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Blade Design Codes
Daniel L. Laird
Wind Energy Technology DepartmentSandia National Laboratories
Albuquerque, New Mexico, USA
Sandia National Laboratories
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Design-Process Overview
Airfoil Data
Performance
Aero-ElasticsExtreme Wind
Full-Field Turbulence
Aerodynamics
Controls
StructuralDesign
StructuralProperties
Sandia National Laboratories
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Design Codes (U.S. usage)
FoilCheckAirfoilPrep (new)
Airfoil Data
WT_PerfPerformance BLADED
commericalmodal
Aero-Elastics
FASTFree
modal18 dof
Aero-Elastics
ADAMScommercial
multibody dynamics‘unlimited’ dof
Aero-Elastics
IECwindWindMaker
Extreme Wind
TurbSim (new)Full-Field Turbulence
AeroDynfree
AerodynamicsRCAS
freemodal or multibody dynamics
‘unlimited’ dofAero-Elastics
ModesCoModes (planned)
Mode Shapes
SNLWIND-3DSNwind
Prop
FAST
2AD
AM
Spr
epro
cess
orMatLab
(SimuLink)commercialControls
ANSYScommercial
FEAStructural
Design
NuMAD/BPEFree
fea/section props
Focuscommercial
section analysis/fea
FLEX5commercial
Aero-Elastics
PreCompfree
section analysisStructuralProperties
Cosmoscommercial
FEAStructural
Design
StructuralProperties
StructuralProperties
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Design Codes (U.S. usage)
FoilCheckAirfoilPrep (new)
Airfoil Data
WT_PerfPerformance BLADED
commericalmodal
??? dofAero-Elastics
FASTFree
modal18 dof
Aero-Elastics
ADAMScommercial
multibody dynamics‘unlimited’ dof
Aero-Elastics
IECwindWindMaker
Extreme Wind
TurbSim (new)Full-Field Turbulence
AeroDynfree
AerodynamicsRCAS
freemodal or multibody dynamics
‘unlimited’ dofAero-Elastics
ModesCoModes (planned)
Mode Shapes
SNLWIND-3DSNwind
Prop
AD
AM
S/W
Tpr
epro
cess
orMatLab
(SimuLink)commercialControls
ANSYScommercial
FEAStructural
Design
NuMAD/BPEFree
fea/section props
Focuscommercial
section analysis/fea
FLEX5commercial
Aero-Elastics
PreCompfree
section analysisStructuralProperties
Cosmoscommercial
FEAStructural
Design
StructuralProperties
StructuralProperties
![Page 5: Blade Design Codes - Sandia Energywindpower.sandia.gov/2004BladeWorkshop/PDFs/DanielLaird.pdf · Blade Design Codes Daniel L. Laird Wind Energy Technology Department Sandia National](https://reader031.vdocuments.site/reader031/viewer/2022022703/5bc859a209d3f258268d32db/html5/thumbnails/5.jpg)
NuMAD – Structural FEA Analysis
Pre-processor and post-processor for ANSYS
Tailored to design and analyze wind turbine blades
Databasesmaterialsairfoilsloadings
Development guided by industry input
Beam Property Extraction capabilityColors indicate different materials
Sandia National Laboratories
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Beam Property Extraction (BPE)• Joint effort between GEC and SNL
• Goal is to automatically produce the 1-D beam element properties needed for an aeroelastic simulation (ADAMS) from the 3-D structural finite element model (NuMAD/ANSYS)
• May be used with legacy ANSYS blade models
ADAMS42 DOF
ANSYS200,000 DOF
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• Almost all 3-D finite element analyses of wind turbine blades use layered shell elements with offset nodes
• The offset node formulation of the layered shell elements does not correctly handle torsion
• It appears that the issue is a limitation in FE shell theory rather than an error in the particular implementation (i.e. ANSYS vs. NASTRAN etc.)
Finite Element Analysis – Shell TheoryNodal Offsets
mid-thicknessformulation
offsetformulation
Sandia National Laboratories
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Test Case – Hollow Cylinder
nodes@mid-thickness offset nodes@top
01020304050
0 4000 8000 12000
# o f e le m e n t s
aspect ratio ≈1.1radius/thickness=7.5L=20
Max
Tw
ist (
% e
rror
)
# of elements
-200
20406080
0.001 0.01 0.1 1 10 100
a sp e c t ra tio
# of elements =19200radius/thickness = 10L=20
Max
Tw
ist (
% e
rror
)
aspect ratio
-90
-60
-30
0
30
0 10 20 30
aspect ratio ≈3.4# of elements =2880L=20
radius/thickness ratio
Max
Tw
ist (
% e
rror
)
Sandia National Laboratories
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Twist-Bend Coupling (24 hr summary)
Bad News:
“The equations are wrong.”K. Wetzel
“The simulation is wrong.”D. Laird
Good News:Tremendous opportunities for improvement
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NuMAD
external profile
shell elements
physical thickness representation
now produces mid-thickness model
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Glue Together
Sandia National Laboratories