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The objective of this project is to develop and demonstrate the capabilities of a new acoustics-based blade structural health monitoring (SHM) system for offshore wind turbines.
Gradient-based optimization offers significant efficiency advantages for wind turbine blade design, but its application has often been limited by the cost and accuracy of finite-difference derivative calculations, especially when fatigue constraints are considered. In this work, we systematically compare and evaluate four differentiation techniques, namely algorithmic differentiation, implicit differentiation, sparsity exploitation, and parallelization, to determine their effectiveness in computing accurate gradients through time-domain aero-structural simulations. By integrating these techniques with unsteady nonlinear aerodynamic and structural models, we develop software designed for accurate gradient computation. We show that combining these techniques addresses memory and runtime challenges associated with long simulations required by design load cases. Specifically, the most effective combination reduces derivative computation wall time by over an order of magnitude compared to finite differencing while maintaining superior accuracy. We demonstrate this approach in a proof-of-concept aero-structural optimization of a wind turbine blade that improves the cost of energy by 12.78 %. This comparative study establishes a viable approach for fatigue-aware blade design that balances computational efficiency with modeling accuracy.
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.
Additively manufactured thermoplastic polymers, such as polylactic acid (PLA), hold significant promise for sustainable engineering structures, including wind turbine blades. Upscaling these structures beyond the limitations of 3D printer build volumes is a challenge; fusion joining presents a potential solution. This paper introduces a displacement-controlled resistance welding process for PLA, as an alternative to the typical force-controlled methods. Here, we investigated the bonding quality of resistance-welded and adhesive-bonded PLA beams through three-point bending and measured the surface deformations using digital image correlation. Different metal meshes (30%/0.11 mm Ni—Cu, 34%/0.07 mm Ni—Cu, and 36%/0.25 mm Co—Ni) served as heating elements. The process parameters were varied for the 34%/0.07 mm Ni—Cu mesh to identify an optimum set of parameters. Results showed that this optimized displacement-controlled welding achieved 94% of the original strength of monolithic samples. This indicates that the new welding process not only ensures high-quality bonding and fine surface finishing but also promotes sustainability, recyclability, and economic efficiency in various polymer and composite structural applications.
DOE Alignment: Reduce the cost of floating offshore wind energy in deep waters to $45/MWh by 2035 from today’s estimated $150/MWh20 by: Developing operations and maintenance strategies and increasing wind turbine reliability to reduce periods of non-operation and reduce labor at sea through remote system health monitoring, inspection, and maintenance capabilities incorporating artificial intelligence and predictive maintenance.
In recent trends, a rising demand for renewable energy has driven wind turbines to larger proportions, where lighter blade designs are often adopted to reduce the costs associated with logistics and production. This causes modern utility-scale wind turbine blades to be inherently more flexible, and their amplified aeroelastic sensitivity results in complex multi-physics reactions to variant atmospheric conditions, including dynamic patterns of aerodynamic loading at the rotor and vortex structure evolutions within the wake. In this paper, we analyze the influence of inflow variance for wind turbines with large, flexible rotors through simulations of the National Rotor Testbed (NRT) turbine, located at Sandia National Labs’ Scaled Wind Farm Technology (SWiFT) facility in Lubbock, Texas. The Common Ordinary Differential Equation Framework (CODEF) modeling suite is used to simulate wind turbine aeroelastic oscillatory behavior and wind farm vortex wake interactions for a range of flexible NRT blade variations, operating in differing conditions of variant atmospheric flow. CODEF solutions of turbine operation in Steady-In-The-Average (SITA) wind conditions are compared to SITA wind conditions featuring a controlled gust-like pulse overimposed, to isolate the effects of typical wind fluctuations. Finally, simulations of realistic time-varying wind conditions from SWiFT meteorological tower measurements are compared to the solutions of SITA wind conditions. These increasingly complex atmospheric inflow variations are tested to show the differing effects evoked by various patterns of spatiotemporal atmospheric flow fluctuations. An analysis is presented for solutions of wind turbine aeroelastic response and vortex wake evolution, to elucidate the consequences of variant inflow, which pertain to wind turbine dynamics at an individual and farm-collective scale. The comparisons of simulated farm flow for SITA and measured fluctuating wind conditions show that certain regions of the wake contain up to a 12% difference in normalized axial velocity, due to the introduction of wind fluctuations. The findings of this study prove valuable for practical applications in wind farm control and optimization strategies, with particular significance for modern utility-scale wind power plants operating in variant atmospheric conditions.
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SAND2024-08606O The pyNuMAD software is used for managing wind turbine blade model data. pyNuMAD specializes in defining the geometry, materials, and boundary conditions for structural analysis of wind turbine blades. This includes loading in data files and providing an interface for users to make updates to the model. The software also features meshing functionality, which takes the blade model and creates a shell or brick mesh for use in finite element analysis. A typical user workflow might be: load in blade information from a yaml file, make adjustments to the blade properties, update the blade based on the adjustments, create a mesh of the blade, export this blade to another software for structural analysis. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.
This final technical report summarizes the outcomes from a project that aimed to design, build, and test a persistent and autonomous monitoring system for avian and bat collisions with offshore wind turbines blades and structures. The system comprises four primary sensor modules: 1) on-blade sensor modules for collision detection and dual-vision image capture on each blade with both visible light and near-infrared imagers; 2) additional on-blade collision sensors mounted further from the root; 3) a nacelle-mounted unit including a 360º camera and ultrasonic microphone array; and, 4) an on-blade, high-performance infrared camera module. Primary targeted outcomes were high sensitivity for the detection of blade strikes from bats and small birds, and automatically captured visual confirmation of the striking object; these features are critical for monitoring offshore wind turbine installations, where ground-based methods are not viable. In addition, local recording will provide a long-term sensor recording database. Following laboratory validation, field testing was conducted on an operational wind turbine in collaboration with the National Wind Technology Center at the NREL Flatirons campus over two planned field tests.
Offshore blades are not just longer, they are wider, heavier and more flexible. These longer blades are a key component of larger wind turbines and for turbines to be more efficient in low wind speeds. These longer blades help reduce the LCOE further and make offshore wind even more competitive. As described earlier, it is essential for the blades to be fully tested to verify and validate the blade designs and manufacturing processes to ensure a reliable product is installed in the field. Through this project WTTC developed and procured new testing equipment required to test longer blades with larger deflections and higher loads. R&D’s BCDA system commissioned was the largest fatigue test exciter system in the world and set the bar for other blade testing facilities worldwide.
NuMAD helps to enable efficient creation and use of high fidelity wind turbine blade models for structural and aerodynamic analysis. NuMAD is a GUI-based tool used to manage the specific geometry and materials inputs required to fully describe a wind turbine blade.
Wind turbine blades are highly engineered structures designed to face temperature extremes and high winds. However, erosion of the blade's leading edge and subsequent repair remains a significant and costly challenge for the wind energy industry. Repair of these leading edges can lead to large amounts of downtime for the turbine and significant operational inefficiencies. In this work, the strength of adhesion and healing ability of a commercially available vitrimer (Mallinda's VITRIMAX) was compared to that of a thermoplastic resin, which has previously been demonstrated in wind energy applications (Arkema's Elium) to evaluate their efficacy as surface coatings for wind turbine blades, particularly their leading edges. Vitrimers are a class of inherently reprocessable thermosets, and it was theorized that vitrimer-based leading edge coatings could enable more robust and efficient wind turbine blades with decreased operational downtime and safer maintenance practices. It was found that the VITRIMAX adhered better to the wind blades' surfaces than both the manufacturer's paint and Elium, with increases in pull-off strength of adhesion ranging from 24% to 83% above that of the original paint. Furthermore, the VITRIMAX adhered strongly to the underlying composite of each blade with strength of adhesion values increasing in ranges from 42% to 97% above that of the original paint. Finally, the vitrimer coating showed an 88% decrease in surface roughness compared to end-of-life blade materials, and initial healing demonstrations in which coatings were manually scratched and subsequently healed exhibited an ~84.5% decrease in scratch depths.
The data was generated with ExaWind (https://github.com/Exawind) which couples AMR-Wind (https://github.com/Exawind/amr-wind/), Nalu-Wind (https://github.com/Exawind/nalu-wind), TIOGA (https://github.com/Exawind/tioga), and OpenFAST (https://github.com/OpenFAST/openfast). This is a large-scale simulation of a blade-resolved wind farm using the ExaWind software stack. ExaWind couples together a background flow solver, AMR-Wind, and a near-body solver, Nalu-Wind, through an overset technique from the TIOGA application. Another application, OpenFAST, handles the structural dynamics of the turbine blades and towers, which informs the fluid-structure interaction of the wind turbines with the flow solvers. This particular simulation includes four blade-resolved wind turbines operating in a turbulent atmospheric boundary layer. The AMR-Wind solver uses 500 million cells and is being solved on 256 AMD GPUs of the Oakridge Leadership Computing Facility Frontier supercomputer. Each turbine is assigned its own Nalu-Wind solver with over 13 million elements per turbine and solved using 448 CPU cores, for a total of 1792 CPU cores. For each node, 56 cores contain Nalu-Wind, while 8 cores correspond to AMR-Wind operations on the GPUs. Consequently, ExaWind is entirely utilizing the CPUs and the GPUs of the nodes concurrently. The data used in the visualization is full flow field data output from the simulation. It is lossy-compressed to a specific accuracy using ZFP and written to disk every 16 time-steps to enable real-time flow visualization. The flow fields are sampled at a high temporal frequency to enable real-time, 24fps visualization. The flow fields are sampled every 12 simulation time steps (every 0.04132s).
Modern wind turbines push the predictive capabilities of state-of-the-art aero-servo-elastic tools. The existing limitations hide across the numerical tool chain and can result in serious issues, such as missing aeroelastic instabilities during the design phase. Structural damping is an input that is usually hard to estimate, but also has a major impact on the turbine behavior. In this paper, we discuss an experiment that aims to accurately quantify the structural damping characterizing the edgewise modes of modern wind turbine blades. The experiment is carried out on a 2.8-MW land-based wind turbine and features a fast yaw actuation that induces an edgewise motion on one of the three blades. The Covariant-subspace system identification (Cov-SSI) method is then used to post-process the blade root moment to estimate the short-term edgewise structural damping. Despite limitations of the Cov-SSI method, which consistently under-predicts the absolute values of damping, we observe that structural damping decreases across the first three blade edgewise modes, which is different from the stiffness-proportional damping model that assumes that structural damping increases with the modes. This paper argues that a stiffness-proportional damping model, which is implemented in most aeroelastic tools, is therefore not conservative and might hide aeroelastic instabilities that can instead appear in the field.
Carbon fiber provides opportunity to reduce weight in structural composites, including wind turbine blades, due to the material's superior specific stiffness and specific strength compared to alternatives. Despite these advantages, cost and compressive performance are considered weaknesses for carbon fiber products available today. Studies to produce low-cost carbon fiber alternatives, including the use of textile-derived precursor systems, have shown progress and merit through the DOE/ORNL low-cost carbon fiber initiatives. Here, this work focuses on enabling increases in compressive strength through design of the carbon fiber geometry, applicable to both textile and conventional precursor systems, while also providing opportunities to reduce carbon fiber processing costs. Fiber-resin interface and fiber alignment are among the most frequently cited factors controlling composite compressive performance. However, it is believed that there is opportunity in traditionally unexplored routes to increasing compressive strength through alteration of the carbon fiber geometry by increasing the fiber area moment of inertia and/or the fiber perimeter and interfacial area. This paper presents initial results from manufacturing carbon fiber materials to assess the impacts of carbon fiber size on tested composite compressive performance with projected neutral or even beneficial impact on fiber and composite manufacturing economics. Carbon fiber systems with increasing size illustrate a favorable correlation for compressive performance greater than predicted from a micromechanical failure model. The manufacturing and mechanical test results support the hypothesis of this work that alterations to fiber geometry can be used to produce improvements of the compressive strength of carbon fiber reinforced polymers and provide incentive for related work in designing alternative shapes to further enhance compressive performance.
Fiber-reinforced thermoplastic composites continue to be implemented in several marketsbecause of their strength capacity and light weight. Especially in the wind industry, wind bladesare made of this material which makes them ideal for wind energy generation, but bladesbecome a problem at end-of-life. Because recycling thermoplastic composites technologiesare still not cost and environmentally effective, research in this space is needed. This paperpresents a case study for coupling repurposed wind turbine blades and 3D printing technology.The purpose is to remanufacture decommissioned wind blades into bus stop roof and seatingsections to then use recycled glass fiber from a decommissioned wind turbine blade to 3Dprint structural and/or fixtures needed in the assembly. We provide an overview of the designprocess, and the development process steps in repurposing and 3D printing the material,delving into key parameters required for a successful implementation.
This data was generated with the ExaWind code suite (https://github.com/Exawind) as a demonstration of a large, 16 turbine wind farm simulation, calculated using two different levels of fidelity. The lower level of fidelity approach uses an actuator line approach to represent the turbines, and was simulated with AMR-Wind (https://github.com/Exawind/amr-wind/) as the background flow solver, coupled to OpenFAST (https://github.com/OpenFAST/openfast). The higher level of fidelity simulation uses a blade-resolved approach, and is done using AMR-Wind, Nalu-Wind (https://github.com/Exawind/nalu-wind), OpenFAST, and TIOGA (https://github.com/Exawind/tioga). In the blade-resolved simulation, ExaWind couples together a background flow solver, AMR-Wind, and a near-body solver, Nalu-Wind, through an overset technique from the TIOGA application. OpenFAST handles the structural dynamics of the turbine blades and towers, which informs the fluid-structure interaction of the wind turbines with the flow solvers. In the actuator line simulation, a mesh of 295M elements was used for a 5km x 5km domain, and it was simulated using 256 nodes (2048 GPU's) on the Oak Ridge Leadership Computing Facility Frontier supercomputer. For the blade-resolved simulation, 1.5B element mesh was used in the AMR-Wind background 5km x 5km domain, and 16M elements were used for each turbine in the Nalu-Wind domains, for a total of 1.7B elements. This was simulated using 384 nodes on Frontier, with each node using 56 cores for Nalu-Wind and 8 GPU cores. The data in this archive includes the turbine outputs from OpenFAST, 2D sampling planes from AMR-Wind, and full-field solution files from AMR-Wind and Nalu-Wind.
The performance benefits of using tip devices on wind turbines has been well-documented. However, previous studies show that adding blade tip devices such as winglets leads to a significant increase in blade root bending moment, potentially requiring structural reinforcement with cost and weight drawbacks. A new and unique design philosophy for retrofit blade tip devices for wind turbines is presented. By balancing generated aerodynamic and centrifugal loads, these devices offer an increase in power production without the need for structural reinforcement. Predicted performance and cost benefits of using retrofit blade tip devices on the National Renewable Energy Laboratory 5 MW reference wind turbine are shown. Finally, the addition of blade tip devices resulted in significant improvements in the coefficient of power (C p ) and annual energy production (AEP).