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CharacterizationofInternalMicrostructure
DamageofCompositeWindTurbineBlade
FollowingStructuralTestinguptoFailure
aslavMitrovi1,NebojsaPetrovi2,DragoljubBekri3,AleksandarBengin4,Vuk Dragovi5
AeronauticalDepartment,FacultyofMechanicalEngineering/UniversityofBelgrade
16KraljiceMarijest.,11000Belgrade,Serbia
cmitrovic@mas.bg.ac.rs;2npetrovic@mas.bg.ac.rs;3dbekric@mas.bg.ac.rs,4abengin@mas.bg.ac.rs
Abstract
turbinebladesandpotentiallybringimprovementsto
theirmechanicalproperties
Structural Testing
The purpose of this research is to test the established
technology of designing the composite rotor
bladeW55RBVSofwindturbineScirocco.
Scirocco is a 5.6 m diameter rotor, 6 kW output
professionalscale wind turbine ideal for remote sites
with medium power needs, such as small farms,
houses, or large homesteads and especially rural or
village electrification, sea water desalination, direct
electrical water winddriven pumping. This wind
turbineisacommonpracticeanditisbuiltinseveral
countriesinEuropeandAmerica(Fig.1&2).
Keywords
Structural Testing; SmallWind Turbine; Composite Blade; Blade
Testing,Microstructure;AtomicForceMicroscopy
Introduction
The programme for testing rigidity of the composite
rotor blade W55RBVS of the wind turbine Scirocco is
defined by standard IEC 614002. The rotor blade
testing is done in an Aerotechnics Laboratory at the
Faculty of Mechanical Engineering, Belgrade
University.Thepurposeofthistestingistodefinethe
rigidity of the rotor blade and to determine the
maximum force that causes the failure of the rotor
blade as well as the spot of the failure. This research
uses atomic and magnetic force microscopy to
determine differences of the surface topography and
magneticpropertiesbetweenpartsofthewindturbine
blade that were under different load during the
mechanical testing of rigidity. This may lead to new
insightinthestructureofthematerialsusedforwind
FIG.1WINDTURBINEEOLTECSCIROCCO
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ProgrammeforTesting
FIG.2EOLTECSCIROCCOWINDTURBINEALONGTHE
HIGHWAYINFRANCE
Sciroccoischaracterizedbylowrotationspeed,avery
high efficiency, especially in the lower to medium
windspeedrangewhichisprevailingmostofthetime.
Thisistheresultoftheconjunctionofanoptimized2
blades rotor, an efficient direct drive PM generator,
and variable speed management combined with the
maximal power point tracking control following the
constantly varying wind speed. Composite rotor
blades W55RBVS are produced in the WING.d.o.o
company(Fig.3&4).
FIG.3DESIGNOFCOMPOSITEBLADESW55RBVS
Thedesignofrotorbladesisabalancedintegrationof
aerodynamics, structural analysis and dynamics,
choice of different type of composite materials,
productiontechnologyandoveralleconomy.
FIG.4BUILTCOMPOSITEBLADESW55RBV
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FIG.5ROTORBLADEACCEPTANCE
StudyofCivilEngineeringandArchitecture(SCEA)Volume1Issue1,December2012www.seipub.org/scea
Aspecialrotorbladeholderispreparedforthistesting.
This holder constitutes of extremely rigid specious
grid made of steel C and L profiles that are mutually
connected by bolt links. The link between the rotor
blade and the holder is accomplished through 30mm
boardandbyboltsM8of8.8quality.
MeasuringEquipment
ThecentralacquisitionunitHBMSPIDER8represents
a multifunctional model of receiving analogue and
digitalsignalswithparalleltracingoftheflowofinput
units, by means of integrated microcomputer, using
higherlevelsystemtorelievetheacquisitionrouteand
to provide the flow of signals from certain smart
sensorsdirectlytothecontrolunit.
SPIDER 8 is a multichannel acquisition unit designed
fordynamicparallelmeasuring.Thankstointegration
with personal computer as a higher level system, the
process of measuring is remarkably simple and the
total acquisition system is compact and of small
dimensions(Fig.6).
This eightchannel acquisition unit provides 9600
measurings per second per each channel with
resolution of 16 bits. All 8 A/D convertors work
simultaneously and in a real time follow the
transformationofphysicalvaluesintoadigitalsignal.
a)
b)
FIG.8FORCESENSORA)SCHEME;B)ONTHEBLADE
Twomodulesareusedforthisexperimentinthisway
providing that 16 measuring values are at a disposal
fortheexperiment.
FIG.6TWOMODULESOFSPIDER8
FIG.7INDUCTIVEDISPLACEMENTSENSORLVDTHBM
FIG.9CONSTRICTIONFORFORCEDISTRIBUTION
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RealizationoftheExperiment
The rotor blade is loaded in six sections by lyres and
measuredfromtheplaceofthebladeclamp(Fig.10).
Therotorblademassis11.9kg
Section
Distancefromtheplaceofbladeclampin(mm)
60.0
102.5
154.0
182.5
206.0
236.5
FIG.12THELOADDISTRIBUTIONOFEACHSECTIONIN
FUNCTIONOFTIME
FIG.10LYRESFORTHEINTRODUCTIONFORCE
FIG.13THERESULTINGFORCEDISTRIBUTIONIN
FUNCTIONOFTIME
Beginning 56.5
End 106.5
Beginning 57
End 103
Thecompositematerialismicroglassfibersreinforced
with epoxide resin. The impellers were exposed to
criticalloaduntilfailureandpartsfromcriticallyand
subcriticallyloadedregionsofwindturbinebladeare
investigated by Magnetic Force Microscopy (MFM).
Magnetic force microscopy is able to provide
characterizationofsurfaceandinternalstructurenear
surface of the sample, which is used in this paper to
give analysis of structural change of material with
different loads. Results and comparison of
microstructureoftwopartsofwindturbinebladeare
analyzedandpresented
MeasuringEquipment
Thescanningprobemicroscopeusedinthisstudyisa
SPM5200 from JEOL, Japan. The SPM5200 is a
multipurpose, high resolution scanning probe
microscope offering ease of use with diverse
measurementandsampleenvironments(Fig.14).
FIG.11THEPOSITIONOFTHEBLADEFRACTURE
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thesample.Inthesecondscan,thetipsampledistance
is increased and the biased tip is scanned along the
topography line obtained from the first scan. The
topographical line maintains constant tip sample
distance,whichequalsthelineoftheconstantvander
Waalsforce.
FIG.14JEOLSPM5200
Typically,thedeflectionismeasuredusingalaserspot
reflectedfromthetopsurfaceofthecantileverintoan
array of photodiodes. TappingMode AFM is a more
recent development in which the imaging probe is
vertically oscillated at or near the resonant frequency
ofthecantilever(Fig.15).
FIG.17LIFTMODETOOBTAINBOTHTOPOGRAPHYAND
MAGNETICFORCEGRADIENT
FIG.15CANTILEVERWITHASHARPTIP(PROBE)
Results
Averageofroughness:
Ra
1 L
f ( s) Z 0 ds
L 0
(1)
FIG.16SCHEMEOFMEASUREMENTSUSINGALASER
ThekeyadvantageofTappingModeistheelimination
of the lateral shear forces present in contact mode,
which,onmanyspecimens,candamagethestructure
being imaged. TappingMode AFM can be conducted
inanairorliquidenvironment.
Rootmeansquareroughness:
Rq
1 L
( f ( s) Z 0 ) 2 ds
L 0
(2)
The10pointaverageroughnessisdefinedasthesum
of the average value of the absolute values of the
deviation from the centerline between the largest
deviation and the fifth deviation, and the average
value of theabsolute values of the deviation between
thesmallestdeviationandthefifthdeviation.
The10pointaverageroughnessisdefinedasthesum
of the average value of the absolute values of the
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Rzijs
z p1 z p 2 z p 3 z p 4 z p 5 zv1 zv 2 zv 3 zv 4 zv 5
10
(3)
Theheightzatthepositiondalongthelineisdefined
as:z=f(s).TheheightZoofthecenterlineisdefinedas:
Z0
1 L
f ( s)ds
L 0
(4)
FIG.17BSAMPLE1
Sample1LessLoaded
Itisexpectedforthepartofmaterialthatislessloaded
(Sample 1, shown on Fig. 17A,B,C,D) to have less
surface roughness as layers of silicone fibers held by
epoxy will be more evenly aligned. AFM research
shows that Sample 1 has smaller average surface
roughness(Ra)by200nmthaninSample2whichhad
higherloadduringthebreakingofwindturbine.This
could mean that inner layers of the material were
deformed and may not be aligned as in their original
position.
FIG.17ASAMPLE1
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FIG.17CSAMPLE1
StudyofCivilEngineeringandArchitecture(SCEA)Volume1Issue1,December2012www.seipub.org/scea
FIG.17DSAMPLE1
Sample2HigherLoad
FIG.18BSAMPLE2
Fromthefiguresrepresentingmagneticcharacteristics
of the material it is apparent that Sample 1 has
relatively uniform distribution of magnetic properties
while Sample 2 has black dots which represent
abrupt change in sample magnetization i.e. change in
magnetic field gradient. The existence of so called
black dots on the figure of higher loaded sample
(Sample 2, shown on Fig. 18A,B,C,D) indicates
possible changes in material structure that is on its
stratificationuponloading.
FIG.18ASAMPLE2
FIG.18CSAMPLE2
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FIG.18DSAMPLE2
Conclusions
Thisexperimentconfirmsthatthewindturbineblade
W55RBVShasveryhighrigidity.
Research by Magnetic Force Microscopy shows that
sampletakenfrompartwithhigherloadhavelargest
surface roughness and height differences as it is
expected. The existence of black dots (magnetic
holes)indicatesstratificationinsidethecomposite.
ACKNOWLEDGMENT
ThisresearchwassupportedbytheMinistryofScience
and Technological Development, Republic of Serbia
projects:TR35035,TR36001.
REFERENCES
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