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Special Topic: Engineering Thermophysics
Article
doi: 10.1007/s11431-014-5741-8
Innovative features of wind turbine blades with flatback at inboard region, thick airfoils at inboard as well as mid-span region
and transversely stepped thickness in spar caps have been proposed by Institute of Engineering Thermophysics, Chinese
Academy of Sciences (IET-Wind) in order to improve both aerodynamic and structural efficiency of rotor blades. To verify the
proposed design concepts, this study first presented numerical analysis using finite element method to clarify the effect of flatback on local buckling strength of the inboard region. Blade models with various loading cases, inboard configurations, and
core materials were comparatively studied. Furthermore, a prototype blade incorporated with innovative features was manufactured and tested under static bending loads to investigate its structural response and characteristics. It was found that rotor
blades with flatback exhibited favorable local buckling strength at the inboard region compared with those with conventional
sharp trailing edge when low-density PVC foam was used. The prototype blade showed linear behavior under extreme loads in
spar caps, aft panels, shear web and flatback near the maximum chord which is usually susceptible to buckling in the blades
according to traditional designs. The inboard region of the blade showed exceptional load-carrying capacity as it survived
420% extreme loads in the experiment. Through this study, potential structural advantages by applying proposed structural
features to large composite blades of multi-megawatt wind turbines were addressed.
wind energy, rotor blade, flatback, local buckling, extreme loads
Citation:
Chen X, Qin Z W, Yang K, et al. Numerical analysis and experimental investigation of wind turbine blades with innovative features: Structural response and characteristics. Sci China Tech Sci, 2015, 58: 18, doi: 10.1007/s11431-014-5741-8
1 Introduction
Wind energy is one of the lowest-priced renewable energy
technologies available today. Installed wind energy capacity
both worldwide and in China has grown exponentially over
the past few years and it is expected to increase significantly
in the years to come [1]. As one of the most critical components in wind turbine system, rotor blades capture kinetic
energy from wind and convert it to mechanical energy,
*Corresponding author (email: drchenxiao@163.com)
Science China Press and Springer-Verlag Berlin Heidelberg 2014
which is eventually converted to electrical energy by generators. Rotor blades are thin-walled composite structures
with airfoil cross-sectional profiles. Typical construction of
blade cross sections is shown in Figure 1. Spar caps of rotor
blades are made of composite laminates and designed to
carry primary bending moments applied to the blades, while
leading panel and aft panel are made of sandwich constructions and designed to provide aerodynamic profiles of blade
cross sections. Shear webs are also sandwich constructions
and designed to support two spar caps and transfer shear
forces in the blades.
tech.scichina.com link.springer.com
Chen X, et al.
Figure 1 (Color online) Typical construction of cross sections of composite wind turbine blades.
Figure 2
Chen X, et al.
IET
Regular root size
Thick airfoil at inboard and
mid-span region
Spar cap with transversely
stepped thickness
Glass spar cap
Polyester resin
Figure 3
Material layups of four blades were assigned to be identical when blade regions are the same. The material layups
of the additional shear web in BS2-2 were the same as those
of the primary shear web in other three blades. The material
layups as well as the geometry of the flatback region in BF
were identical to those of the additional shear web in BS2-2.
Because mechanical properties of core materials significantly affect buckling strength of sandwich constructions in
the blades, two different core materials, i.e., PVC foam and
balsa wood, which are commonly used in wind turbine
blades were selected to perform parametric study in the
numerical analysis. Typical material properties of cores
used in this study are shown in Table 2.
2.2
(Color online) Blade geometry and cross-sections of blades considered in numerical modeling.
Chen X, et al.
Table 2
Figure 4
Figure 5
Figure 6
Chen X, et al.
3 Experimental investigation
Based on simulation results and discussion presented in
section 2, it is evident that the blade with flatback showed
stronger local buckling strength at the inboard regions than
the blade with conventional sharp trailing edges when other
variables such as outboard geometry, material layups, and
applied loads were the same. Therefore, it is expected that
local geometry modification from the commonly used sharp
trailing edge to the flatback could be an efficient way to
Chen X, et al.
3.1
3.2
Test program
Static bending was applied to the blade which was rootfixed at a test stand. Two cranes were used to introduce
loads at 4 and 8 m blade spans as shown in Figure 10.
The loads were applied in a step-wise form following a
test sequence as shown in Table 3. Once a loading case was
finished, the blade was rotated along its longitudinal axis to
a desired position and tested in a subsequent loading case.
At each load level, applied loads were recoded by load
cells mounted on cranes, deflections of the blade were
measured at two loading saddle locations and at the blade
tip using draw-wire displacement transducers. Blade strains
were recorded by strain gauges located along the center line
of spar caps, at the middle of flatback, aft panels and shear
webs. Only strains longitudinal to the blade axis were
measured on spar caps, while both longitudinal and transverse strains were measured at other locations by the corresponding strain gauges labeled as 0 and 90, respectively.
The use of these orthogonal gauges were intended to better
indicate the occurrence of local buckling at flatback, aft
panels, and shear webs during the tests through changes of
load-strain path directions.
The blade successfully passed 100% test loads simulating
the extreme loads in the loading cases of Edge_min,
Flap_min, and Edge_max. In the following loading
case Flap_max, it was decided to load the blade to failure
if it could survive 100% test loads. Applied loads continued
to increase and when they were close to 220% test loads, the
blade failed catastrophically at 6-m span. Measurements of
Figure 10
Table 3
Sequence
1
2
3
Cases
Edge_min
Flap_min
Edge_max
Loading history
0-40%-60%-80%-100%-unloading
0-40%-60%-80%-100%-unloading
0-40%-60%-80%-100%-unloading
Flap_max
0-40%-60%-80%-100%-120%140%-160%-180%-200%blade failure
Chen X, et al.
Figure 11
Figure 12
(Color online) Comparison of blade deflections and spar cap strains. (a) Blade deflections; (b) spar cap strains.
(Color online) Local strain responses of the blade. (a) Spar cap strains; (b) aft panel strain; (c) shear web strains; (d) flatback strain.
blades.
3.2.3 Ultimate strength of inboard region
Because the blade failure at 6-m span prohibited the assessment of the inboard region at the ultimate failure, it was
decided to conduct an additional static bending test with an
intention to fail the blade at the inboard region in the loading case Flap_max. This load test was achieved by using
the loading saddle previously mounted at 4-m span. Pulling
forces were continuously applied and monitored. When the
root moment reached approximately 294 kNm which was
Chen X, et al.
about 420% of the root moment caused by the 100% extreme loads, the inboard region did not exhibit any sign of
failure.
The load test was then aborted due to safety concern.
Subsequently, the inboard region of the blade was visually
inspected and no material failure was found. It was concluded that the inboard region of the blade had exceptional
ultimate strength.
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