Presented by Jose R. Zayas Authored by Tom Ashwill, Jose Zayas, and Paul Veers Sandia National Laboratories Innovations in Blade Technology For Multi-Mega Watt Turbines Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy under contract DE-AC04-94AL85000.

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 2 Outline  DOE Wind Program Structure  SNL Research Focus  Numerical Analysis Tools  Sub-Scale Blades  Active Flow Control and Sensors  Future Work

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 3 U.S. DOE Wind Program DOE Headquarters Stan Calvert Jack Cadogan Linda Silverman Dennis Lin Steve Lindenberg Phil Dougherty Jim Ahlgrimm Laura Miner-Nordstrom Ian Baring-Gould (M&O) Sandia Labs Paul Veers NREL R. Thresher, B. Smith

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 4 Sandia National Labs Research Focus  SNL Blade Technology Research  Design innovations  Design tools  Materials & manufacturing  Sub-scale blade design & fabrication  Laboratory and field testing

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 5 Blade Design Advances & New Concepts  Lightweight Designs  Slender planform  New materials  Load Alleviation  Passive  Sweep  Off-axis fibers  Active control  Individual blade pitch control  Embedded devices  Enhanced Performance  New airfoils  Very thick (high t/c)  Flatbacks  Active devices  Manufacturing  Remote build  Coupon testing  Manufacturing process  Hand lay-up  RTM  Pre-preg  Infusion

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 6 Numerical Analysis Tools  NuMAD - SNL  ANSYS FEA preprocessor  Linear and non-linear buckling  Dynamic Simulation Tools  FAST ( Fatigue, Aerodynamics, Structures, and Turbulence ) – NREL, SNL  Modal representation  Limited degrees of freedom  Used as a preprocessor to ADAMS  ADAMS ( Automatic Dynamic Analysis of Mechanical Systems ) – NREL, SNL  Commercial multi body dynamic simulation software  Virtually unlimited degrees of freedom  NASTRAN - SNL  Flutter analysis and predictions Micon 65 – ADAMS Model NuMAD FEA Model

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 7 CFD Capabilities  CFD Codes  ARC2D  OVERFLOW 2.0y  Applications for CFD  Airfoil performance predictions  Understanding of the effects of embedded devices Three-dimensional Compressible RaNS

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 8 Advance Airfoils with Highly Efficient Structure Flatback Airfoils Flatback Airfoil Traditional Airfoil

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 9 Passive and Active Blade Control Active Devices Passive Bend-Twist Coupling Courtesy: NREL

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 10 Materials & Manufacturing Research Carbon Coupon TestsNew Forms – Large & Medium Carbon Tows Large Database in Collaboration with Montana State University

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 11 Applications of Innovations  Prototype Sub-scale Blades Manufactured ( 9 meters )  CX-100  Carbon spar cap  Glass skin and shear web  TX-100  Carbon triax in skin for bend-twist  Constant spar cap thickness  BSDS ( Blade System Design Study )  Flatback airfoils  Carbon spar cap  Slenderized planform  Large scale architecture  Highly efficient structural design  LWST Phase II Components  Knight & Carver  25m blade sweep twist  Replacement blades Subscale Blade Design & Fabrication

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 12 CX-100 – Carbon Spar Cap Carbon Spar Cap Manufactured by TPI Composites Root Stud Inserts

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 13 TX-100 Carbon Tri-ax Skin & Glass Spar-Cap Passive Bend-Twist Coupling – Off Axis Carbon Fiber Manufactured by TPI Composites

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 14 BSDS – Flatback Airfoils Manufactured by TPI Composites

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 15 Blade Test Site  3 Micon 65/13 (modified)  115 kW generator  Stall regulated  55 RPM  Heavily Instrumented  15 rotor strain gauges  Rotor speed and position  Nacelle acceleration  Tower instrumentation  Inflow Array

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 16 Active Flow/Load Control Active Load Control on Blade/Turbine can be Achieved by Modifying:  Blade incidence angle (pitch)  Flow velocity (modification in RPM)  Blade length  Blade aerodynamic characteristics through:  Changes in section shape (aileron, smart materials, microtab)  Surface blowing/suction  Other flow control techniques (VG’s, surface heating, plasma)  SNL Focus on Fast-Acting, Low Actuation Energy Devices  Will operate within the boundary layer of the blade  Must be rugged and easily implemented

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 17 Sensors  Focus on Cost Effective Sensors (for lab and field environments)  Strain sensors  Pressure sensors for airflow measurements  Fiber optic sensors  Piezo-ceramic  Displacement and proximity (blade tip deflection)  Sensor Networks  Control inputs  Damage detection and health monitoring  Embedded Sensors  Composite structures  Exploring possibilities with SNL MEMS facility

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 18 Fiber Optics (FO) Research  Goal: Develop new fiber optic interrogating method to reduce system cost  Use FO’s to measure flap and edge bending, as well as twist  Relies on using tunable filter and superluminescent diode - Eliminates costly interferometer  Temperature compensated  Currently under development  Partnership with UCDavis

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 19 Future Work  Offshore  SeaCon – Seabased Concepts  O&M  Smarter blades  Embedded sensor networks  Advanced Controls  Materials for Offshore Applications

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 20 Summary  Efforts underway to reduce blade weight growth for larger blades  Active control may prove beneficial for future blade designs  Coupon testing and sub-scale blades show advantages of carbon hybrid materials  New airfoils enable structural and manufacturing improvements in blade designs  3 Sets of sub-scale blades have been manufactured – demonstrate improvements  Static testing complete – all blades met or exceeded design goals  Fatigue and field testing scheduled

March 1, 2006 EWEC Innovative Turbines, Components, Systems and TechniquesPage 21 Questions ???