upcoming years, especially with the installation and operation of large numbers of wind turbines in offshore wind parks. However these developments are limited by technological, institutional and financial barriers. The major objective of this paper is to identify technological challenges for wind turbine industry development, discussed research opportunities and introduces a mechanism based on university- industry- research institute linkage to enhance future technology innovations. Key Words: Composites, wind turbine blades, university- industry- research institute linkage

Introduction

The wind energy sector is expected to develop by 21-28 % of European energy consumption at year 2030 (European Wind Energy Platform, 2008). The market for new wind turbines showed 42 % of an increase, and reaches an overall size of 27261 MW compare to 19776 MW in 2007. These statistics indicates global wind energy sector projected to have vast development. However growth of wind energy industry is restricted by higher cost of wind turbines and their limited life time (Around 20-25 years). Therefore optimization of materials usage and improvement of fatigue life of turbines becomes more effective and necessary since 30-50% of total investments of wind farms are allocated to wind turbines (European Environment Agency, 2009). The conversion of aerodynamic power to mechanical torque is perhaps the most unique aspect of wind turbine operation. The ability to withstand changing aerodynamic loads and effectively extract power from the wind over a 20-year lifespan makes wind turbines cost effective. As machines grow larger and larger, rotors must increase accordingly (Thresher and Laxson, 2006).In this context, wind turbine designers and manufactures are facing numerous challenges and demand for wide range of technical responses. Innovation in aerodynamic design approaches, structural and fatigue design, materials, and manufacturing methods, will all have to be explored to achieve the projected future cost reductions. The global technological demand in wind turbine manufacturing sector has created a several research challenges?????. new challenges include: lighter; improved aerodynamic and structural dynamics codes that accurately predict unsteady loads and aerodynamic stall effects for lighter more flexible turbines under wide ranging atmospheric conditions; improved rotors that utilize aero elastically tailored blades of advanced materials such as carbon-epoxy composites; higher blade tip speeds with reduced blade chord; efficient condition monitoring technologies and productive manufacturing technologies (Thresher and Laxson, 2006). However the efficiency on these individual research involvements is low The major wind turbine manufactures universities and research institutions are working on these research objectives. In this perspective, research, university and industry collaboration is important.. . There are few university industry collaboration projects which targeted to achieve above research objectives. The authors believe it is high time to establish formal university industry and research institute linkage mechanism.

Technological challenges for wind turbine blade manufacture research opportunities

and

The blade material demand, extreme whither conditions, lighting challenges and manufacturing cost and productivity are the main challenges for wind turbine blades manufacture.

Manufacturing Cost Extreme Weather Conditions Productivity

Material Demand

Technological challenges

Lighting Challenges

Figure 1 Technological challenges Wind Turbine Blades

 Blades Material Demands Aerodynamic design Strength & fatigue life Lightweight & Stiffness Easy to manufacture Lowest cost possible

Material fatigue properties are an important consideration in wind turbine design and materials selection. During the expected 30 year life of a wind turbine, many of the components will need to be able to endure 4 x 108 fatigue stress cycles. This high cycle fatigue resistance is even more severe than aircraft, automotive engines, bridges and most other man-made structures. In the past, various programmers have been carried out to investigate the behavior of composite materials for rotor blades under static and fatigue loading. The results of these research projects were useful databases, and research has led to design recommendations that were necessary for designing the blades. An overview of European research efforts can be found in Kensche C.1996  Extreme Weather Conditions Typhoon Storm Hurricane / Tornado Earthquakes Tsunami Icing

The severe weather conditions, including typhoons blowing down turbines (in Japan), extremely cold temperature (North America, North China etc.), hot temperature (North America, North China etc.) Strong gusts and high turbulence were severely damaged wind turbine blades in last two decades. Therefore, a safety standard designed for Japanese meteorological and geographical conditions is being developed to provide technical measures against typhoons and lightning strikes and to help future wind turbine development There are undesired effects on turbine healthy and performance due to extreme weather conditions. One of the immediate challenges for designs is to predict loads and resulting dynamic responses of the coupled wind turbine and platform system to combined stochastic wave and wind loading in extreme weather conditions. .

Offshore Turbine Loading Sources (S. Butterfield, etl, 2005)

 Lighting Challenges Two thousand thunder storms are active throughout the world at any given moment producing approx. 100 flashes of lightning per second (National Meteorological Library and Archive, 2011).The lightning releases currents of up to 200 kA in an extremely short period of time. The current wind turbine blades are made with several exterior copper receptor air termination discs, which are fastened to interior aluminum conductors running the length of the blade

The lightning conductor did not conduct as designed. Lightning created an internal shock wave from air or moisture expansion, or both. Lightning temperatures may have caused interior moisture to transition to an expansive state (steam). In turn, over-pressures stressed the blade to subsequent failure. Further research into wind turbine blade interior air/moisture expansion issues is needed.

7.0

Ordinary lightning usually has a maximum stroke of approx. 30 kA

Productivity

Extremely cold temperature (North America, North China etc..): There is problem with wind speed and direction sensor if they are rotating cup and vane, for cold region installations electronic sensors are used. The DC power supply/batteries for pitch control system may experience charging problem in cold. Hot temperature (North America, North China etc..): This may cause overheating of electronics components and may need to operate the turbine in reduced power mode to avoid any component damage. Blades may experience dust/ice deposition in extreme hot/cold temperature which leads to performance reduction.

It can be identified four different development stages of composite wind turbine blade material research studies. At the initial stage most of the research studies were focused on studying the behavior of composite materials for rotor blades under static and fatigue loading. However around 1990 most of the research studies were aimed to develop necessary data bases and data base structures with fatigue properties of composite material since it was become industrial requirement at that time.

2.1

Wind turbine as mechanical structure/materials

Objectives

The objective is to improve the structural integrity of the wind turbine through: y y y y y An improved estimation of design loads; New materials; optimized designs; Verification of structural strength; and Reliability of components, such as drive trains, blades and the tower.

Research priorities The research priorities are to: y y improve knowledge of design loads for the components of the wind turbine system; investigate and identify the physical characteristics of new materials, including recycling possibilities y Further develop design and verification methods for structural strength and reliability of components.

An improved knowledge of design loads, material characteristics and component strength and reliability will enable designers to optimize structure and safety. This knowledge will lead to more structurally efficient wind turbine components and an optimum use of materials, and will have a positive impact on the lifetime cost of energy 2.2 Second Phase of Study: Conclusion

A study concentrating on a topic relevant to Wind turbine as mechanical structure/materials will be an important study to assist offshore wind energy sector future developments.
Further, following points were noted

1. The most of the wind turbines are failed as result of fatigue. Therefore, it was considered to carry out fatigue failure analysis of a turbine blades based on different cyclic loads application on it. 2. Although, the cyclic load pattern was identified as the main factor affecting for a failure of a turbine, according to the information presented through this publication it was identified ,it is needed to carry out a study to identify how other factors such as environmental, corrosion, the height and the distance from the land affecting for life cycle of a turbine 3. The recommendation of deferent materials/ composite structures or manufacturing methods to improve fatigue life turbines and reduced the cost through introducing recycling were pointed out as more important research outputs. Selected Research topic: Influence of material and process parameters on fatigue of wind turbine blades in an offshore environment

The manufacturing defects of wind turbine blades influence the fatigue properties of the blade because defects can lead to high stress concentrations in the material. This can create more crack initiations or growth of the individual defects during service life. The load carrying capacity for manufacturing defects is mainly influenced by the type, size and position of the defect (Hayman, B., 2007). The type of defect is important because not all failure modes are influenced by a particular type of defect. Delaminations, Wrinkles, Matrix cracks, Voids and Adhesive failure are the five key manufacturing defects in wind turbine blades (Figure 1) (Henrik Stensgaard Toft, etl, 2009).

Manufacturing Defects of Wind Turbine Blades

Type of the Position of the Defect

Voids Wrinkles Matrix Cracks Delaminations Adhesive Failure

Size of the Defect

Figure 1: Manufacturing Defects of Wind Turbine Blades

The size of the defect affects the amount of strength reduction and the position determines the critical loading and failure modes. Therefore, it is vital to analyse the differences of distribution of defects affecting the fatigue failure of wind turbine blades (Henrik Stensgaard Toft, etl, 2009).

Delamination of Wind Turbine Blades

Delamination is considered as a prominent manufacturing defect in wind turbine blades. The compression strength of wind turbine blade is reduced by delamination because of out-ofplane buckling (Hayman, B., 2007). In fatigue loading the delaminations create high stress concentration areas which will further increase the crack growth and significantly reduce the fatigue life of wind turbine blades.
Near Outer or Inner Surface

Position Delamination of Wind Turbine Blades

Local Buckling

Near Centre

Global Buckling

Size

Large Delaminations Small Delaminations

Failed at Ultimate Loading

Less Fatigue Life

Figure 2: Local and Global Modes of Delamination Induced Buckling

The mode of buckling is determined by the position of the delamination. If it is placed near the outer or inner surface of the laminate the delamination induces local buckling of a group of plies. If the delamination is placed near the centre of the material the strength reduction will be caused by global buckling of the laminate (Short GJ, 2001). The large delaminations create high probability of failure in ultimate loading. However, large delaminations can be detected by available non-destructive quality control methods. The smaller delaminations are much harder to detect and can develop due to high stress concentrations. As a result, smaller delaminations can significantly influence the fatigue life of wind turbine blades and the ultimate capacity in its service life (Henrik Stensgaard Toft, etl, 2009). Delamination of wind turbine blades caused by, y y y A poor infusion of resin in a definite area Manufacturing process imperfections (Prepreg : the delaminations can also be due to a poor consolidation during curing) Air Traps

Delamination Analysis Methods

Fracture mechanics and cohesive zone methods are used to analyse the delamination failure of composite laminates. Fracture mechanics (FM) base methods are applied when a starting crack exists since it requires the knowledge of initial delamination pattern and they are based on the assumption that existence of singular stress field around the delamination crack tip (Camanho PP, etl, 2002) . FM methods are considered, the crack propagate when energy release rate along the delamination front locally exceeds a certain value called fracture toughness (Rybicki EF, Kanninen MF, 1998).The dissimilarity among FM methods generally depends on the means of calculating strain energy release rate (Parks DM,etl, 1974) One of the criteria, which extensively used in literature, is the power of law expression. Virtual Crack Closure Technique (VCCT), J integral, and Virtual Crack Extension Technique (VCET) have also been used successfully in the past. The VCCT technique is base on the assumption that when a crack extends by a small amount, the energy released in the process is equal to the work required to close the crack to its original length (Pubudu Ranaweera, 2010). Cohesive zone methods (CZM) are based framework in Damage Mechanics and Strain Softening. This method is competent of predicting both onset and growth of delamination without previous facts of the crack location and propagation direction (Pubudu Ranaweera, 2010). The limitations of FM and CZM based fatigue life estimation models for wind turbine blade design process. Composite materials are required to be used in their full potential in wind turbine blades. The major deficiency in existing life prediction methodologies for composite wind turbine blades is the use of large safety factors for design stage calculations. Fracture mechanics and cohesive zone approaches based on assumptions. These pre-assumptions altered the mathematically calculated stress variation and crack propagation figures with actual values. Therefore low ultimate design strain levels are used for wind turbine structures. To develop enhanced life prediction methodologies that would result more weight-and-cost effective composite wind turbine blades, the understanding of fatigue failure process in composites needs to be extended and links between visible damage/ failure mechanisms and fatigue life require to be established. Moreover it is important to increase design strain level and damage growth in fatigue life have to take as key design consideration.

5 Prediction of Delamination Based On FEM, Testing and Condition Monitoring Data

Review relevant national policies

Review Current status of Engin. edu

Review ongoing projects Engin edu

Strengthen Dept Mechanism

Inputs from University, Industry

Establish DIIU

Establish SC/AC

Establish project Implementation Network

SC& AC University Industry link

Database of core industries

Scientific & Technical Inputs through Academics

Projects providing industry solutions for technical development (R&D)

Developed solutions

Business ventures

Initiate Business ventures

Sustainable program

Industry, NRIs

Development of CPD courses Immediate term

CPD Courses

The proposed methodology is based on finite element analysis, full scale blade testing, Nun destructive testing (NDT), and condition monitoring results at different stages of turbine blade life cycle (Figure 3). According to the proposed methodology full scale testing results and condition monitoring data are been used to compare with design stage predications and develop more weight-and-cost effective composite design models for wind turbine blades. Non-Destructive testing methods are (visual inspection, ultrasound scanning, X-ray imaging, etc) performed after production, in order to identify manufacturing defects in wind turbine blades. Full scale testing of wind turbine blades is important to identify stress and strain variation pattern in wind turbine blades with or without identified delaminations. Moreover the wind turbine blades should be model with known defects and the testing results and FEM models out comes should be compared with condition monitoring data for developing more accurate design stage stress and strain prediction models.
Design Stage Stress and Strain Predictions FEM Analysis Results Cohesive Laws Design stage mathematical models Manufacturing Manufacturing Process control NDT Testing to Identify Manufacturing Defects Ultrasound, x-ray, etc Type, size and position of defects

Full Scale Testing

Maximum load Stress and strain variation pattern in the turbine blade

Post Manufacturing Stage Information Base

Maximum load Stress and strain variation/ Defects

Model (FEM) of Blade without Manufacturing Defects

Maximum loading points Stress and strain variation pattern in the turbine blade

Condition Monitoring
Visual inspection, Ultrasound, x-ray, etc Type, size and position of defects

Compare Stress and Strain Variation

Maximum loading points The effect of manufacturing defects for the predicated stress variation, etc

Model (FEM) of Blade with Manufacturing Defects

Type of defects Maximum loading points Stress and strain variation pattern in the turbine blade

Improve Design Stage Calculations and Mathematical Models. Build up new Relations to Reduce Material Consumption and Higher Safety Factors Enhanced the Manufacturing Quality Control Process through NDT Testing

Figure 3: Prediction of Delamination Based On FEM, Testing and Condition Monitoring Data

The prediction efficiency of design stage mathematical models can be improved by increasing the size of the samples and number of calculation cycles. The figure no 03 illustrates this approach more descriptively. This methodology makes a link between design, manufacture, and quality control and condition monitoring process. This method can be used to develop quality control guide lines by giving stress and strain limits in different points of the wind turbine blades. It is possible to use NDT based information at selected points in wind turbine blades to predict the manufacturing defects and develop quality control guide lines.

Figure 4: Comparison of FEM Stress Distribution Result with and without Delamination

6 Conclusion
The global wind turbine manufacturing sector needs novel materials which reduce the cost and weight of wind turbine blades. The turbine blade manufacturing processes should be developed to enhance quality and quantity of production. It is necessary to produce turbine blades with higher life time. These are main research challenges and today the major wind turbine manufactures, universities and research institutions are working on it. There are few university industry collaboration projects which targeted to achieve above research objectives. The authors believe it is high time to establish formal university industry and research institute linkage mechanism and such mechanism will help to achieve wind turbine manufacturing sector challenges. This paper presents the basic overview for universityindustry-research institute linkage mechanism for wind turbine manufacturing sector

References
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Thresher and Laxson,2006

R. Thresher and A. Laxson Presented at the European Wind Energy Conference Athens, Greece February 27March 2, 2006

Conference Paper
NREL/CP-500-39537 June 2006

National Renewable Energy Laboratory

Engineering Challenges for Floating Offshore Wind Turbines S. Butterfield, W. Musial, and J. Jonkman National Renewable Energy Laboratory P. Sclavounos Massachusetts Institute of Technology Presented at the 2005 Copenhagen Offshore Wind Conference Copenhagen, Denmark October 2628, 2005 National Meteorological Library and Archive, 2011, Fact sheet No. 2 Thunderstorms http://library.metoffice.gov.uk/