wind turbine materials and - sandia...
TRANSCRIPT
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Knowledge Centre
Wind turbine Materials and
Constructions
Bi-axial fatigue test developments
Sandia blade workshops 2012
Maaik Borst
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Overview
• Introduction
• Blade testing at WMC
• Full scale fatigue tests
• Advances in bi-axial fatigue testing
• Concluding remarks
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
● Full-scale structural testing
● Material research
● Software development
Wind turbine Materials & Constructions
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
WMC History
Blade design and testing (1984)
WMC did a re-design of the all steel WPS30 blade and
developed the full scale testing procedure for rotor blades.
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Blades became larger
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
WMC Wieringerwerf
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Full Scale Test Lab
● High flexibility
● Strong floor 66 x 28 m
● Three blade test stands
● Blades up to 60 m (75 m planned)
● In house workshop
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Blade testing
Proposed minimum test programme
acc. IEC 61400-23
● Mass, COG
● Natural frequency test
● Static tests
● Fatigue test(s)
● Post fatigue static tests
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Frequency
modal analysis
mode 06 (FAROB coupled, no shear) 7.918 Hz
Y
Z
X
Z
X
Y
Z
X
Y
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Blade Testing
Multiple-point Single-axis Static Test
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Single Axial Fatigue
● Advantages
● Simple hardware
● Simple tuning of bending
moment distribution
● High frequency
● Low energy consumption
● Distributed loading
● Disadvantages
● Separate flap and edge
test
● Not testing total
circumference
● Mass on blade for R≠-1
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Bi-axial Fatigue Testing
● Advantages
● Accurate coordination of flat & edge
loading combinations
● Torsion loading
● Short test time
● All R-values, weight compensation
possible
● Automated stiffness measurements
● Moderate energy consumption
● Disadvantages
● More complicated hardware and
controlling
● Tuning of moment curve requires
additional hardware
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Bi-axial test setup development
Forced displacement
High energy consumption
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Bi-axial test setup development
Crank rod mechanism to drive flap
displacement in resonance
Mass
Mass
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Add crack rod mechanism in
edge direction
Bi-axial test setup development
Mass
Mass
Mass
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
However……
Post fatigue static testing requires
that the tip remains on the blade
Bi-axial test setup development
Mass
Mass
Mass
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Test is driven at flatwise frequency to
create moment curve .
Edgewise (bi-)linear.
Bi-axial test setup development
Mass
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Bi-axial test setup development
Mo
men
t ra
nge
Blade span
Mo
men
t ra
nge
Blade span
flatwise
edgewise
target test
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
Bia-axial fatigue test
● Flatwise moment distribution as single
axis (near) resonance: larger portion of
the blade tested.
● Edgewise moment distribution (bi-)
linear.
● Blade tip not removed: blade ready for
post fatigue static test.
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WMC
Knowledge
Centre
Wind turbine Materials and Constructions
● The type of blade fatigue test should be based
upon the critical areas of the blade
● Single axial tests focus on spar and leading and
trailing edge. Easy to test a large blade span
● Bi-axial tests give a better distribution of
fatigue damage over the circumference of the
blade.
● Demand for post fatigue static testing is
important requirement for test selection
Concluding remarks