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Structural investigation of composite wind turbine blade considering various load cases and fatigue life

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  • Kong, C.
  • Bang, J.
  • Sugiyama, Y.

Abstract

This study proposes a structural design for developing a medium scale composite wind turbine blade made of E-glass/epoxy for a 750kW class horizontal axis wind turbine system. The design loads were determined from various load cases specified at the IEC61400-1 international specification and GL regulations for the wind energy conversion system. A specific composite structure configuration, which can effectively endure various loads such as aerodynamic loads and loads due to accumulation of ice, hygro-thermal and mechanical loads, was proposed. To evaluate the proposed composite wind turbine blade, structural analysis was performed by using the finite element method. Parametric studies were carried out to determine an acceptable blade structural design, and the most dominant design parameters were confirmed. In this study, the proposed blade structure was confirmed to be safe and stable under various load conditions, including the extreme load conditions. Moreover, the blade adapted a new blade root joint with insert bolts, and its safety was verified at design loads including fatigue loads. The fatigue life of a blade that has to endure for more than 20 years was estimated by using the well-known S–N linear damage theory, the service load spectrum, and the Spera's empirical equations. With the results obtained from all the structural design and analysis, prototype composite blades were manufactured. A specific construction process including the lay-up molding method was applied to manufacturing blades. Full-scale static structural test was performed with the simulated aerodynamic loads. From the experimental results, it was found that the designed blade had structural integrity. In addition, the measured results of deflections, strains, mass, and radial center of gravity agreed well with the analytical results. The prototype blade was successfully certified by an international certification institute, GL (Germanisher Lloyd) in Germany.

Suggested Citation

  • Kong, C. & Bang, J. & Sugiyama, Y., 2005. "Structural investigation of composite wind turbine blade considering various load cases and fatigue life," Energy, Elsevier, vol. 30(11), pages 2101-2114.
    • Handle: RePEc:eee:energy:v:30:y:2005:i:11:p:2101-2114
    DOI: 10.1016/j.energy.2004.08.016
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    2. Wei Li & Shinai Xu & Baiyun Qian & Xiaoxia Gao & Xiaoxun Zhu & Zeqi Shi & Wei Liu & Qiaoliang Hu, 2022. "Large-Scale Wind Turbine’s Load Characteristics Excited by the Wind and Grid in Complex Terrain: A Review," Sustainability, MDPI, vol. 14(24), pages 1-29, December.
    3. Ozbek, Muammer & Rixen, Daniel J. & Erne, Oliver & Sanow, Gunter, 2010. "Feasibility of monitoring large wind turbines using photogrammetry," Energy, Elsevier, vol. 35(12), pages 4802-4811.
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    5. Radičević, Branko M. & Savić, Milan S. & Madsen, Søren Find & Badea, Ion, 2012. "Impact of wind turbine blade rotation on the lightning strike incidence – A theoretical and experimental study using a reduced-size model," Energy, Elsevier, vol. 45(1), pages 644-654.
    6. Lu, Liang & Wu, Haijun & Wu, Jianzhong, 2021. "A case study for the optimization of moment-matching in wind turbine blade fatigue tests with a resonant type exciting approach," Renewable Energy, Elsevier, vol. 174(C), pages 769-785.
    7. Senthil Kumar Madasamy & Vijayanandh Raja & Hussein A Z AL-bonsrulah & Mohammed Al-Bahrani, 2022. "Design, development and multi-disciplinary investigations of aerodynamic, structural, energy and exergy factors on 1 kW horizontal-axis wind turbine [Composite materials for wind power turbine blad," International Journal of Low-Carbon Technologies, Oxford University Press, vol. 17, pages 1292-1318.
    8. Peter J. Schubel & Richard J. Crossley, 2012. "Wind Turbine Blade Design," Energies, MDPI, vol. 5(9), pages 1-25, September.
    9. Liao, C.C. & Zhao, X.L. & Xu, J.Z., 2012. "Blade layers optimization of wind turbines using FAST and improved PSO Algorithm," Renewable Energy, Elsevier, vol. 42(C), pages 227-233.
    10. Jinghua Lin & You-lin Xu & Yong Xia, 2019. "Structural Analysis of Large-Scale Vertical Axis Wind Turbines Part II: Fatigue and Ultimate Strength Analyses," Energies, MDPI, vol. 12(13), pages 1-18, July.
    11. Dimitris Al. Katsaprakakis & Nikos Papadakis & Ioannis Ntintakis, 2021. "A Comprehensive Analysis of Wind Turbine Blade Damage," Energies, MDPI, vol. 14(18), pages 1-31, September.
    12. Tjiu, Willy & Marnoto, Tjukup & Mat, Sohif & Ruslan, Mohd Hafidz & Sopian, Kamaruzzaman, 2015. "Darrieus vertical axis wind turbine for power generation II: Challenges in HAWT and the opportunity of multi-megawatt Darrieus VAWT development," Renewable Energy, Elsevier, vol. 75(C), pages 560-571.
    13. Habibi, Hossein & Cheng, Liang & Zheng, Haitao & Kappatos, Vassilios & Selcuk, Cem & Gan, Tat-Hean, 2015. "A dual de-icing system for wind turbine blades combining high-power ultrasonic guided waves and low-frequency forced vibrations," Renewable Energy, Elsevier, vol. 83(C), pages 859-870.
    14. Liao, Ding & Zhu, Shun-Peng & Correia, José A.F.O. & De Jesus, Abílio M.P. & Veljkovic, Milan & Berto, Filippo, 2022. "Fatigue reliability of wind turbines: historical perspectives, recent developments and future prospects," Renewable Energy, Elsevier, vol. 200(C), pages 724-742.
    15. Xin Cai & Jie Zhu & Pan Pan & Rongrong Gu, 2012. "Structural Optimization Design of Horizontal-Axis Wind Turbine Blades Using a Particle Swarm Optimization Algorithm and Finite Element Method," Energies, MDPI, vol. 5(11), pages 1-14, November.
    16. Yang, Jinshui & Peng, Chaoyi & Xiao, Jiayu & Zeng, Jingcheng & Yuan, Yun, 2012. "Application of videometric technique to deformation measurement for large-scale composite wind turbine blade," Applied Energy, Elsevier, vol. 98(C), pages 292-300.
    17. Marín, J.C. & Barroso, A. & París, F. & Cañas, J., 2008. "Study of damage and repair of blades of a 300kW wind turbine," Energy, Elsevier, vol. 33(7), pages 1068-1083.
    18. Jie Zhu & Xin Cai & Pan Pan & Rongrong Gu, 2014. "Multi-Objective Structural Optimization Design of Horizontal-Axis Wind Turbine Blades Using the Non-Dominated Sorting Genetic Algorithm II and Finite Element Method," Energies, MDPI, vol. 7(2), pages 1-15, February.
    19. Dai, Juchuan & Li, Mimi & Chen, Huanguo & He, Tao & Zhang, Fan, 2022. "Progress and challenges on blade load research of large-scale wind turbines," Renewable Energy, Elsevier, vol. 196(C), pages 482-496.
    20. Chehouri, Adam & Younes, Rafic & Ilinca, Adrian & Perron, Jean, 2015. "Review of performance optimization techniques applied to wind turbines," Applied Energy, Elsevier, vol. 142(C), pages 361-388.
    21. Zhiyu Jiang & Weifei Hu & Wenbin Dong & Zhen Gao & Zhengru Ren, 2017. "Structural Reliability Analysis of Wind Turbines: A Review," Energies, MDPI, vol. 10(12), pages 1-25, December.
    22. Xiao Chen & Wei Zhao & Xiao Lu Zhao & Jian Zhong Xu, 2014. "Failure Test and Finite Element Simulation of a Large Wind Turbine Composite Blade under Static Loading," Energies, MDPI, vol. 7(4), pages 1-24, April.
    23. Jiang, Wenchun & Fan, Qinshan & Gong, Jianming, 2010. "Optimization of welding joint between tower and bottom flange based on residual stress considerations in a wind turbine," Energy, Elsevier, vol. 35(1), pages 461-467.

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