wind energy research at iowa state university
TRANSCRIPT
![Page 1: Wind Energy Research at Iowa State University](https://reader035.vdocuments.us/reader035/viewer/2022071601/613d3712736caf36b75aae8a/html5/thumbnails/1.jpg)
Wind Energy Research at Iowa State University
Dr. Matt Frank Associate Professor
Industrial and Manufacturing Systems Engineering
The Iowa State University of Science and Technology
Ames, Iowa
![Page 2: Wind Energy Research at Iowa State University](https://reader035.vdocuments.us/reader035/viewer/2022071601/613d3712736caf36b75aae8a/html5/thumbnails/2.jpg)
• The Wind Energy Manufacturing Laboratory (WEML)
• The Advanced Manufacturing Innovation Initiative (AMII)
• Other Wind Energy Efforts at ISU
• Wind Blade Manufacturing Challenges
Overview
![Page 3: Wind Energy Research at Iowa State University](https://reader035.vdocuments.us/reader035/viewer/2022071601/613d3712736caf36b75aae8a/html5/thumbnails/3.jpg)
The Wind Energy Manufacturing Laboratory
![Page 4: Wind Energy Research at Iowa State University](https://reader035.vdocuments.us/reader035/viewer/2022071601/613d3712736caf36b75aae8a/html5/thumbnails/4.jpg)
Advanced Manufacturing
Innovation Initiative (AMII)
Research
Iowa State University
TPI Composites
Sandia National Laboratories Funding
U.S. Department of Energy
TPI Composites
Iowa Power Fund
![Page 5: Wind Energy Research at Iowa State University](https://reader035.vdocuments.us/reader035/viewer/2022071601/613d3712736caf36b75aae8a/html5/thumbnails/5.jpg)
AMII Research Projects at ISU
1. Non-Destructive Evaluation of thick composite for wind blades
2. Dimensional Variability Reduction during blade component fabrication and assembly
3. Automated Fabric Layup for broad panel fiberglass
1: Non-Contact, Air Coupled
Ultrasound
2: Dimensional analysis of production
wind blades, via laser scanning and
laser tracking
Detection of manufactured waves on a trailing edge of a
mega-watt class turbine blade using non-contact air-
coupled ultrasound
Combinations of dense point cloud laser
scanning coupled with laser tracker
measurements in order to map dimensional
variability during blade production
![Page 6: Wind Energy Research at Iowa State University](https://reader035.vdocuments.us/reader035/viewer/2022071601/613d3712736caf36b75aae8a/html5/thumbnails/6.jpg)
AMII Research Projects
3: Measurement, Analysis and Process Planning
(MAPP) for UD Fabric Layup
New laser scanning method to identify
individual tows of UD fabric as opposed to
conventional point clouds; enables more
advanced analysis of out-of-plane waviness
New process planning methods to map
out automated fabric manipulations that
can re-distribute shear deformation of
the fabric to enable wave-free layups
Automated manufacturing of root preforms in
the ISU lab (50% scale from a ~40meter blade)
Fabric manipulation device developed which
allows for wave-free UD fabric layup about
extreme direction changes
![Page 7: Wind Energy Research at Iowa State University](https://reader035.vdocuments.us/reader035/viewer/2022071601/613d3712736caf36b75aae8a/html5/thumbnails/7.jpg)
Other Wind Energy Efforts at
Iowa State University • NSF REU
– 3 years; 10 students each year for 10-week program
– Individual & group projects, short course, lectures, tours
• NSF Grant
– $300K
– “Surface Wind Energy Resources and Wake Interferences”
• DOE 3.1 Grant (New)
– ~$4.4M (expected)
– Title: “Innovative Offshore Vertical-Axis Wind Turbine Rotors”
– Partners: Sandia, TPI, ISU, Umaine, TUDelft
• Wind Energy Initiative
– 1 of 3 initiatives funded by College of Engineering
– $500,000 over 3 years to pursue funding (but not to do research)
– Establish a Wind Energy Institute
– Over 40 investigators collaborating at ISU as well as other institutions
– External partners
• NSF IGERT
– 30 PhD students over 5 year period, beginning 1/12
– New PhD program: Wind Energy Science, Engineering & Policy
– Includes (3 month) international and industrial components
![Page 8: Wind Energy Research at Iowa State University](https://reader035.vdocuments.us/reader035/viewer/2022071601/613d3712736caf36b75aae8a/html5/thumbnails/8.jpg)
• Much of the composite manufacturing state-of-
the-art is too expensive for blades (aerospace solutions
are not always feasible/cost-effective)
• Glass composites for blades use broad fabric
panels which do not “want” to go into a 3D mold (this is not Automated Tape Layup, therefore… touch labor required)
• Automation solutions must utilize “reduced” axes
solutions for multi-axis placement problems (complex manipulation with simple automation = cheaper and easier)
Challenges in Blade Manufacturing
![Page 9: Wind Energy Research at Iowa State University](https://reader035.vdocuments.us/reader035/viewer/2022071601/613d3712736caf36b75aae8a/html5/thumbnails/9.jpg)
Contact:
Matt Frank, PhD
Associate Professor
Industrial and Manufacturing Systems Engineering
Co-Director, The Wind Energy Manufacturing Laboratory
Iowa State University
3004 Black Engineering Building
Ames, Iowa 50011
P: 515-294-0389
Email: [email protected]