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8/13/2019 Integration & Actuation Presentation
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Integration Team
ME 580Smart Wind Turbine BladesIntegration Team
Palmer, Milliren, Lucon, Ehresman
ME 580 - Smart Structures
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ME 580Smart Wind Turbine BladesIntegration Team
Background Peter
Sensing Eric~Nate
Actuation Jon Data Acquisition Jon
Manufacturing and Testing Jon
Recommendations Jon~Eric~Nate
Outline:
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ME 580Smart Wind Turbine BladesIntegration Team
Background Wind Power
1926 Betz Limit (~59%)
Wind Velocity Blade Length
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ME 580Smart Wind Turbine BladesIntegration Team
Background Current Sensors
Ground Support
Power GenerationHousing
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ME 580Smart Wind Turbine BladesIntegration Team
Background Current Issues
Tower Strikes
Reliability ofComponents
limited actual data of the
wind loading for design
Design andManufacturing
http://www.windpower.org/en/tour/wtrb/powtrain.htm
http://www.windpower.org/en/tour/wtrb/powtrain.htmhttp://www.windpower.org/en/tour/wtrb/powtrain.htm8/13/2019 Integration & Actuation Presentation
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ME 580Smart Wind Turbine BladesIntegration Team
Background Need
Smart Structure Sensors
Control
Actuators
Blade Health Monitoring
Reliability Wind Loading Profile
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ME 580Smart Wind Turbine BladesIntegration Team
SensingFailure Modes
De-lamination of the
composite Base
Webs
Blade tip
Buckling of the blade Near the base
Tower strikes
Tip damage
Damaged blade due to tower strike
Buckling of the turbine blade in a laboratory Test.
De-lamination of the blades web
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SensingAreas of Interest
Base of the turbine blade
- High strain regions
- Potential buckles
Length of the blade
- Vibration detection
Actuation area
- stress concentrations
- un-known forces
Tip deflection of 5 kW wind turbine blade designed for
personal wind turbines
Tip deflection of a circular beam given the approximate diameterand load of a 9m wind turbine blade.
ME 580Smart Wind Turbine BladesIntegration Team
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SensingMajor Steps
Lay-up all necessary
components of
assembly Re-enforce mounting
points for actuator
and wiring harnesses
Apply sensors,
actuator components,a wiring harness
Assemble all
components
Test and calibrate
Construction of one halve of a turbine
blade using the SCRIMP process
Separation of the top and bottom halves of
the turbine blade
One skin in the mold using Veneer Lay-up
ME 580Smart Wind Turbine BladesIntegration Team
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Retro Fit Actuator Concerns
Limited placement options On outside surface without massive destruction and
rebuilding
Aerodynamics will need to be maintained
Balance must be maintained Heavy actuators and systems will need to be balanced
Outside of wing mounting causes concerns for
running wire or Pneumatic tubing
ME 580Smart Wind Turbine BladesIntegration Team
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Retro Fit Integration issues Adhesives
How do they affect the material?
Reliability, Robustness
Drilling holes for bolts Weakens structure?
Stress concentrations
Hard to use nuts and bolts on a very large blade
Taps or tap inserts
Pop Rivets
Hard mounting required for Large actuators Brackets
Plates
Other hardware
ME 580Smart Wind Turbine BladesIntegration Team
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Actuation The false wallcompressed air is a verysimple form for providinga means for boundary
layer separation. The means for this type
of actuation were veryeasy to manufacture.
The tube containing the
perforations andnecessary tubes can beseen in the right of thisphoto.
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Actuation The control surface ispresently powered by anelectric linear actuatingmotor.
This is attached to thecontrol surface with ahinge connection
This particular motor isfast acing enough to
accommodate the needfor deployment timeunder 500 mS from timeof sensing
ME 580Smart Wind Turbine BladesIntegration Team
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Manufacturing for Testing I am heading up the linearactuator and wing integration.
Integration into a flat plate for
testing.
Integration into a wing for
Computational fluid dynamicsand wind tunnel testing at U.C.
Davis.
The blades we are focusing on are
9 meters
These blades are the onesthat Sandia National labs uses
for their research.
They are for a 65 kW turbine
ME 580Smart Wind Turbine BladesIntegration Team
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Flat plate for simple CFD
Pictured are the
Linear actuator
Mechanism for actuator
transfer
LVDT position sensor
Control surface
False wall air pressure
tube
Solid state relays
fuse for relays
ME 500Smart Wind Turbine BladesIntegration Team
Manufacturing for Testing
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Manufacturing for Testing Presently the blade we have towork with is one for a 50 kW
turbine
This blade was sectioned out and
the linear actuator and control
surface were mounted inside. The purpose of this control
surface is to break up the
boundary layer during a gust
loading condition.
Quick actuation (under 500 mS) isone component of success.
Placement of control surface for
different loading conditions is
desired
Variable location on blade
Variable height of control surface
ME 500Smart Wind Turbine BladesIntegration Team
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ME 580Smart Wind Turbine BladesIntegration Team
Data Acquisition The interrogators that
we would use for
testing would probablybe the Wx interrogator
from Smart Fibres.
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Data Acquisition The DAQ system we
would use for the
industrial application
for this scheme would
be the W5 FBG
interrogator also from
Smart Fibres
ME 580Smart Wind Turbine BladesIntegration Team
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ME 580Smart Wind Turbine BladesIntegration Team
Recommendations Specific Hardware
Data Acquisition Testing
Wx Series Interrogators
Industrial Use
W5 Series Interrogators
Sensing Fiber Bragg Grating
Actuation Linear Pneumatic and
Electric
Air Jetting
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References Mark Rumsey, Wind Turbine Technology, 11/28/07
http://www.coe.montana.edu/me/faculty/jenkins/Smart%20Structures/default.html
Burton, Tony; Sharpe, David; Jenkins, Nick; Bossanyi, Ervin
Wind Energy Handbook. John Wiley & Sons. Online version available at:
http://www.knovel.com/knovel2/Toc.jsp?BookID=1057&VerticalID=0 Derek Berry, Wind Turbine Blades Manufacturing Improvements and Issues, 2/24/2004,
http://www.sandia.gov/wind/2004BladeWorkshopPDFs/DerekBerry.pdf
Sundaresen, Schulz, Ghoshal, Structural Health Monitoring Static Test of a Wind Turbine Blade,
8/1999, http://www.osti.gov/bridge
FEA Test of a 5kW Turbine Blade, 12/8/07
http://images.google.com/imgres?imgurl=http://www.aerogenesis.com.au/images/5kW_finite_elem
ents_600x345.gif&imgrefurl=http://www.aerogenesis.com.au/5kW_turbine.php&h=345&w=600&sz=28&hl=en&start=1&um=1&tbnid=ZC9AADL2DQ4a1M:&tbnh=78&tbnw=135&prev=/images%3Fq
%3DFEA%2Btesting%2Bof%2Bwind%2Bturbine%2Bblades%26ndsp%3D20%26svnum%3D10%
26um%3D1%26hl%3Den%26sa%3DN
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No Question, Chuck says so