Fabrication and Performance of Segmented Thermoplastic Composite Wind Turbine Blades
Large-scale wind turbine blades exceed 50 m in length, and they are currently fashioned as single pieces. Along with the significant challenge of fabricating these blades, there is also an issue of transporting them to field sites, which can account for a substantial portion of the installation cost...
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| Published in | International Journal of Precision Engineering and Manufacturing-Green Technology, 5(2) Vol. 5; no. 2; pp. 271 - 277 |
|---|---|
| Main Authors | , , |
| Format | Journal Article |
| Language | English |
| Published |
Seoul
Korean Society for Precision Engineering
01.04.2018
Springer Nature B.V 한국정밀공학회 |
| Subjects | |
| Online Access | Get full text |
| ISSN | 2288-6206 2198-0810 |
| DOI | 10.1007/s40684-018-0028-3 |
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| Abstract | Large-scale wind turbine blades exceed 50 m in length, and they are currently fashioned as single pieces. Along with the significant challenge of fabricating these blades, there is also an issue of transporting them to field sites, which can account for a substantial portion of the installation cost. Further, typical blades are produced from thermoset composite materials, which cannot be reused at the end of the turbine lifetime. Therefore, a new manufacturing process is developed, forming the blades in smaller segments that can be joined after transportation to the field. The process uses vacuum-assisted thermoforming of thermoplastic composites, which can be recycled after use. Six turbine blades were fabricated from two separate segments composed of two elements each, and they were joined using fusion welding and adhesives. A set of three blades was tested at a small-scale wind farm, producing power outputs on the order of 20 W at low wind speeds, comparable to an existing commercial turbine. |
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| AbstractList | Large-scale wind turbine blades exceed 50 m in length, and they are currently fashioned as single pieces. Along with the significant challenge of fabricating these blades, there is also an issue of transporting them to field sites, which can account for a substantial portion of the installation cost. Further, typical blades are produced from thermoset composite materials, which cannot be reused at the end of the turbine lifetime. Therefore, a new manufacturing process is developed, forming the blades in smaller segments that can be joined after transportation to the field. The process uses vacuum-assisted thermoforming of thermoplastic composites, which can be recycled after use. Six turbine blades were fabricated from two separate segments composed of two elements each, and they were joined using fusion welding and adhesives. A set of three blades was tested at a small-scale wind farm, producing power outputs on the order of 20 W at low wind speeds, comparable to an existing commercial turbine. KCI Citation Count: 5 Large-scale wind turbine blades exceed 50 m in length, and they are currently fashioned as single pieces. Along with the significant challenge of fabricating these blades, there is also an issue of transporting them to field sites, which can account for a substantial portion of the installation cost. Further, typical blades are produced from thermoset composite materials, which cannot be reused at the end of the turbine lifetime. Therefore, a new manufacturing process is developed, forming the blades in smaller segments that can be joined after transportation to the field. The process uses vacuum-assisted thermoforming of thermoplastic composites, which can be recycled after use. Six turbine blades were fabricated from two separate segments composed of two elements each, and they were joined using fusion welding and adhesives. A set of three blades was tested at a small-scale wind farm, producing power outputs on the order of 20 W at low wind speeds, comparable to an existing commercial turbine. |
| Author | Kim, Dave Solovitz, Stephen A. Garate, Juan |
| Author_xml | – sequence: 1 givenname: Juan surname: Garate fullname: Garate, Juan organization: Vestas Argentina S.A – sequence: 2 givenname: Stephen A. surname: Solovitz fullname: Solovitz, Stephen A. organization: School of Engineering and Computer Science, Washington State University – sequence: 3 givenname: Dave surname: Kim fullname: Kim, Dave email: kimd@wsu.edu organization: School of Engineering and Computer Science, Washington State University |
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| Cites_doi | 10.1080/15376494.2013.834090 10.1146/annurev.matsci.35.100303.110641 10.1016/S1755-0084(09)70045-6 10.1007/s40684-015-0029-4 10.1007/s12541-016-0081-1 10.1007/s40684-014-0042-z 10.1007/s40684-014-0021-4 10.1146/annurev.fl.25.010193.000555 10.1007/s40684-016-0008-4 10.1115/1.1629750 10.1016/1359-835X(95)00048-7 10.1002/we.90 10.2172/785133 10.1007/s40684-016-0042-2 |
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| References | SungC.-M.HanM.-C.Design and Performance Evaluation of Hinge Type Pitch Control System in Small-Size Wind TurbineInt. J. Precis. Eng. Manuf.-Green Tech.20163433534110.1007/s40684-016-0042-2 MelinT.Parametric Airfoil Catalog, Part II: Göttingen 673 to YS930: An Aerodynamic and Geometric Comparison Between Parametrized and Point Cloud Airfoils2013 ParkY.-J.KimJ.-G.LeeG.-H.KimY.-J.OhJ.-Y.Effects of Bearing Characteristics on Load Distribution and Sharing of Pitch Reducer for Wind TurbineInt. J. Precis. Eng. Manuf.-Green Tech.201631556510.1007/s40684-016-0008-4 ParksL. G.DawsonH.Wind Turbine Manufacturing in the U.S.: Developments and Considerations2012New YorkNova Science KimH.KimK.PaekI.Power Regulation of Upstream Wind Turbines for Power Increase in a Wind FarmInt. J. Precis. Eng. Manuf.201617566567010.1007/s12541-016-0081-1 SmithK.WindPACT Turbine Design Scaling Studies Technical Area 2 -Turbine, Rotor, and Blade Logistics200110.2172/785133 LarsenK.Recycling WindRenewable Energy Focus200997707310.1016/S1755-0084(09)70045-6 HansenA. C.ButterfieldC. P.Aerodynamics of Horizontal-Axis Wind TurbinesAnnual Review of Fluid Mechanics19932511514910.1146/annurev.fl.25.010193.000555 PrabhakaranR. T. D.Are Reactive Thermoplastic Polymers Suitable for Future Wind Turbine Composite Materials BladesMechanics of Advanced Materials and Structures201421321322110.1080/15376494.2013.834090 BullisK.The Quest for the Monster Wind Turbine Blade2018 BrondstedP.LilholtH.LystrupA.Composite Materials for Wind Power Turbine BladesAnnual Review of Materials Research20053550553810.1146/annurev.matsci.35.100303.110641 Da RosaA. V.Fundamentals of Renewable Energy Processes2013 BhandariB.PoudelS. R.LeeK. T.AhnS. H.Mathematical Modeling of Hybrid Renewable Energy System: A Review on Small Hydro-Solar-Wind Power GenerationInt. J. Precis. Eng. Manuf.-Green Tech.20141215717310.1007/s40684-014-0021-4 VeersP. S.AshwillT. D.SutherlandH. J.LairdD. L.LobitzD. W.Trends in the Design, Manufacture and Evaluation of Wind Turbine BladesWind Energy20036324525910.1002/we.90 TanglerJ. L.The Evolution of Rotor and Blade Design2000 DrelaM.XFOIL: An Analysis and Design System for Low Reynolds Number Airfoils1989 CotrellJ.MusialW.HughesS.Necessity and Requirements of a Collaborative Effort to Develop a Large Wind Turbine Blade Test Facility in North AmericaNational Renewable Energy Laboratory2006 GriffinD. A.AshwillT. D.Alternative Composite Materials for Megawatt-Scale Wind Turbine Blades: Design Considerations and Recommended TestingJournal of Solar Energy Engineering-Transactions of the ASME2003125451552110.1115/1.1629750 AbediniaO.AmjadyN.Short-Term Wind Power Prediction Based on Hybrid Neural Network and Chaotic Shark Smell OptimizationInt. J. Precis. Eng. Manuf.-Green Tech.20152324525410.1007/s40684-015-0029-4 GrandJ. A.Wind Power Blades Energize Composites ManufacturingPlastics Technology200854106877 HodgeB. K.Alternative Energy Systems and Applications2009 KimJ.-W.LeeD.-G.Study on the Fiber Orientation during Compression Molding of Reinforced Thermoplastic CompositesInt. J. Precis. Eng. Manuf.-Green Tech.20141433533910.1007/s40684-014-0042-z U.S. Energy Information Administration, “International Energy Statistics,” www.eia.gov (Accessed 16 MAR 2018) OffringaA. R.Thermoplastic Composites -Rapid Processing ApplicationsComposites Part A-Applied Science and Manufacturing199627432933610.1016/1359-835X(95)00048-7 Wind Power Monthly, “The Ten Biggest Turbines in the World,” https://www.windpowermonthly.com/10-biggest-turbines (Accessed 16 MAR 2018) Sunforce Products, “600 Watt Marine Turbine,” User’s Manual, 2011. K. Larsen (28_CR13) 2009; 9 B. Bhandari (28_CR10) 2014; 1 H. Kim (28_CR3) 2016; 17 Y.-J. Park (28_CR4) 2016; 3 28_CR19 B. K. Hodge (28_CR26) 2009 A. V. Rosa Da (28_CR24) 2013 C.-M. Sung (28_CR5) 2016; 3 A. R. Offringa (28_CR16) 1996; 27 A. C. Hansen (28_CR20) 1993; 25 J. A. Grand (28_CR18) 2008; 54 O. Abedinia (28_CR2) 2015; 2 J. Cotrell (28_CR7) 2006 L. G. Parks (28_CR9) 2012 M. Drela (28_CR22) 1989 R. T. D. Prabhakaran (28_CR25) 2014; 21 T. Melin (28_CR23) 2013 J. L. Tangler (28_CR21) 2000 P. S. Veers (28_CR12) 2003; 6 P. Brondsted (28_CR8) 2005; 35 K. Smith (28_CR11) 2001 J.-W. Kim (28_CR14) 2014; 1 28_CR1 D. A. Griffin (28_CR17) 2003; 125 28_CR6 K. Bullis (28_CR15) 2018 |
| References_xml | – reference: Wind Power Monthly, “The Ten Biggest Turbines in the World,” https://www.windpowermonthly.com/10-biggest-turbines (Accessed 16 MAR 2018) – reference: BullisK.The Quest for the Monster Wind Turbine Blade2018 – reference: ParkY.-J.KimJ.-G.LeeG.-H.KimY.-J.OhJ.-Y.Effects of Bearing Characteristics on Load Distribution and Sharing of Pitch Reducer for Wind TurbineInt. J. Precis. Eng. Manuf.-Green Tech.201631556510.1007/s40684-016-0008-4 – reference: HodgeB. K.Alternative Energy Systems and Applications2009 – reference: BrondstedP.LilholtH.LystrupA.Composite Materials for Wind Power Turbine BladesAnnual Review of Materials Research20053550553810.1146/annurev.matsci.35.100303.110641 – reference: SungC.-M.HanM.-C.Design and Performance Evaluation of Hinge Type Pitch Control System in Small-Size Wind TurbineInt. J. Precis. Eng. Manuf.-Green Tech.20163433534110.1007/s40684-016-0042-2 – reference: VeersP. S.AshwillT. D.SutherlandH. J.LairdD. L.LobitzD. W.Trends in the Design, Manufacture and Evaluation of Wind Turbine BladesWind Energy20036324525910.1002/we.90 – reference: BhandariB.PoudelS. R.LeeK. T.AhnS. H.Mathematical Modeling of Hybrid Renewable Energy System: A Review on Small Hydro-Solar-Wind Power GenerationInt. J. Precis. Eng. Manuf.-Green Tech.20141215717310.1007/s40684-014-0021-4 – reference: KimH.KimK.PaekI.Power Regulation of Upstream Wind Turbines for Power Increase in a Wind FarmInt. J. Precis. Eng. Manuf.201617566567010.1007/s12541-016-0081-1 – reference: Da RosaA. V.Fundamentals of Renewable Energy Processes2013 – reference: ParksL. G.DawsonH.Wind Turbine Manufacturing in the U.S.: Developments and Considerations2012New YorkNova Science – reference: DrelaM.XFOIL: An Analysis and Design System for Low Reynolds Number Airfoils1989 – reference: KimJ.-W.LeeD.-G.Study on the Fiber Orientation during Compression Molding of Reinforced Thermoplastic CompositesInt. J. Precis. Eng. Manuf.-Green Tech.20141433533910.1007/s40684-014-0042-z – reference: Sunforce Products, “600 Watt Marine Turbine,” User’s Manual, 2011. – reference: MelinT.Parametric Airfoil Catalog, Part II: Göttingen 673 to YS930: An Aerodynamic and Geometric Comparison Between Parametrized and Point Cloud Airfoils2013 – reference: TanglerJ. L.The Evolution of Rotor and Blade Design2000 – reference: CotrellJ.MusialW.HughesS.Necessity and Requirements of a Collaborative Effort to Develop a Large Wind Turbine Blade Test Facility in North AmericaNational Renewable Energy Laboratory2006 – reference: AbediniaO.AmjadyN.Short-Term Wind Power Prediction Based on Hybrid Neural Network and Chaotic Shark Smell OptimizationInt. J. Precis. Eng. Manuf.-Green Tech.20152324525410.1007/s40684-015-0029-4 – reference: PrabhakaranR. T. D.Are Reactive Thermoplastic Polymers Suitable for Future Wind Turbine Composite Materials BladesMechanics of Advanced Materials and Structures201421321322110.1080/15376494.2013.834090 – reference: SmithK.WindPACT Turbine Design Scaling Studies Technical Area 2 -Turbine, Rotor, and Blade Logistics200110.2172/785133 – reference: U.S. Energy Information Administration, “International Energy Statistics,” www.eia.gov (Accessed 16 MAR 2018) – reference: GrandJ. A.Wind Power Blades Energize Composites ManufacturingPlastics Technology200854106877 – reference: GriffinD. A.AshwillT. D.Alternative Composite Materials for Megawatt-Scale Wind Turbine Blades: Design Considerations and Recommended TestingJournal of Solar Energy Engineering-Transactions of the ASME2003125451552110.1115/1.1629750 – reference: OffringaA. R.Thermoplastic Composites -Rapid Processing ApplicationsComposites Part A-Applied Science and Manufacturing199627432933610.1016/1359-835X(95)00048-7 – reference: HansenA. C.ButterfieldC. P.Aerodynamics of Horizontal-Axis Wind TurbinesAnnual Review of Fluid Mechanics19932511514910.1146/annurev.fl.25.010193.000555 – reference: LarsenK.Recycling WindRenewable Energy Focus200997707310.1016/S1755-0084(09)70045-6 – volume: 21 start-page: 213 issue: 3 year: 2014 ident: 28_CR25 publication-title: Mechanics of Advanced Materials and Structures doi: 10.1080/15376494.2013.834090 – ident: 28_CR19 – ident: 28_CR6 – volume: 35 start-page: 505 year: 2005 ident: 28_CR8 publication-title: Annual Review of Materials Research doi: 10.1146/annurev.matsci.35.100303.110641 – volume: 54 start-page: 68 issue: 10 year: 2008 ident: 28_CR18 publication-title: Plastics Technology – ident: 28_CR1 – volume: 9 start-page: 70 issue: 7 year: 2009 ident: 28_CR13 publication-title: Renewable Energy Focus doi: 10.1016/S1755-0084(09)70045-6 – volume: 2 start-page: 245 issue: 3 year: 2015 ident: 28_CR2 publication-title: Int. J. Precis. Eng. Manuf.-Green Tech. doi: 10.1007/s40684-015-0029-4 – volume: 17 start-page: 665 issue: 5 year: 2016 ident: 28_CR3 publication-title: Int. J. Precis. Eng. Manuf. doi: 10.1007/s12541-016-0081-1 – volume: 1 start-page: 335 issue: 4 year: 2014 ident: 28_CR14 publication-title: Int. J. Precis. Eng. Manuf.-Green Tech. doi: 10.1007/s40684-014-0042-z – volume: 1 start-page: 157 issue: 2 year: 2014 ident: 28_CR10 publication-title: Int. J. Precis. Eng. Manuf.-Green Tech. doi: 10.1007/s40684-014-0021-4 – volume-title: Wind Turbine Manufacturing in the U.S.: Developments and Considerations year: 2012 ident: 28_CR9 – volume-title: The Quest for the Monster Wind Turbine Blade year: 2018 ident: 28_CR15 – volume: 25 start-page: 115 year: 1993 ident: 28_CR20 publication-title: Annual Review of Fluid Mechanics doi: 10.1146/annurev.fl.25.010193.000555 – volume-title: Alternative Energy Systems and Applications year: 2009 ident: 28_CR26 – volume: 3 start-page: 55 issue: 1 year: 2016 ident: 28_CR4 publication-title: Int. J. Precis. Eng. Manuf.-Green Tech. doi: 10.1007/s40684-016-0008-4 – volume: 125 start-page: 515 issue: 4 year: 2003 ident: 28_CR17 publication-title: Journal of Solar Energy Engineering-Transactions of the ASME doi: 10.1115/1.1629750 – volume: 27 start-page: 329 issue: 4 year: 1996 ident: 28_CR16 publication-title: Composites Part A-Applied Science and Manufacturing doi: 10.1016/1359-835X(95)00048-7 – volume-title: Parametric Airfoil Catalog, Part II: Göttingen 673 to YS930: An Aerodynamic and Geometric Comparison Between Parametrized and Point Cloud Airfoils year: 2013 ident: 28_CR23 – volume-title: XFOIL: An Analysis and Design System for Low Reynolds Number Airfoils year: 1989 ident: 28_CR22 – volume: 6 start-page: 245 issue: 3 year: 2003 ident: 28_CR12 publication-title: Wind Energy doi: 10.1002/we.90 – volume-title: Fundamentals of Renewable Energy Processes year: 2013 ident: 28_CR24 – volume-title: National Renewable Energy Laboratory year: 2006 ident: 28_CR7 – volume-title: WindPACT Turbine Design Scaling Studies Technical Area 2 -Turbine, Rotor, and Blade Logistics year: 2001 ident: 28_CR11 doi: 10.2172/785133 – volume: 3 start-page: 335 issue: 4 year: 2016 ident: 28_CR5 publication-title: Int. J. Precis. Eng. Manuf.-Green Tech. doi: 10.1007/s40684-016-0042-2 – volume-title: The Evolution of Rotor and Blade Design year: 2000 ident: 28_CR21 |
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| SubjectTerms | Composite materials Energy Efficiency Engineering Fabrication Fusion welding Industrial and Production Engineering Installation costs Manufacturing industry Regular Paper Segments Sustainable Development Thermoforming Turbine blades Turbines Wind farms Wind power Wind speed Wind turbines 기계공학 |
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| Title | Fabrication and Performance of Segmented Thermoplastic Composite Wind Turbine Blades |
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