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Presented by Jose R. Zayas Authored by Tom Ashwill, Jose Zayas, and Paul Veers

Innovations in Blade Technology For Multi-Mega Watt Turbines. Presented by Jose R. Zayas Authored by Tom Ashwill, Jose Zayas, and Paul Veers Sandia National Laboratories.

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Presented by Jose R. Zayas Authored by Tom Ashwill, Jose Zayas, and Paul Veers

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  1. Innovations in Blade Technology For Multi-Mega Watt Turbines Presented by Jose R. Zayas Authored by Tom Ashwill, Jose Zayas, and Paul Veers Sandia National Laboratories Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company,for the United States Department of Energy under contract DE-AC04-94AL85000.

  2. Outline • DOE Wind Program Structure • SNL Research Focus • Numerical Analysis Tools • Sub-Scale Blades • Active Flow Control and Sensors • Future Work EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  3. Sandia Labs Paul Veers NREL R. Thresher, B. Smith U.S. DOE Wind Program DOE Headquarters Stan Calvert • Jack Cadogan • Linda Silverman • Dennis Lin • Steve Lindenberg • Phil Dougherty • Jim Ahlgrimm • Laura Miner-Nordstrom • Ian Baring-Gould (M&O) EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  4. Sandia National Labs Research Focus • SNL Blade Technology Research • Design innovations • Design tools • Materials & manufacturing • Sub-scale blade design & fabrication • Laboratory and field testing EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  5. Lightweight Designs Slender planform New materials Load Alleviation Passive Sweep Off-axis fibers Active control Individual blade pitch control Embedded devices Enhanced Performance New airfoils Very thick (high t/c) Flatbacks Active devices Manufacturing Remote build Coupon testing Manufacturing process Hand lay-up RTM Pre-preg Infusion Blade Design Advances & New Concepts EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  6. NuMAD - SNL ANSYS FEA preprocessor Linear and non-linear buckling Dynamic Simulation Tools FAST (Fatigue, Aerodynamics, Structures, and Turbulence) – NREL, SNL Modal representation Limited degrees of freedom Used as a preprocessor to ADAMS ADAMS (Automatic Dynamic Analysis of Mechanical Systems) – NREL, SNL Commercial multi body dynamic simulation software Virtually unlimited degrees of freedom NASTRAN - SNL Flutter analysis and predictions Micon 65 – ADAMS Model Numerical Analysis Tools NuMAD FEA Model EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  7. Three-dimensional Compressible RaNS CFD Capabilities • CFD Codes • ARC2D • OVERFLOW 2.0y • Applications for CFD • Airfoil performance predictions • Understanding of the effects of embedded devices EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  8. Advance Airfoils with Highly Efficient Structure Flatback Airfoil Traditional Airfoil Flatback Airfoils EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  9. Passive and Active Blade Control Passive Bend-Twist Coupling Active Devices Courtesy: NREL EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  10. Materials & Manufacturing Research Carbon Coupon Tests New Forms – Large & Medium Carbon Tows Large Database in Collaboration with Montana State University EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  11. Applications of Innovations • Prototype Sub-scale Blades Manufactured (9 meters) • CX-100 • Carbon spar cap • Glass skin and shear web • TX-100 • Carbon triax in skin for bend-twist • Constant spar cap thickness • BSDS (Blade System Design Study) • Flatback airfoils • Carbon spar cap • Slenderized planform • Large scale architecture • Highly efficient structural design • LWST Phase II Components • Knight & Carver • 25m blade sweep twist • Replacement blades Subscale Blade Design & Fabrication EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  12. CX-100 – Carbon Spar Cap Manufactured by TPI Composites Carbon Spar Cap Root Stud Inserts EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  13. TX-100 Carbon Tri-ax Skin & Glass Spar-Cap Manufactured by TPI Composites Passive Bend-Twist Coupling – Off Axis Carbon Fiber EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  14. BSDS – Flatback Airfoils Manufactured by TPI Composites EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  15. Blade Test Site • 3 Micon 65/13 (modified) • 115 kW generator • Stall regulated • 55 RPM • Heavily Instrumented • 15 rotor strain gauges • Rotor speed and position • Nacelle acceleration • Tower instrumentation • Inflow Array EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  16. Active Flow/Load Control • Active Load Control on Blade/Turbine can be Achieved by Modifying: • Blade incidence angle (pitch) • Flow velocity (modification in RPM) • Blade length • Blade aerodynamic characteristics through: • Changes in section shape (aileron, smart materials, microtab) • Surface blowing/suction • Other flow control techniques (VG’s, surface heating, plasma) • SNL Focus on Fast-Acting, Low Actuation Energy Devices • Will operate within the boundary layer of the blade • Must be rugged and easily implemented EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  17. Sensors • Focus on Cost Effective Sensors (for lab and field environments) • Strain sensors • Pressure sensors for airflow measurements • Fiber optic sensors • Piezo-ceramic • Displacement and proximity (blade tip deflection) • Sensor Networks • Control inputs • Damage detection and health monitoring • Embedded Sensors • Composite structures • Exploring possibilities with SNL MEMS facility EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  18. Fiber Optics (FO) Research • Goal: Develop new fiber optic interrogating method to reduce system cost • Use FO’s to measure flap and edge bending, as well as twist • Relies on using tunable filter and superluminescent diode - Eliminates costly interferometer • Temperature compensated • Currently under development • Partnership with UCDavis EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  19. Future Work • Offshore • SeaCon – Seabased Concepts • O&M • Smarter blades • Embedded sensor networks • Advanced Controls • Materials for Offshore Applications EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  20. Summary • Efforts underway to reduce blade weight growth for larger blades • Active control may prove beneficial for future blade designs • Coupon testing and sub-scale blades show advantages of carbon hybrid materials • New airfoils enable structural and manufacturing improvements in blade designs • 3 Sets of sub-scale blades have been manufactured – demonstrate improvements • Static testing complete – all blades met or exceeded design goals • Fatigue and field testing scheduled EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

  21. Questions ??? EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

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