Compos|te W|nd 8|ade Lng|neer|ng and

Manufactur|ng
!"#$#%&#'(&)(*&+'#%&$(,%'(-,.+/&0()1(2
Massachuseus Insntute of 1echno|ogy
3%'#4#%'#%&(5.6786#$(!#"8)'(98%8:;)+"$#
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Ianuary 20, 2011
Cverv|ew of
1I Compos|tes
! 1ransformed lnLo a
leadlng provlder of
Lurblne blades Lo Lhe
rapldly expandlng wlnd
lndusLry
! 1rack record of rsL of
Lhelr klnd lnnovauons ln
LransporLauon and
mlllLary vehlcle markeLs
! Solld growLh Lhrough
advanced Lechnology and
world class focused
facLorles LhaL enable long
Lerm parLnershlps wlLh
ma[or players
!anuary 20, 2011 | age 2
WIND 8LADLS
! 10,000+ blades supplled
over 10-years Lo Lhe sLrlcLesL
quallLy sLandards
! near aerospace quallLy aL
lndusLrlal cosL
! CusLom deslgns, Lallored Lo
cusLomers Lurblne
! reclslon moldlng and
assembly sysLems
! aLenLed SC8lM vacuum
lnfuslon process Lechnology
! 8obouc sysLems lmprove
producuvlLy and quallLy
! Laser Lracklng and ulLrasonlc
lnspecuon verlfy accuracy
!anuary 20, 2011 | age 3
4
CVLk 1M I1
2
CI MANUIAC1UkING SACL
!uarez, Mx (477k lL
2
)
newLon, lA (316k lL
2
)
1alcang orL, CP (190k lL
2
)
lall 8lver, MA (69 k lL
2
)
Warren, 8l (91k lL
2
)
!anuary 20, 2011 | age
1I INNCVA1ICN DLLCMLN1
1LAM
98$$8)%2(;"#,&#($+$&,8%,</#(.)=4#667#(
,'7,%&,>#(1)"(?!3(&@")+>@('#4/)0=#%&(
,%'(4")&#.6)%()1(,'7,%.#'(&#.@%)/)>0A((
B#'+.#(.)$&()1(#%#">0(:(8=4")7#(
4#"1)"=,%.#(C("#/8,<8/8&0(D@8/#("#'+.8%>(
</,'#(.)$&A(
3 !anuary 20, 2011 | age
IALL kIVLk WIND 8LADL INNCVA1ICN CLN1Lk
! 69k sq faclllLy wlLh waLer access
! Lnable 43M Lo 62M+ proLoLype wlnd
blades
! ConducL blade lnnovauon
! 8ulld lnlual proLoLype blades
! 8ulld plloL producuon blades
! ulal ln producuon Loollng
! CreaLe producuon documenLs
! 1echnology Lransfer
! hase ll expanslon opporLunlLy
6 !anuary 20, 2011 | age
1I roducts
Wlnd 1urblne 8lades
1I roducts
Wlnd 1urblne 8lades
20 W|nd Lnergy by 2030
! u.S. ueparLmenL of Lnergy (uCL)
! ower Markeung AdmlnlsLrauons
(MAs)
! nauonal 8enewable Lnergy
LaboraLory (n8LL)
! Lawrence 8erkeley nauonal
LaboraLory (8erkeley Lab)
! Sandla nauonal LaboraLorles (SnL)
! 8lack & veaLch
! Leadlng wlnd manufacLurers and
suppllers
! uevelopers and elecLrlc uullues
Check out www.20percentwind.org
So What does a Modern W|nd
1urb|ne 8|ade Look L|ke?
10 !anuary 20, 2011 | age
Anatomy of a W|nd 1urb|ne 8|ade (near Max Chord)
Sandwich Shell
TE Shear
Web
LE Shear
Web
Trailing Edge
Sandwich Shell
Sandwich Shell
Sandwich Shell
Lower (HP) Spar Cap
Upper (LP)
Spar Cap
Leading Edge
11 !anuary 20, 2011 | age
.and [ust what |s a Compos|te?
! LeLs keep lL slmple:
! A composlLe maLerlal ls one, LhaL on a macro-scale,
ls composed of muluple non-homogeneous
maLerlals.
! 1he composlLes LhaL 1l ComposlLes concerns
lLself wlLh ls conunuous ber relnforced polymers.
S1kING and GLUL!
Seemann Compos|te kes|n Infus|on Mo|d|ng rocess (SCkIM)
13 !anuary 20, 2011 | age
Manufactur|ng of W|nd 1urb|ne 8|ades
14 !anuary 20, 2011 | age
Lvo|unon of Commerc|a| W|nd 1echno|ogy
13 !anuary 20, 2011 | age
Growth of kotor D|ameter
16 !anuary 20, 2011 | age
! MaLerlals Lnglneerlng
! SLrucLural ueslgn
! Lmbedded Sensor
1echnologles
! 1oollng/rocess Lnglneerlng
! MeLrology and nuL
! SLrucLural 1esung/Cerucauon
! 1ransporLauon/Loglsucs
8|ade Lng|neer|ng w|th Lxpernse |n MAN D|sc|p||nes
!anuary 20, 2011 | age 17
Mater|a|s Lng|neer|ng
18 !anuary 20, 2011 | age
Mater|a|s Lng|neer|ng
MaLerlals are Lhe prlmary drlvers ln sysLem
performance and producuon cosLs:
! SLrucLural ComposlLe MaLerlals
! 8elnforcemenLs
! Class: Low-cosL hlgh speclc
sLrengLh, modesL speclc suness
! Carbon: Plgh cosL buL wlLh hlgh
speclc sLrengLh Anu suness
! CLhers : Aramlds, 8asalL eLc.
! 8eslns
! Lpoxles
! vlnyl/oly-esLer
! 1oughened 8eslns
! L18n/C18n 8eacuve Llquld olymers
! Core Shell 8ubber
! nano-Lechnologles
! 1hermoplasucs
19 !anuary 20, 2011 | age
M1S 810 Servo-nydrau||c Un|versa| 1esnng Mach|nes
at 1I Compos|tes Lng|neer|ng]Deve|opment Center
300kn Load CapaclLy wlLh
LnvlronmenLal Chamber
100kn Load CapaclLy for 8esln Lesung
and Cross-lled LamlnaLes
20 !anuary 20, 2011 | age
ke|nforcement Iorms for W|nd 8|ade Manufactur|ng
! relmpregnaLed versus ury relnforcemenL
forms
! rocesslng
! Consolldauon of repregs
! vacuum 8esln lnfuslon (vA81M, SC8lM, eLc)
! Pand Layup/vacuum AsslsLed Pand Layup
! AuLomauon (repreg Lape and 1ow-pregs)
! Woven labrlcs
! MosL oen used ln Loollng appllcauons and
prelmpregnaLed forms
! Plgher cosL, less appllcable as sLrucLural componenLs
for blades
! Speclallzed use ln areas of hlgh 3u sLress elds (reslsL
peel)
! non-woven Muluaxlals
! MosL wldely used ln vA81M processes
! Low-cosL, non-crlmp form resulLs ln superlor
performance
! Plgh areal welghLs posslble reduce labor cosL ln layup
! unl-dlrecuonal, 8laxlal, uouble 8las, 1rlaxlal and
Cuadraxlal maLerlal forms avallable.
! Class/Carbon/Aramld Pybrlds
Courtesy of Saertex USA
21 !anuary 20, 2011 | age
kes|ns Matr|ces and Adhes|ves
! Lpoxles remaln a prlmary resln
of use ln Luropean based blade
deslgns
! vlnyl-esLers are auracung much
lnLeresL by blade deslgners
! olyesLer resln are sull
promlnenL ln Lhe lndusLry.
! 1hermoplasucs and oLher
Loughened maLrlces
Composite Matrices:
22 !anuary 20, 2011 | age
kes|ns Matr|ces and Adhes|ves
(connnued)
! 1wo-arL Lpoxy asLe Adheslves
speclcally formulaLed for Lhelr
LhlxoLroplc properues are Lhe
malnsLay for bondlng and
assembly
! MeLhyl-meLhacrylaLes provlde
excellenL adheslon Lo polyesLer
resln composlLes
! olyureLhane bondlng agenLs
Blade Assembly/Bonding Adhesives:
23 !anuary 20, 2011 | age
Core Mater|a|s |n 8|ade Manufactur|ng
! Core MaLerlals, used prlmarlly for large area
unsupporLed sLablllLy ln leadlng/Lralllng edge
panels and shear webs.
! Lnd Craln 8alsa
! Low CosL, Plgh Shear roperues, Plgher WelghL
! loam Cores
! vC
! SAn
! ureLhane
! L1 (exLruded forms look cosL eecuve)
! Lnglneered Core MaLerlals
! Webcore 1?CC8
! nexCore
24 !anuary 20, 2011 | age
Structura| Des|gn
23 !anuary 20, 2011 | age
Structura| Des|gn
! CpporLunlues for lnnovauve deslgn sull exlsL
! lrom maLerlals selecuon and fundamenLal
layouL of componenLs Lo funcuonal
performance, Lhe cholces are endless.
! A muludlsclpllnary exerclse requlrlng close
coordlnauon beLween sysLems and aero
englneers, maLerlals and sLrucLures groups as
well as manufacLurlng englneers.
! ueLalled analysls of componenLs and dynamlc
analysls of enure Lurblne sysLem requlred for
compleung producL deslgn.
26 !anuary 20, 2011 | age
Iu||-sca|e I|n|te L|ement Ana|ys|s Us|ng |ates and She||s
!anuary 20, 2011 | age 27
Stanc kesu|ts rov|de Deecnon and Stress Informanon
to Gu|de Des|gn
!anuary 20, 2011 | age 28
Des|gn Deve|opment Work for US Department of Lnergy
! nlne MeLer (9M) 8lade rogram
! nS 100 8lade: a 8asellne
! Cx-100 8lade: Carbon Spar Cap Lpoxy 8lade
! 1x-100 8lade: 8end-1wlsL Coupllng Lpoxy 8lade
! 8SuS 8lade: 1hlck Alrfoll / Carbon Spar Cap
Lpoxy 8lade
!anuary 20, 2011 | age 29
9M Ck-100 Carbon I|ber Spar Cap 8|ade
! 1rlaxlal suLched fabrlc carbon
ber unl-dlrecuonal.
! Spar cap plles lnLerleaved wlLh
rooL plles.
! Lpoxy lnfuslon for hlghesL
compresslon deslgn sLraln.
!anuary 20, 2011 | age 30
New Materials Carbon/Glass Hybrid
8end-1w|st Coup|ed 8ehav|or: E(D,0$(&)(*F8%(&@,&(;,&(1)"(G),'(986>,6)%(
Aero-Elastic Tailoring:
Passive load reduction
Material-based
Geometry-based
9M 1k-100 8end-1w|st Coup|ed 8|ade w]Carbon I|ber Sk|n(
!anuary 20, 2011 | age 31
9m 8|ade w|th Advanced A|rfo|| Des|gn: 8|ade System
Des|gn Stud|es (8SDS)
! used on lnboard secuons of blade (3 - 43 8adlus)
! lncreased Lhlckness (L/c) alrfolls provlde more apwlse secuon (l),
AND 8lunL 1L on aLback alrfoll provldes more edgewlse secuon (l)
! Can reduce maLerlal usage Lo achleve same Ll
! Alrfoll Lhlckness (L/c) and aLback Lhlckness (ub/c) can be Lallored
for opumum sLrucLural deslgn emclency
Can allow for consLanL wldLh / consLanL Lhlckness spar cap for mosL of
Lhe blade
! CuLs down on maLerlal scrap and labor (cumng and maLerlal placemenL)
hours
<':#7=,>&3'/&'?/3%"#.@?+&3#.'A,1;#7'
! I|atback A|rfo|| (I8-6S-200)
! 1hlckness Lo Chord 8auo (L/c): 0.63
! llaLback 1hlckness Lo Chord 8auo (L
m
/c): 0.20
! ApproxlmaLe Span Locauon: 13 8adlus
32 !anuary 20, 2011 | age
9m 8|ade Des|gn]Manufactur|ng Study kesu|ts
**Note: Total weight savings achieved from a combination of reduced root thickness resulting from
incorporation of molded in studs and increased net section diameter. Normalized weight savings due
to airfoilshape is approximately 24%.
8lade
LengLh
8lade
WelghL
Spanwlse
CC
SLauc
8alance
WL 8educuon
lrom 8asellne
(mm) (kg) (mm) (kg-m) ()
nS 100 (8ase llne) 8,997 221.4 2,430 342.4 --
Cx -100 (Carbon llber Spar Cap) 9,000 173.7 2,287 397.0 22
1x-100 (8end-1wlsL Coupled) 9,000 163.7 2,339 382.8 26
8SuS ("llaL-back" Alrfoll ueslgn) 9,000 129.1 n/a n/a 42**
33 !anuary 20, 2011 | age
Us|ng Geometry for Load M|nganon
! SLrucLural 1esL of knlghL and
Carver S1A8 8lade
! 1esL preparauon of a swepL 27.3m
Lurblne blade.
! SwepL deslgn provldes bend-LwlsL
coupllng for gusL load reducuon.
! S1A8 = SwepL 1wlsL Adapuve 8oLor.
! 8eplaces cosL of bulldlng
carbon ber sklns wlLh cosL/
challenge of form curvlllnear
spar caps.
Courtesy of Knight and Carver!
34 !anuary 20, 2011 | age
Lmbedded Sensor 1echno|og|es
33 !anuary 20, 2011 | age
Sensor 1echno|og|es
! ueslgns mlgraung Loward larger
and llghLer welghL roLors
! Cshore and lmproved Cp
! 8educed Margln ueslgns
! 1he cosL of fallure ls unaccepLably
hlgh, buL Lhe cosL of C&M may
also be prohlbluve
! PealLh monlLorlng sysLems ln a
varleLy of forms where lnnovauon
rules, may be Lhe answer.
36 !anuary 20, 2011 | age
9m Ck-100 8ased 1I Sensor 8|ade and Next
Generanon Smart 8|ade
! uevelopmenL uslng Lhe 9m
plauorm conunues:
! 1l, Sandla , urdue unlverslLy and
AlLher Lnglneerlng collaboraLed Lo
bulld Lhe Sensor 8lade
! lully embedded llber Cpuc 8ragg
Craung (l8C), lull 3u acceleromeLers
and foll sLraln gages applled wlLhln Lhe
assembled blade
! 8eal-ume measuremenL up Lower Lo
supporL beuer undersLandlng of acLual
blade loadlng Lo aero models.
! nexL Cenerauon SmarL 8lade
belng fabrlcaLed ln Warren, 8hode
lsland Lhls Lhls week!
! Slmllar lnsLrumenLauon as Sensor
8lade
! leedback Lo conLrol acLuaLed Labs
ouLboard
!anuary 20, 2011 | age 37
Insensys (Moog) - Independent |tch Contro|
Load Measurement System
!anuary 20, 2011 | age 38
Use of Connnuous I|ber Cpnc Sens|ng for In-s|tu Measurement
of Lam|nate Stra|ns
39 !anuary 20, 2011 | age
! use of Cpucal 8ackscauer 8eecLomeLry
! near real-ume conunuous sLraln
measuremenL of over 40M long ber
opuc wlLh <0.3cm resoluuon
! Can be used for boLh measuremenL of
sLralns ln process/fabrlcauon and for up
Lower healLh-monlLorlng appllcauons.
A/R = 10.6
I|ber Cpnc S|gna|: 8efore and Aher Vacuum App||canon
Baseline (before embedding)
Embedded no vacuum applied
Lmbedded ber defecLs
become readlly vlslble!
!anuary 20, 2011 | age 40
Ion-|asma Actuators
! LlecLrlcal currenL causes
alr Lo lonlze and creaLe
plasma eld (purple).
! LlecLrlcal eld manlpulaLes
plasma Lo ln[ecL LhrusL lnLo
alrow (reshaplng).
! 1ralllng edge acLuaLors can
perform ldenucally Lo
Lralllng edge aps.
! Leadlng edge acLuaLors can
prevenL alrow separauon
and curLall sLall.
!anuary 20, 2011 | age 41
!""# !$#
1oo||ng and rocess Lng|neer|ng
!anuary 20, 2011 | age 42
1oo| and 1oo| Manufactur|ng
! 1l ComposlLes malnLalns an
comprehenslve seL of capablllues Lo
address all aspecLs of Lool and mold
fabrlcauon.
! 3-u Cad ueslgn ued Lo englneerlng
daLa of deslgn.
! ueslgn of MasLer Models (lugs) for
mold fabrlcauon.
! ueploymenL of lugs wlLhln 1l faclllLy
wlLh full meLrology reporung prlor Lo
mold bulld.
! lully lnfused molds wlLh lnLegraLed
process conLrol (heaung) and process
soware (Cyber1herm) as requlred.
! CompleLe meLrology and Lhermal
Lolerance reporLs provlded Lo
cusLomer.
!anuary 20, 2011 | age 43
So||d Mode||ng - 8|ade Geometry and 1oo| Deve|opment
! Blade OML Geometry generated
from advanced airfoil design."
! Geometry feeds FEA model
development and BoM"
! Engineering data feeds tool and
xture design."
! Single source of engineering data
ensures delity of nished tools to
the model."
!anuary 20, 2011 | age 44
3D So||d Mode||ng Irom CAD to Master to Mo|ded art
43
! CATIA V5 solid modeling is now applied
for design of all geometric surfaces.
! Applied to both structural analysis and
surface generation for tooling.
! CAD models uploaded to 3 and 5 axis
machine centers for plug fabrication.
! Multiple mold sets pulled from
machined plugs to build final product
structure.
!anuary 20, 2011 | age
L|ectro-kes|snve neanng for Lpoxy Matr|x Mo|ded 8|ades
! ln-house fabrlcauon wlLh proprleLary elecLro-reslsuve cables and L
for purpose lamlnaLe deslgn.
! uedlcaLed mulu-zone lu LemperaLure conLrol wlLh supervlsory
conLrol vla 1C/l based remoLe SCAuA for seL polnL conLrol,
producuon monlLorlng and logglng.
!anuary 20, 2011 | age 46
Assemb|y I|xtures
! AccuraLe assembly of blades
wlLh conslsLenL bond llne
Lhlckness depends noL only
on accuraLe moldlng buL
locaung xLures Lo properly
place ma[or assemblles.
! Pere a 1l deslgned and
fabrlcaLed shear web
bondlng xLure locaLes Lhe
40m Shear web for bondlng
Lo Lhe Low ressure skln.
47
1l Shear web xLure uses Loollng polnLs and vacuum asslsLed handllng for shear web placemenL.
!anuary 20, 2011 | age
nydrau||c ower n|nges for 8|ade Assemb|y
! Plnges ellmlnaLe lp xLures and P or L Skln
de-moldlng prlor Lo bonded assembly
! CreaLly reduces assembly ume
! lmproves accuracy
! LllmlnaLes rlsk of damage Lo elLher skln as a
resulL of handllng
**nLW**
Pydraullc Clamps
around perlmeLer
of shell molds for
conslsLenL and
unlform clamplng
forces
!anuary 20, 2011 | age 48
keusab|e S|||con 8ag 1echno|ogy for SCkIM

49
! Slllcone bags are rapldly ued Lo Lhe lnfuslon Lool.
! leed llnes, vacuum llnes and embossed dlsLrlbuuon
channels are lnLegraLed lnLo Lhe bag lmprovlng Lhe
repeaLablllLy of Lhe process.
! SeLup ume and process robusLness greaLly lmproved
wlLh reduced dlsposable maLerlal cosL/wasLe.
!anuary 20, 2011 | age
3D Laser ro[ecnon Systems
! Laser Projection Systems for real
time tool based projection of ply
locations, bonding adhesive outlines
and shear web location.
! Ceiling mounted laser projectors. Up
to five ganged together to provide
full coverage across a single pair of
47.2m molds.
! Technology is now applied to all
2.4MW blade production
!anuary 20, 2011 | age 30
Automanon of 8|ade Iabr|canon
! AuLomauon of aerospace composlLe manufacLurlng
ls vlrLually rouune wlLh hundreds of prepreg Lape
machlnes operaung across Lhe globe.
! 1urblne blade manufacLurlng
conslsLs of a labor lnLenslve seL
of hlghly dlsLrlbuLed manual
operauons.
! lrom pauern cumng for
maLerlal klLs Lo layup Lo lnfuslon
and demoldlng of a mulupllclLy
of sub assemblles over a vasL
area and dlsLance, auLomauon ls
a challenglng and expenslve
endeavor.
! 8eLurn on CALx ls rapld for
sLrucLures wlLh cosL of nlshed
goods from $200 Lo $700/lb as
opposed Lo $3.00 Lo $10.00/lb
requlred for Lhe energy
markeLs.
!anuary 20, 2011 | age 31
Automanon of 8|ade Iabr|canon
! AuLomauon ls aL work ln blade
facLorles Loday:
! use of x-y ply cumng for maLerlal klLs,
auLomaLed ply nesung soware, plck
and place auLomauon.
! LlmlLed use of maLerlal Lransfer
sysLems lnLo open molds, prlmarlly
wlLh seml-auLomaLed or drlven A-
frames and ganLrles
! AuLomaLed Lrlmmlng and llmlLed
machlne asslsLed surface grlndlng/
nlshlng
! AuLomaLed rooL Lrlm, machlne, and
drlll for 1-8olL lnsLallauon.
! 8obouc appllcauon of coaungs.
!anuary 20, 2011 | age 32
Automanon |n 8|ade I|n|sh|ng
! 8lade moldlng operauons accounL
for less Lhan 30 of LoLal labor
conLenL.
! llnlshlng operauons oer a
brllllanL opporLunlLy for cosL-
eecuve CALx spendlng.
! CompllanL grlndlng/nlshlng, scu
sandlng and coaung appllcauons
wlll become ublqulLous ln Lhe near
Lerm.
! 1he advance ln vlslon sysLems and
on Lhe oor compuLauonal power
coupled wlLh Lhe avallablllLy of low
cosL mulu-axls roboLs makes
auLomauon of many Ledlous
processes posslble.
!anuary 20, 2011 | age 33
Automanon of 8|ade Components a I|rst Step
! Spar Cap componenLs are Lhe
loglcal rsL sLep wlLh rooL
preform parLs a naLural
exLenslon of capablllLy.
! Slmple CeomeLry.
! unl-dlrecuonal maLerlals for lowesL
posslble cosL of prepreg/Low preg
maLerlals.
! SLeerable for curvlllnear spar
caps ln swepL blade deslgn.
! erformance crlucal.
! Assurance by ma[or machlne
manufacLurers LhaL layup raLes
approach 1,200 kg/hr ln sLralghL
run spar caps posslble!
!anuary 20, 2011 | age 34
Automanon of 8|ade Manufactur|ng to Come
! 1he [ury ls sull ouL regardlng Lhe shape
and form of fuLure blade auLomauon,
buL lL ls sure Lo come.
! Longer blades, use of carbon ber and
Lhe need Lo ensure lower parual safeLy
facLors for manufacLurlng and maLerlal
varlance wlll expedlLe Lhe drlve for more
auLomauon ln blade layup.
! WheLher fuLure auLomauon ls ln Lhe
form of ber/Low placemenL, prepreg or
dry fabrlc robouc appllcauon, Lhere are
deslgns walung ln Lhe wlngs.
! 1l ls lnumaLely lnvolved ln Lhls process
and helplng Lo shape Lhls fuLure.
!anuary 20, 2011 | age 33
Metro|ogy and Non-Destrucnve Lva|uanon (NDL)
36 !anuary 20, 2011 | age
Metro|ogy and NDL
! Plgh performance, Lechnlcally
complex producL.
! Plgh sklll level wlLh mulupllclLy
of operauons requlred by each
manufacLurlng Lechnlclan.
! ueLalled documenLauon and
consLanLly revlsed work
lnsLrucuons drlve Lralnlng and
cerucauon of u/L.
! ln-comlng/recelvlng lnspecuon
and Lesung
! hyslcal sclences lab wlLh weL
chemlsLry, LesL and lnspecuon
servlces.
! Plgh level capablllLy for
meLrology Lhrough laser
Lracklng CMM.
37 !anuary 20, 2011 | age
Surface Metro|ogy for 8oth 1oo|s and Iabr|cated arts
38
! Comblned use of lA8C 3u Laser
1racklng and verlSurf CompuLer
MeLrology ackage ylelds full
sulLe of measuremenL capablllLy
for boLh 1ool and Mold
labrlcauon and llnlshed arL
verlcauon.
! lA8C Lracker provldes 3u olnL
measuremenL wlLh accuracy Lo
0.1mm
! verlSurf lnLegraLes measuremenL
daLa wlLh as deslgned 3u parL
geomeLry Lo provlde real ume
meLrology reporung and
formaued CuallLy Assurance
documenLauon.
!anuary 20, 2011 | age
ua||ty Systems]Lng|neer|ng: Stanc roof 1esnng
Full-Scale Blade Proof Testing:
!46.2m Blade at 90% Max Operating load during proof testing at Vientek
!Tip deflections exceed 8 meters at max load.
!Root test stand designed to react over 30 million N-m of bending load!
!anuary 20, 2011 | age 39
Non-Destrucnve Lva|uanon - U|trason|c
! 1l has applled ulLrasonlc pulse
echo bond LesLers for over Len
years Lo lnLerrogaLe adheslve
bond llnes ln wlnd blades.
! More recenLly Lhe use of C-Scan
and A-Scan has become
prevalenL ln lamlnaLe lnspecuon
as well.
! LaLesL work lncludes porLable
sysLems provldlng eld servlce
lnspecuon capablllLy up-Lower!
!anuary 20, 2011 | age 60
Laser Shearography - W|de Area Inspecnon
! 1echnlque readlly ldenues
defecLs ln lamlnaLed sandwlch
composlLes.
! SllghLesL surface exclLauon
(Lhermal loadlng) leads Lo
surface deformauons resulung
from lnLernal aws.
! lull-eld, non-conLacL
Lechnology.
D|g|ta| Image Corre|anon for W|de Area
Stra|n Measurement and NDL
!anuary 20, 2011 | age 62
Structura| 1esnng]Cernhcanon
63 !anuary 20, 2011 | age
Stanc 1esnng of Megawau Sca|e 1urb|ne 8|ades
64
! SLauc Lesung Lo slmulaLe
maxlmum operauonal loadlng
ls a crlucal elemenL of deslgn
cerucauon and ls requlred by
ALL cerufylng agencles (CL,
lLC, unv, eLc.)
! 1esung has formally been
accompllshed wlLh makeshl
operauons:
! ueadwelghL loadlng
! use of overhead cranes
! new faclllues are comlng
onllne domesucally LhaL uullze
fully compuLer operaLed
dedlcaLed loadlng sysLems.
!anuary 20, 2011 | age
Iangue 1esnng of Megawau Sca|e 1urb|ne 8|ades
! Cycllc load Lesung has prevlously been accompllshed Lhrough forced dlsplacemenL uslng
dlsLrlbuLed hydraullc acLuaLors.
! 1hls has been replaced wlLh Lhe developmenL of resonanL frequency cycllc load Lesung.
! ulsLrlbuLed mass can be used Lo develop arblLrary momenL proles Lo slmulaLe operauonal
aerodynamlc pressure loadlng.
63 !anuary 20, 2011 | age
Large 8|ade 1est Centers North Amer|ca
! nauonal 8enewable Lnergy
LaboraLory
! 8oulder Colorado: 1esung up Lo
30m
! Wlnd 1echnology 1esL CenLer
! CharlesLown Massachuseus:
1esung up Lo 90m (open !anuary
2011)
! ALWC (Advance SLrucLures and
ComposlLes CenLer) aL Lhe
unlverslLy of Malne
! Crono Malne: 1esung up Lo 70m
(open March 2011)
66 !anuary 20, 2011 | age
Ia|| k|ver 8|ade Deve|opment Center:
Access to Large 8|ade Structura| 1est
Capab|||ty, W11C
67 !anuary 20, 2011 | age
ulsLance = 34.8 mlles
1ransportanon]Log|sncs
68 !anuary 20, 2011 | age
8|ade 1ransportanon
69 !anuary 20, 2011 | age
Mu|n-Megawau 8|ades Sh|p |n S|ng|e Un|ts er 1ruck
o! MPl's 2.4 MW wlnd Lurblne
! MW192/2.4 and MW1 93/2.4
o! 44.7m W18 Class ll Servlce
o! 46.2m W18 Class lll servlce
70 !anuary 20, 2011 | age
44.7M 8|ade: Work|ng to keduce 1ransportanon Cost
! TPI Engineers are looking for designs
to minimize transportation costs."
! Shortened Maximum Chord
reduces shipping package height."
! Increased root thickness translates
to structural weight reduction. "
! Will ship TWO blades per
truck without exceeding
weight restrictions."
Current shipping configuration of
2.4MW 46.2m wind blade
71 !anuary 20, 2011 | age
urlvlng ComposlLes lnnovauon