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At least 73 records · Page 4

Wind Turbine Blade Finishing Automation: Robotic Toolpath Generation

Wind turbine blades are now over 100 meters long and can reach heights of several meters while in the finishing area of the factory. Because of this, automation should be used to lower the manufacturing cost and make the process safer for blade manufacturing technicians. This session will present a novel method that generates a six degree of freedom robotic toolpath with 3D cameras for the finishing of wind turbine blades to drive down the levelized cost and make wind energy even more competitive in the utility scale energy generation industry.

3d imaging↗

Design and evaluation of low-cost laminated wood composite blades for intermediate size wind turbines: Blade design, fabrication concept, and cost analysis

As part of a program to reduce wind turbine costs, an evaluation was conducted of a laminated wood composite blade for the Mod-OA 200 kW wind turbine. The effort included the design and fabrication concept for the blade, together with cost and load analyses. The blade structure is composed of laminated Douglas fir veneers for the primary spar and nose sections, and honeycomb cored plywood panels for the trailing edges sections. The attachment of the wood blade to the rotor hub was through load takeoff studs bonded into the blade root. Tests were conducted on specimens of the key structural components to verify the feasibility of the concept. It is concluded that the proposed wood composite blade design and fabrication concept is suitable for Mod-OA size turbines (125-ft diameter rotor) at a cost that is very competitive with other methods of manufacture.

Lieblein, S.↗

Using Large-Scale Additive Manufacturing for Wind Turbine Blade Core Structures

This report describes the techno-economic potential of using additive manufacturing technologies to design large wind turbine blade structures. After considering all additive technologies, the authors identified large-scale, polymer-based, material extrusion as the three-dimensional (3D) printing technology best suited to meet modern wind turbine blade manufacturing costs, cycle times, and geometric scale. Due to the lower structural performance requirements and the opportunity to reduce resin uptake mass penalties within the blade, the core material within the sandwich composite sections of the wind turbine blade is established as a logical entry point into advanced wind turbine blade manufacturing.

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Low cost carbon fiber as potential lightning strike protection for wind turbine blades

Until recently, glass fiber composites (GFRP) were the preferred choice to prepare wind turbine blades due to their low cost compared to their counterpart carbon fiber composites (CFRP). However, to harvest the maximum wind energy, ever larger wind turbine blades are being manufactured. To support such a large structure carbon fiber composites CFRP have become the integral part of load bearing structures in the blade. In this work, we are proposing to utilize the low cost carbon fiber (LCCF), manufactured at Carbon Fiber Technology Facility (CFTF) of Oak Ridge National Laboratory (ORNL) as not only the cost effective alternative to the currently used carbon fiber (CF) but also as the lightning strike protection of the wind turbine blades. Wind turbines often get hit by lightning strikes due to their operating locations. LCCF can provide structural integrity to these gigantic structures and mitigate the effect of lightning strike on them by effectively dissipating the current. Two composite panels made of LCCF were tested against artificial lightning strikes of 100 kA and 200 kA (component A of lightning waveform SAE ARP 5412-B). The results showed very high resilience of LCCF composite due to their high electrical conductivity both in-plane and in through-thickness directions. There was no significant damage (fiber breakage, resin evaporation or delamination) in both the cases.

Kumar, Vipin↗

Spatiotemporal Variability in Wind Turbine Blade Leading Edge Erosion

Wind turbine blade leading edge erosion (LEE) reduces energy production and increases wind energy operation and maintenance costs. Degradation of the blade coating and ultimately damage to the underlying blade structure are caused by collisions of falling hydrometeors with rotating blades. The selection of optimal methods to mitigate/reduce LEE are critically dependent on the rates of coating fatigue accumulation at a given location and the time variance in the accumulation of material stresses. However, no such assessment currently exists for the United States of America (USA). To address this research gap, blade coating lifetimes at 883 sites across the USA are generated based on high-frequency (5-min) estimates of material fatigue derived using a mechanistic model and robust meteorological measurements. Results indicate blade coating failure at some sites in as few as 4 years, and that the frequency and intensity of material stresses are both highly episodic and spatially varying. Time series analyses indicate that up to one-third of blade coating lifetime is exhausted in just 360 5-min periods in the Southern Great Plains (SGP). Conversely, sites in the Pacific Northwest (PNW) exhibit the same level of coating lifetime depletion in over three times as many time periods. Thus, it may be more cost-effective to use wind turbine deregulation (erosion-safe mode) for damage reduction and blade lifetime extension in the SGP, while the application of blade leading edge protective measures may be more appropriate in the PNW. Annual total precipitation and mean wind speed are shown to be poor predictors of blade coating lifetime, re-emphasizing the need for detailed modeling studies such as that presented herein.

Pryor, Sara C. (ORCID:0000000348473440)↗

Analysis of temperature distribution in liquid-cooled turbine blades

The temperature distribution in liquid-cooled turbine blades determines the amount of cooling required to reduce the blade temperature to permissible values at specified locations. This report presents analytical methods for computing temperature distributions in liquid-cooled turbine blades, or in simplified shapes used to approximate sections of the blade. The individual analyses are first presented in terms of their mathematical development. By means of numerical examples, comparisons are made between simplified and more complete solutions and the effects of several variables are examined. Nondimensional charts to simplify some temperature-distribution calculations are also given.

Livingood, John N B↗

Radar-derived precipitation climatology for wind turbine blade leading edge erosion

Wind turbine blade leading edge erosion (LEE) is a potentially significant source of revenue loss for wind farm operators. Thus, it is important to advance understanding of the underlying causes, to generate geospatial estimates of erosion potential to provide guidance in pre-deployment planning, and ultimately to advance methods to mitigate this effect and extend blade lifetimes. This study focuses on the second issue and presents a novel approach to characterizing the erosion potential across the contiguous USA based solely on publicly available data products from the National Weather Service dual-polarization radar. The approach is described in detail and illustrated using six locations distributed across parts of the USA that have substantial wind turbine deployments. Results from these locations demonstrate the high spatial variability in precipitation-induced erosion potential, illustrate the importance of low-probability high-impact events to cumulative annual total kinetic energy transfer and emphasize the importance of hail as a damage vector.

Letson, Frederick (ORCID:0000000192750359)↗

Progress in the prediction of unsteady heat transfer on turbines blades

Progress toward developing a general method for predicting unsteady heat transfer on turbine blades subject to blade-passing frequencies and Reynolds numbers relevant to the Space Shuttle Main Engine (SSME) is discussed. The method employs an invisid/viscous interactive procedure which has been tested extensively for steady subsonic and transonic external airfoil problems. One such example is shown. The agreement with experimental data and with Navier-Stokes calculations yields confidence in the method. The technique is extended to account for wake generated unsteadiness. The flow reversals around the stagnation point caused by the nonuniform onset velocity are accounted for by using the Characteristic Box scheme developed by Cebeci and Stewartson. The coupling between the inviscid and viscous methods is achieved by using a special procedure, which, with a novel inverse finite-difference boundary-layer method, allows the calculations to be performed for a wide range of flow conditions, including separation. Preliminary results are presented for the stagnation region of turbine blades for both laminar and turbulent flows. A laminar model problem corresponding to a flow on a circular cylinder which experiences the periodic passing of wakes from turbine blades is presented to demonstrate the ability of the method to calculate flow reversals around the stagnation region.

Cebeci, T.↗

Aero-Thermo-Structural Design Optimization of Internally Cooled Turbine Blades

A set of robust and computationally affordable inverse shape design and automatic constrained optimization tools have been developed for the improved performance of internally cooled gas turbine blades. The design methods are applicable to the aerodynamics, heat transfer, and thermoelasticity aspects of the turbine blade. Maximum use of the existing proven disciplinary analysis codes is possible with this design approach. Preliminary computational results demonstrate possibilities to design blades with minimized total pressure loss and maximized aerodynamic loading. At the same time, these blades are capable of sustaining significantly higher inlet hot gas temperatures while requiring remarkably lower coolant mass flow rates. These results suggest that it is possible to design internally cooled turbine blades that will cost less to manufacture, will have longer life span, and will perform as good, if not better than, film cooled turbine blades.

Dulikravich, G. S.↗

Closed-loop brayton cycle system with turbine blade cooling

A closed-loop Brayton cycle system utilizes supercritical carbon dioxide as the working fluid for the system to achieve higher efficiencies than can be achieved with traditional open-loop gas turbine engines. A bleed channel is used to direct a flow of cooling fluid to cool the turbine blades during operation of the system, preventing damage to the turbine blades during operation of the system. The bleed channel includes a bleed inlet fluidly coupled between a first recuperator and a second recuperator and a bleed outlet fluidly coupled to the turbine blades. The bleed channel is configured to direct the flow of cooling fluid to the turbine blades at a desired temperature and pressure.

Taylor, Stephen H.↗

Finite element analysis of the Space Shuttle Main Engine (SSME) high pressure fuel turbopump turbine blade (HPFTP)

Cracking of the turbine blades of the SSME HPFTP is studied using two- and three-dimensional finite element analysis. The development and composition of the two- and three-dimensional models are described. Analyses are conducted under the speed, pressure, and thermal load conditions that occur during the full power level of the engine. The effects of friction on the two-dimensional model are examined. The strain and life cycle data reveal that the LCF cracking in the first stage is not probable unless the effects of fit-up tolerance between the blade and rotor are present, and for the second stage it is predicted that hydrogen assisted LCF cracking will occur under the present thermal environment. Design modifications to alleviate this cracking are discussed.

Lee, H. M.↗

Tungsten fiber reinforced FeCralY: A first generation composite turbine blade material

Tungsten-fiber/FeCrAlY (W/FeCrAlY) was identified as a promising aircraft engine, first generation, turbine blade composite material. Based on available data, W/FeCrAlY should have the stress-rupture, creep, tensile, fatigue, and impact strengths required for turbine blades operating from 1250 to 1370 K. It should also have adequate oxidation, hot corrosion, and thermal cycling damage resistance as well as high thermal conductivity. Concepts for potentially low cost blade fabrication were developed. These concepts were used to design a first stage JT9D convection cooled turbine blade having a calculated 50 K use-temperature advantage over the directionally solidified superalloy blade.

Petrasek, D. W.↗

Cyclic Structural Analyses of SSME Turbine Blades

The problems of calculating the structural response of high-temperature space propulsion components such as turbine blades for the fuel turbopump are addressed. The first high-pressure-stage fuel turbine blade (HPFTB) in the liquid-hydrogen turbopump of the space shuttle main engine (SSME) was selected for this study. In the past these blades have cracked in the blade shank region and at the airfoil leading edge adjacent to the platform. To achieve the necessary durability, these blades are currently being cast by using directional solidification. Single-crystal alloys are also being investigated for future SSME applications. The study evaluated the utility of advanced structural analysis methods in assessing the low-cycle fatigue lives of these anisotropic components. The turbine blade airfoil of the high-pressure stage of the SSME fuel turbopump was analyzed because it has a history of rapid crack initiation.

Kaufman, A.↗

Effects of Trailing Edge Thickness and Blade Loading Distribution on the Aerodynamic Performance of Simulated CMC Turbine Blades

The aerodynamic performance of three blade sets that represent the geometric manufacturing constraints of Ceramic Matrix Composite (CMC) blades was measured experimentally in a large-scale transonic turbine blade cascade. The trailing edge thicknesses of CMC blades are anticipated to be significantly larger than those of current state-of-the-art metallic blades. The blades tested in the current study had trailing edge thicknesses of 5%, 7%, and 9% relative to the blade axial chord. The three blade sets were designed with matching throat dimensions, so the blade loading distributions were varied to retain similar overall loading levels. Data were acquired at four Reynolds numbers, covering a factor of six range. All data were acquired at the design isentropic exit Mach number of 0.74. Measurements include blade loading and five-hole probe surveys at two downstream stations. The effects of inlet turbulence intensity were also quantified. Total pressure loss data were integrated to determine overall loss levels for each of the three measured blade passages. Excellent periodicity was noted. For low inlet turbulence levels, losses were surprisingly lower for the thickest trailing edge at low Reynolds numbers, but were highest at the maximum Reynolds number. In general, losses were found to scale well with Reynolds number, although front loading was found to significantly reduce the sensitivity of loss to Reynolds number. For high inlet turbulence intensity, losses were found to scale with trailing edge thickness as expected, and the Reynolds number sensitivity was reduced for all three blade sets. Loss levels at the highest Reynolds number were comparable at low and high inlet turbulence intensity levels.

Turbine↗

Predicted inlet gas temperatures for tungsten fiber reinforced superalloy turbine blades

Tungsten fiber reinforced superalloy composite (TFRS) impingement cooled turbine blade inlet gas temperatures were calculated taking into account material spanwise strength, thermal conductivity, material oxidation resistance, fiber-matrix interaction, and coolant flow. Measured values of TFRS thermal conductivities are presented. Calculations indicate that blades made of 30 volume percent fiber content TFRS having a 12,000 N-m/kg stress-to-density ratio while operating at 40 atmospheres and a 0.06 coolant flow ratio could permit a turbine blade inlet gas temperature of over 1900K. This is more than 150K greater than similar superalloy blades.

Winsa, E. A.↗

Phenomena Identification and Ranking Tables (PIRT) analysis of wind turbine blade leading edge erosion

Leading edge erosion (LEE) of wind turbine blades has been identified as a major factor in decreased wind turbine blade lifetimes and energy output over time. Accordingly, the International Energy Agency Wind Technology Collaboration Programme (IEA Wind TCP) has created the Task 46 Phase 2 to undertake cooperative research in the key topic of blade erosion. The purpose of Task 46 Erosion Phase 2 is to further improve understanding of erosion driving factors, develop datasets and model tools to enhance prediction of leading-edge erosion likelihood, identify damage at the earliest possible stage and advance potential solutions. The scope of work covers several technical areas, reflecting the multidisciplinary nature of the challenge. Participants in the task are given in Table 1.

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