presented by jose r. zayas authored by tom ashwill, jose zayas, and paul veers sandia national...

Presented by

Jose R. Zayas

Authored by Tom Ashwill, Jose Zayas, and Paul VeersSandia National Laboratories

Innovations in Blade Technology For Multi-Mega Watt Turbines

Innovations in Blade Technology For Multi-Mega Watt Turbines

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.

March 1, 2006

EWEC 2006 - Innovative Turbines, Components, Systems and Techniques

OutlineOutline

DOE Wind Program Structure SNL Research Focus Numerical Analysis Tools Sub-Scale Blades Active Flow Control and Sensors Future Work

March 1, 2006


U.S. DOE Wind ProgramU.S. DOE Wind Program

DOE HeadquartersStan Calvert

• Jack Cadogan• Linda Silverman• Dennis Lin• Steve Lindenberg

• Phil Dougherty • Jim Ahlgrimm • Laura Miner-Nordstrom • Ian Baring-Gould (M&O)

Sandia LabsPaul Veers

NRELR. Thresher, B. Smith

Technology Research & Development Technology Application

ProgramGoals

By 2012, COE from large systems in Class 4 winds 3 cents/kWh

onshore

By 2007, COE from distributed wind systems 10-15

cents/kWh in Class 3

By 2014, COE in shallow water (<30 m depth) with Class 6

winds of 5 cents/kWh;

By 2016, COE in transitional water depths (30-60 m

depth) with Class 6 winds of 5 cents/kWh

By 2012, complete program activ ities addressing

electric power market rules, interconnection impacts, operating strategies, and

system planning needed for wind energy to compete without disadv antage to

serve the Nation's energy needs.

By 2010, at least

By 2010, at least 100 MW installed in 30

states.

By 2014, COE from large systems in

Class 6 winds3.6 cents/kWh

onshore

Low Wind Speed

Technology

Distributed Wind

Technology

SR&T

Offshore Wind

Technology

SR&T

Wind GridIntegration

SE&A**

TechnologyAcceptance & Coordination

SE&ASR&T*

*SR&T – Supporting Research and Testing

Figure 1. Quick reference to program structure

**SE&A – Supporting Engineering and Analysis

Technology Research & Development Technology Application

ProgramGoals

By 2012, COE from large systems in Class 4 winds 3 cents/kWh

onshore

By 2007, COE from distributed wind systems 10-15

cents/kWh in Class 3

By 2014, COE in shallow water (<30 m depth) with Class 6

winds of 5 cents/kWh;

By 2016, COE in transitional water depths (30-60 m

depth) with Class 6 winds of 5 cents/kWh

By 2012, complete program activ ities addressing

electric power market rules, interconnection impacts, operating strategies, and

system planning needed for wind energy to compete without disadv antage to

serve the Nation's energy needs.

By 2010, at least

By 2010, at least 100 MW installed in 30

states.

By 2014, COE from large systems in

Class 6 winds3.6 cents/kWh

onshore

Low Wind Speed

Technology

Distributed Wind

Technology

SR&T

Offshore Wind

Technology

SR&T

Wind GridIntegration

SE&A**

TechnologyAcceptance & Coordination

SE&ASR&T*

*SR&T – Supporting Research and Testing

Figure 1. Quick reference to program structure

**SE&A – Supporting Engineering and Analysis

March 1, 2006


Sandia National Labs Research Focus

Sandia National Labs Research Focus

SNL Blade Technology Research Design innovations Design tools Materials & manufacturing Sub-scale blade design & fabrication Laboratory and field testing

March 1, 2006


Blade Design Advances & New Concepts

Blade Design Advances & New Concepts

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

March 1, 2006


Numerical Analysis ToolsNumerical Analysis Tools

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 ModelNuMAD FEA Model

March 1, 2006


CFD CapabilitiesCFD Capabilities

CFD Codes ARC2D OVERFLOW 2.0y

Applications for CFD Airfoil performance

predictions Understanding of the effects of

embedded devices

Three-dimensionalCompressible RaNS

March 1, 2006


Advance Airfoils with Highly Efficient Structure

Advance Airfoils with Highly Efficient Structure

Flatback Airfoils

FlatbackAirfoil

TraditionalAirfoil

March 1, 2006


Passive and Active Blade ControlPassive and Active Blade Control

Active DevicesPassive Bend-Twist Coupling

Courtesy: NREL

March 1, 2006


Materials & Manufacturing Research Materials & Manufacturing Research

Carbon Coupon Tests New Forms – Large & Medium Carbon Tows

Large Database in Collaboration with Montana State University

March 1, 2006


Applications of InnovationsApplications 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

March 1, 2006


CX-100 – Carbon Spar CapCX-100 – Carbon Spar Cap

Carbon Spar Cap

Manufactured by TPI Composites

Root Stud Inserts

March 1, 2006


TX-100 Carbon Tri-ax Skin & Glass Spar-Cap

TX-100 Carbon Tri-ax Skin & Glass Spar-Cap

Passive Bend-Twist Coupling – Off Axis Carbon Fiber


March 1, 2006


BSDS – Flatback AirfoilsBSDS – Flatback Airfoils


March 1, 2006


Blade Test SiteBlade Test Site

34-m Pad

CTL B

RESERVOIR

ROAD

N

0 100 200

Scale, ft

Prevailing Wind

2.5 Dia Lateral Spacing

Turbine

Anemometer Tower

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

March 1, 2006


Active Flow/Load ControlActive 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

α

CL

αC

L

March 1, 2006


SensorsSensors

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

March 1, 2006


Fiber Optics (FO) ResearchFiber 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

“Edge Bending”

“Flap Bending” “Twist”

Blade Structure

Fiberglass I-Beam

March 1, 2006


Future WorkFuture Work

Offshore SeaCon – Seabased Concepts

O&M Smarter blades Embedded sensor networks

Advanced Controls Materials for Offshore Applications

March 1, 2006


SummarySummary

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

March 1, 2006


Questions ???Questions ???

presented by jose r. zayas authored by tom ashwill, jose zayas, and paul veers sandia national...

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