rapid questions – rapid prototyping – rapid answers: 3d...
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Maciej Karczewski, Michal Kulak, Damian KadrowskiMichal Lipian, Filip Grapow, Malgorzata Stepien, Katarzyna Telega, Dominika Raszewska, Piotr Baszczynski, Jeremiasz Czarnecki, Rafal Skalski, Pawel Rogowski, Lukasz Pokrzywka,
Marcin Miller, Karol Zawadzki
Bloomington, MN, USA, 04/10/2018
Rapid questions – rapid prototyping – rapid answers: 3d printing in small wind turbine tests
Our people behind the success
3d printing in lab scale…
Question: How to conduct load tests for a 3d printed wind turbine blade?
Prototype:Small scale prototype 1:6 scale – bench and force platform
Answer:…. It’s coming!
Blade testing standard BS EN 61400-23:2014
Mass/COG of the blade
Static load test
Fatigue load test
X
Y
Z
Test procedure
Natural frequencies of the blade
Static test – design load caseCharacteristics of a wind turbine stage
@ 18 m/s wind speed
Rotational speed range 300 rpm to 7100 rpm
Increment of 200 rpm between each test
5
Characteristics of a wind turbine stage
0
10
20
30
40
50
60
70
80
0 2000 4000 6000 8000
Pow
er (
W)
Rotational speed (rpm)
Maximum load at 3900 rpm @ wind speed of 18 m/s
1st flapwise at 4980 rpm
Static test – design load case
Characteristics of a wind turbine stage
Maximum load at 3900 rpm @ wind speed of 18 m/s
1st flapwise at 4980 rpm
0.0
0.5
1.0
1.5
2.0
2.5
3.0
0 0.025 0.05 0.075 0.1 0.125 0.15 0.175
Shea
r fo
rce
(N)
Radial distance (m)
Shear force distributions F=f(r/R) @3900 rpm
Shear Z (N)Shear X (N)
-0.2
-0.1
0.0
0.1
0.2
0.3
0 0.025 0.05 0.075 0.1 0.125 0.15 0.175
Mo
men
t (N
.m)
Radial distance (m)
Moment distributions M=f(r/R) @3900 rpm
Mx (Nm)
Mz (Nm)
My (Nm)
Static test – design load case
0
10
20
30
40
50
60
70
80
0 2000 4000 6000 8000
Pow
er (
W)
Rotational speed (rpm)
8
Ø0,4 mm nylon strings
3D printed blade
Holder
1st stage beams
2nd stage beamWhiffle-tree design
Static test – design load case
Turnbuckle
Ø0,4 mm nylon strings
3D printed blade
Holder
1st stage beams
2nd stage beamWhiffle-tree design
Turnbuckle:to level the beam
Static test – design load case
Turnbuckle
Ø0,4 mm nylon strings
Counter-weights
3D printed blade
Holder
1st stage beams
2nd stage beamWhiffle-tree design
Turnbuckle:to level the beam
Counter-weight: to balance the beam
Static test – design load case
Whiffle-tree design
Turnbuckle:to level the beam
3d printing turnbuckle bolts and frame Static test – design load case
Whiffle-tree design
Turnbuckle:to level the beam
3d printing turnbuckle bolts and frame
Design with channels and holders for 3d printing
Easy: rope slides into the channel
Secure: pin is locked between the holders
Fast: pin is knotted to the rope before assembly
Static test – design load case
Counter-weight: to balance the beam
Blade testing
Mass (g) Primary load (N)
78 0,765
206 2,02
362 3,55
791 7,76
1040 10,2
1130 11,1
1240 12,2
1370 13,4
1490 14,7
1540 15,1
1620 15,9
1830 17,9
2030 19,9
2170 21,3
3430 33,6
Design load case
Nylon string was torn apart
… while 3d printed blade returned to its original shape!
Static test – design load case
Test results (deflection)
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
0 500 1000 1500 2000 2500
Bla
de
def
lect
ion
(cm
)
Primary mass (g)
Deflection
Tip
Saddle 4
Saddle 3
Saddle 2
Static test – design load case
Test results (deflection)
Static test –design load case
y = 1870x
0
2
4
6
8
10
12
0 0.002 0.004 0.006
Stre
ss (
Mp
a)
deflection (m)
Stress – deflection @ Saddle 2
y = 904x
0
5
10
15
20
0 0.005 0.01 0.015 0.02
Stre
ss (
Mp
a)
deflection (m)
Stress – deflection@ Saddle 3
Test results (Young modulus)
y = -7,4226x + 2,2341R² = 0,90
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
0 0.05 0.1 0.15 0.2E
(Gp
a)Radial distance (m)
Young modulus evolutionRadial distance (m)
0,11 0,14 0,16
Pri
mar
yLo
ad(N
)
10,2 1,34 1,02 0,99
11,1 1,48 0,94 0,88
12,2 1,34 1,11 1,10
13,4 1,43 1,04 1,00
14,7 1,32 1,10 1,09
15,1 1,45 1,07 1,03
15,9 1,40 1,15 1,14
17,9 1,35 1,23 1,25
19,9 1,67 1,18 1,13
21,3 1,69 1,33 1,30
Average (GPa) 1,45 1,12 1,09
E=1,95 GPa – Young modulus of ABS according to Zortrax
Static test –design load case
Nowadays…
Rapid question: How much does a winglet increase power output of a small wind turbine?
Rapid prototype:Small scale prototype 1:6 scale – wind tunnel
Rapid answer:By about 2-3%
3d printing for lab test…
Rotor
Bearing unit Torquemeter Generator
3d printed rotor, torquemeterand generator housings
0
0.2
0.4
0 2 4 6 8 10
Cp
TSR
Cp vs TSREXP WT IMP12.5 m/s
Qblade BEM12.5 m/s
Yd the perpendicular distance to the neutral axis
Open field test to quantify real data
0
20
40
60
80
100
120
0 2 4 6 8
Pow
er [
W]
Wind speed [m/s]
Cpavg = 0.65, AF=99% OPEN FIELD TEST
Cpavg = 0.75, AF=100% 3D CFD
TSRavg = 6.76, Vavg=3.1 m/s
TSRavg = 6.00, Vavg=5.0 m/s
Concept
Verification
Empirical model
Empirical test
Product
No
Yes
Design Exploration
No
Yes
ValidationWT
correction
Yes
No
Aerodynamic
numerical model
Verification
Aeroelastic
numerical model
ISO/IEC
standard
WT correction
ISO/IEC
standard
Algorithm for the innovative product development in the field of aerodynamics using multiple levels of numerical-experimental research integration
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