Integration & Actuation Presentation

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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Background Peter

Sensing Eric~Nate

Actuation Jon Data Acquisition Jon

Manufacturing and Testing Jon

Recommendations Jon~Eric~Nate

Outline:


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Background Wind Power

1926 Betz Limit (~59%)

Wind Velocity Blade Length


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Background Current Sensors

Ground Support

Power GenerationHousing


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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.htm


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Background Need

Smart Structure Sensors

Control

Actuators

Blade Health Monitoring

Reliability Wind Loading Profile


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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.



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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



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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



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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



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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



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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



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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


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



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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



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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

Integration & Actuation Presentation

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