wind turbine blades manufacturing improvements and...
TRANSCRIPT
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Wind Turbine Blades
Manufacturing Improvementsand Issues
TPI Composites, Inc.Structural Composites Division
Derek Berry
24 February, 2004
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Manufacturing Overview
• TPI Composites: Brief History
• SCRIMP Infusion Process
• Blade Manufacturing Improvements
• Current Issues
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TPI Composites, Inc.
• Fabricating Composite Parts Since 1966• Rhode Island Facility:
Warren (250,000 sq. ft., 23 acres)• Joint Venture: Vientek Blade Manufacturing –
Juarez, Mexico
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Warren, Rhode Island Facility
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Wind Blade Manufacturing
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Sailboat Manufacturing
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Disney Imagineering
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Airport Shuttles
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Composite Bus
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Vientek Facility
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MHI 1-Megawatt Turbine
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SCRIMP
• Seemann Composites ResinInfusion Molding Process
• Vacuum Bag Resin Infusion Process• Patented Silicone Bags• Materials Laid-Up Dry• Virtually Eliminates VOCs• Aerospace Quality – Large Structural Parts
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The SCRIMP Process
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The SCRIMP Process
Vacuum Vacuum
Resin Feed
Mold
Resin Flow
Front
Flow Medium
Pervious Conduit
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The SCRIMP Process
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TheSCRIMPProcess
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Manufacturing Improvements and Issues
• Blade Manufacturing Process Approaches• Blade Construction Approaches• Blade Manufacturing Verification Approaches• Blade Design Approaches• Current Blade Issues and Future Trends
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Blade Manufacturing Process Approaches
• Silicone Bags• Remote Build• Heated Molds
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Silicone Bag Technology
• Custom bag, formed to a part
•Patented product and process
•Resin feed conduit and distribution pattern built into the bag
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Remote Build
• Original Intent• Lessons Learned• Robust Process Steps:
• Material Cutting• Material Kitting• Laminate Schedules• Silicone Bags
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Remote Build – Material Kits
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Remote BuildLaminate Schedules
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Remote Skin Infusion Preparation
Remote Blade Assembly
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Heated Molds
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Blade Construction Approaches
• LE Bond Line• Spar Cap – Constant Width –
Constant Taper• Root Connection
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Aerodynamicists?
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Offset LE Bond
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Preliminary 50m Blade DesignPlanform and Thickness Distributions
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Preliminary 50m Blade DesignConstant Spar Cap
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Root System Study
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Root Stud Testing at NREL
• Back to back rootstud configuration
• Static testing• Fatigue testing
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Root Stud Fatigue TestLoad – Life Results
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Post Mortem of Epoxy Bonded Stud
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NPS-100 – Bonded Root Inserts
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Blade ManufacturingVerification Approaches
• Blade Sectioning• NDT – UT: Bond Lines• Testing
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Blade Sectioning
• Laminate design• Internal blade
geometry• Blade adhesive• Chordwise CG• Static Balance• Manufacturing
variations
Laminate Fabric Wrinkle
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Blade Proof Testing
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Blade Proof Testing
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Blade Design Approaches
• Blade Materials• E-glass• Carbon / E-glass hybrid• S-glass• Carbon / Wood / E-glass hybrid
(zebrawood)• Blade Geometry
• Thick Airfoils• Flat-Back Airfoils
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Innovative Design ResultsAlternate Blade Materials
0
2000
4000
6000
8000
10000
12000
E-glass(str=.45%)
E-glass(truncated)
Carbon/glass(str=.34%)
S-glass(str=.45%)
Zebrawood(str=.21%)
BladeShell
Weight(kg)
Shell Weight Comparison for Alternative
Spar Cap Materials
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Examples of Thick Airfoils
Illustration of Blade Sections at 25% Span
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Examples of Flatback Airfoils
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Current Blade Issues andFuture Trends
• Adaptive Blades• Increased use of Carbon Fiber• Split Blades – Spanwise Joint• Pultruded Spar Caps• Iterative Design Process