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CHALLENGES IN BLADE DESIGN AND

MANUFACTURING

Sandia Blade Work Shop 2016

Jesper Månsson

1

The

early years

2004 61.5 m blade

introduced

(world’s longest

blade at the time)

1996 1st generation

Lightning-Protection

Vortex generators

2003 FutureBlade

technology

2002 Pre-bending

1999 VARTM

vacuum infusion

technology

2012 73.5 m blade

introduced

(world’s longest

blade at the time)

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And we keep breaking records! LM 88.4 P

Validated aerodynamics – large catalog of airfoils,

designed in an integrated design context

Glass fiber/polyester technology – validated and

scalable in a global manufacturing/sourcing setup

Carbon hybrid technology supporting existing

footprint – cost, performance and reliability

What have we achieved

Carefull validation of all steps

Field validation of spoiler

Full scale fatigue test

Lightning capture efficiency test

Rain erosion testing

Wind tunnel test Mixed loading test of laminate

Coupon testing of Carbon laminates

6

Selection of tests

used to validate new

blade concepts

Design for manufacturing and Quality

Reliability, further supported by leading edge

protection and lightning protection.

Big blades LM 61.5P, LM 73.5P, LM 88,4P and long

offshore track record, but also high volume on

shore blade portfolio, scalable in our global

footprint.

What have we achieved

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8

What’s next

9

Cost reductions for large wind turbines are possible by applying integrated design philosophies which maximize energy production under blade response constraints.

Larger diameter

Lower solidity

Higher tip speed

Design space is becoming more narrow and complex.

Especially when designing new blade for existing platforms.

Turbine component are getting even more optimized reducing design space.

Challenging rotor designs

10

Leading Edge erosion:

Erosion increases with V2

Erosion can lead to dramatic reduction in aerodynamic performance over lifetime

LE protection systems have an impact on aerodynamic performance

In field erosive environment need to be classified

Non-validated and unknown aerodynamic effects:

High Reynolds numbers effects

High Mach numbers effects (compressibility)

How to implement

High tip speeds will lead to:

11

Thick airfoils balanced for aerodynamic performance and structural/aero-elastic implications

Supporting material technology and blade structure

Increased flexibility will lead to larger deflections and more pronounced non-linear aero-elastic behavior with unknown aerodynamic implications etc.

Validated design models to accommodate the challenges

Long slender blades calls for:

Diversified market requirements

Site specific vs IEC conditions – wind farms

Site specific designs

Intelligent blades

Use of continuous monitoring and control systems to optimize performance /cost,

and adaptively match site condition

Technology validation

Aerodynamics in laboratory and in field – feed back to design models

Blade structure testing both faster full scale and component level – challenge is typically

realistic loading

Further trends and focus areas

12

Volume – is needed to drive down LCOE – efficiency, quality and

reliability

Scale - efficient manufacturing

NDT – faster, specific – feedback to statistical process control

Efficient manufacturing setup

13

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Thank you !

April 2016