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Contents
1
Introduction ............................................................................................................. 7
1.1 The Global Energy Scenario ................................................................................. 7
1.2 Wind Energy Outlook 2012 .................................................................................. 8
1.3 Motivation and Aims of Research ...................................................................... 11
1.4 Methodology ..................................................................................................... 12
2.3 Ideal Horizontal Axis Wind Turbine with Wake Rotation [16] ........................... 16
2.3.1
2.8.1
2.8.2
2.8.3
3.4.1
3.4.2
3.4.3
Theory....................................................................................................... 44
4.2.2
Procedure ................................................................................................. 44
4.2.3
4.2.4
5.4.2
5.4.3
5.4.4
5.4.5
5.4.6
5.4.7
5.6.2
Meshing .................................................................................................... 59
5.6.3
5.6.4
5.7.2
5.7.3
5.7.4
Conclusions ..................................................................................................... 69
5.11
Recommendations .......................................................................................... 70
REFERENCES ........................................................................................................... 71
Appendix ................................................................................................................ 73
7.1 Aerodynamic calculations in Matlab code: ........................................................ 73
Figure 30: height of the inside box section curve fitted against length of the beam ..... 46
Figure 31: width of the outside box section curve fitted against length of the beam ... 47
Figure 32: width of the inside box section curve fitted against length of the beam ...... 47
Figure 33: Moment of inertia of the box section interpolated with an exponential
function .......................................................................................................................... 49
Figure 34: Graph of IzzVs x for Case2 ........................................................................... 50
Figure 35: Airfoil cross section ( Sketch drawn on Abaqus 6.10).................................... 54
Figure 36: Loadings induced in cross section of airfoil [21]............................................ 55
Figure 37: Figure showing difference between balanced and unbalanced layup sequence
....................................................................................................................................... 57
Figure 38: Room temperature ultimate tension strength for high strength graphite epoxy
laminates ........................................................................................................................ 57
Figure 39: Room temperature ultimate shear strength for high strength graphite epoxy
laminates ........................................................................................................................ 58
Figure 40: Pressure Loads on Various Cross-Sections of the Blade ................................ 60
Figure 41: Drag Force on Various Cross-Sections of the Blade....................................... 62
Figure 42: Maximum deflections in the blade ................................................................ 63
Figure 43: Flap-wise deflections of the blade................................................................. 64
Figure 44: Span-wise deflections of the blade ............................................................... 64
Figure 45: Von misses stress distribution for the blade, viewing from the low pressure
surface ............................................................................................................................ 65
Figure 46: Maximum principal stresses in the blade ...................................................... 66
Figure 47: Cutaway section of the blade viewing from the blade root end ................... 67
Figure 48: Maximum principal strains distribution within the blade ............................. 67
Figure 49: Cut-away section viewed from the root end showing Maximum in plane
Principal stresses ............................................................................................................ 68
Figure 50: Tip Deflections and various Mesh Sizes......................................................... 69
1 Introduction
1.1 The Global Energy Scenario
Secure, reliable and abundant energy reserves are vital to the economic stability of the
world. Industrialization of countries like China, India and Brazil has increased the
consumption of energy reserves like petrol and coal. The worlds primary energy needs
are projected to grow by 56% between 2005 and 2030, by an average annual rate of 1.8%
per year [1]. Moreover, worlds energy supply and demand is subjected to many
uncertainties due to insufficient energy supplies, global politics, technological advances,
government policies, and customers behavior. Fluctuation of crude oil prices and global
warming has forced various countries to find energy solutions in terms of abundant and
non-depleting energy supplies.
Alternative or renewable energy is one of the solutions to ensure energy security in
world. Basic idea of renewable energy is to harness energy from the non-depleting
energy reserves like wind, water, solar, geo-thermal and bio-mass. Today the world is
investing in this sector to ensure a stable and prosperous economic growth. Total
investment of world in clean energy reached $211 billion in 2010, up from $160 billion
in 2009. Top countries to invest were Germany, the United States, Brazil and Italy [2].
Third world countries like India is investing $2.6 billion in wind energy sector [3]. By the
end of 2015, China will complete total offshore wind installed capacity of 5GW, and will
complete about 30 GW before the end of 2020 [4].
Being a third world country Pakistan needs to develop its clean energy sector, which has
remained quite underdeveloped in recent years due to lack of funding and poor
government policies. Pakistan is the 31st largest emitter of carbon-dioxide in the world
with annual carbon-dioxide emissions totaling up to 163,178 thousand of metric tons
(2008)[5]. Pakistan's energy requirement is increasing manifold every year. The primary
energy consumption in Pakistan grew by almost 80% in the past 15 years from 34 million
tons oil equivalent (TOE) in 1994-95 to 61 million TOE in 2009-10.[6]
The countrys energy supplies is extracted primarily from local natural gas which is 45%
of the energy mix and oil imports at 35% of the energy mix, hydel at 12%, coal at 6% and
nuclear at 2% of the mix respectively. So current investment of Pakistan is clean energy
sector is quite less which needs to be increased manifold in coming years. [7]
7
Europe: Wind energy will play an integral role in meeting the future energy requirements
of Europe. So wind energy in on the forefront of European Union (EU) energy policy The
modeling scenario used for the Second Strategic Energy Review suggests that wind will
represent more than one third of all electricity production from renewable energy
sources by 2020 and almost 40% by 2030, representing an accumulated investment of
at least 200-300 billion Euros (or about a quarter of all power plant investments) by 2030
[12].
Australia: Australian government is subsidizing wind energy market at large scale. It is
expected that wind energy will provide the largest share of Australias targeted 20%
renewable energy by 2020.
Middle East: Wind energy market hasnt shown robust growth in Middle East due to
abundance of oil and other fossil fuel reserves. Vestas has installed 600 megawatts (MW)
of wind farms from Morocco to the Arabian Peninsula. Abu Dhabi's clean energy
company, is considering building a US$200 million (Dh734.6m) wind farm near the Saudi
Arabian border that would be the first of its kind in the region .This plant will have a
generating capacity of 20-30MW. Figure 2 shows a landscape of this wind farm [13].
Asia: New wind energy road map of china foresees wind power capacity reaching
200 GW by 2020, 400 GW by 2030 and 1 000 GW by 2050. [14]. Figure 3 shows one of
the wind farm located in remote area of Xinxiang province. Moreover 3rd largest
economy of Asia ie. India has an installed capacity of 14158.00 MW (as on March 31,
2011). In terms of wind power installed capacity, India is ranked 5th in the World. Asias
largest wind farm of 207 MW is being built in central Thailand.
Pakistan: The wind map developed by National Renewable Energy Laboratory (NREL),
USA in collaboration with USAID, has indicated a potential of 346,000 MW in Pakistan.
The Gharo-Keti Bandar wind corridor spreading 60 KM along the coastline of Sind
Province and more than 170 km deep towards the land alone has a potential of
approximately 50,000 MW. By 2030 government plans to generate 5% of the energy
from alternate resources this proves Asia is on forefront of wind energy business. [15]
Figure 3: Turbines from Chinas largest wind farm dot a windswept plain in the remote northwest
Xinjiang
10
11
1.4 Methodology
Following is the flow chart which highlights the methodology to carry out this research:
First step to carry out aerodynamic loading calculations on each section of wind
turbine blade with the help of blade element and blade momentum theory.
Consequently drawing a CAD model of wind turbine blade on Abaqus 6.10 or
Solid Works 2012.
Then structural loadings will be estimated and structural analysis will be carried
out in Abaqus 6.10. In structural model, aerodynamic and structural loadings will
be used as input parameters.
A simplified analytical model of wind turbine blade will be formulated under
similar aerodynamic and structural loading conditions.
At the end FE structural and analytical model will be compared and validated.
12
13
Where:
U1 = Far up-stream wind velocity
U2 = Wind velocity just before the rotor
U3 = Wind velocity just after the rotor
U4 = Far down-stream wind velocity
Following assumptions were made,
Below is the list of the assumptions that have been made to simplify the actual wind
turbine model to the Actuator-Disk Model.
ii.
[( )]
( )
Where
= Density of Air
A = Area of actuator disk
T = Thrust force on the actuator disk
P = Power produced by the actuator disk
And
iii.
( )
The axial induction factor a is a measure of how much the wind slows down at the rotor.
Equation (ii) assumes that all the thrust force experienced by the actuator disk is
converted to useful power of the rotor. Ideally for the simplifications presented in this
analysis this would be the case, however aerodynamic phenomenon prevent this from
happening and as a result the aerodynamic performance of the rotor decreases.
However, this kind of simplified analysis can tell us of the limit of efficiency of the rotor.
The assumptions help us determine the efficiency limit of an ideal rotor in ideal wind
conditions. This limit is called Betz limit.
The Coefficient of Power CP is defined as the ratio of the rotor power to the maximum
power in the wind
iv.
The Coefficient of Thrust is defined as the ratio of the thrust force on the rotor to the
dynamic force of the wind
v.
15
The maximum value of CP = 0.59occurs at = 13. This means that an ideal rotor can
only be up to 59% efficient. For a> 12 , U4 becomes negative. This indicates the
occurrence of complicated flow patterns for which the Betz theory does not hold.
2.3 Ideal Horizontal Axis Wind Turbine with Wake Rotation [16]
This section builds on the previous section and extends the analysis to a 2-D analysis. The
added dimension in this analysis is along the length of the blade. Wake rotation is also
considered in this analysis. Wake rotation occurs due to the torque of the blade. As the air
particles hit the blade they bounce off at an angle in a direction opposite to the rotation
of the blade due to angular momentum of the air particles. As a result the wake that
leaves the blade has a higher kinetic energy than a non-rotating wake which reduces the
performance of the blade.
16
Figure 7: 2-D analysis of the actuator disk model which considers wake rotation [16]
r is the distance of the annulus under consideration from the center of the rotor
dr is the thickness of the annulus under consideration.
U is the free stream velocity
a is the axial induction factor.
The control volume remains the same but analysis in this section will be done on an
annulus which is at a distance r from the center of the rotor and has a thickness dr
Following assumptions were made,
Following is a list of simplifying assumptions which will be used for the analysis:
Two-Dimensional flow analysis
Homogenous, Incompressible, steady state fluid flow
An infinite number of blades
Uniform thrust over the disk area
A rotating wake is considered
Pressure at 1 is equal to pressure at 2 i.e. Pressure far up-stream and far down-stream
are equal
Wind Velocities at 2 and 3 are equal (in both, magnitude and direction)
17
= ( + )
Where the axial induction factor a, which is the measure of how much the wake rotates
behind the rotor, is defined as
vii.
^ = /
Where
is the rotational speed of the wake relative to the rotor
is the rotational speed of the rotor
The Tip Speed Ratio is defined as the tangential speed of the tip of the blade to the
speed of the free stream of air.
viii.
= /
The local speed ratio r is defined as the ratio of the tangential speed of any point on the
blade to the speed of the free stream of air
ix.
_( =) /
The equation for the differential torque on the annulus can be determined by applying
the equation for the conservation of angular momentum i.e. the moment of the blade is
equal to the change in angular momentum of the wake (written in terms of induction
factors).
x.
= ( )
The expression for CP in terms of the induction factors, local speed ratio and the tip speed
ratio comes out to be
xi.
= ( )
18
xii.
()()()
]
With the corresponding values of a substituted in the above equation for the start and
end of the blade (.i.e. r = 0 and r = , a = 0.25 and 1 = 0.33 respectively) and performing
the integration the expression is ready for some parametric studies.
Note: The values of CP that lie on the dotted or the solid line represent the maximum
value of CP which can be obtained for that particular tip speed ratio i.e. CP max values.
As expected, the faster the wind turbine rotates for a particular speed of the wind, the
more efficient it will be. This is because for a particular power of the wind turbine rotor,
a higher rotational speed obtained for a particular wind speed means a lower torque of
the blade and hence lower wake rotation.
19
Figure 9: Variation of Induction Factors along the length of the blade for a constant tip speed ratio [16]
As we move along the length of the blade, the angular induction factor decreases
because the force required in turning the blade decreases due to a longer moment
arm. This means that less torque has to be applied by the wind to rotate the blade and
hence less wake rotation.
Figure 10: Terminologies for airfoils based on their geometry. These terminologies help in recognizing
different kinds of Airfoils. [16]
20
The Lift and the Drag forces are shown on the geometrical center of the Airfoil in
Figure.11. However, in reality these forces act at the center of pressure of the airfoil.
When the point of application of these forces is changed from the center of pressure to
the center of gravity, a balancing moment needs to be applied so the static equilibrium
of the Airfoil is not disturbed. This balancing moment is called Pitching Moment and is
responsible for the chord-wise bending of the blade.
21
Figure 12: How directions are termed for a Horizontal Axis Wind Turbine (HAWT) and some more force
related terminology with respect to the plane of rotation of the wind turbine [16]
The Coefficient of Lift, Drag and Pitching Moment are defined as follows:
xiii.
xiv.
xv.
Where
22
It can be seen in Figure.14 that value of lift coefficient increases with an increase in the
value of the Reynolds number. This is due to formation of the turbulent boundary layer
which sticks better to the surface; less flow separation is experienced. A decrease in the
magnitude of the Drag force is seen because of the same reason.
23
Where
R = Length of the blade
r = Distance of the element from the center of the rotor
dr = Thickness of the element
24
Figure 16: Section of the rotor blade and the angles relating these forces to the direction of the
incident air. A cross-section of the rotor blade is in fact an airfoil with a certain depth dr. [16]
25
dFT (Tangential Force) is the useful force as it is responsible for the blade torque.
It too is a sum of the components of the Lift and Drag forces but in the direction
of the plane of rotation.
Urel (Relative Velocity of the Wind on the rotor) is the vector sum of the incident
velocity of air on the blade [U (1-a)] and the tangential velocity of the blade section
[r (1+a)]. Since the magnitude of the tangential velocity is different for every
section of the blade (different r) the magnitude and the direction of Urel will be
different for every section of the blade. It is the reason why a twist is required in
the blade i.e. subsequent blade elements are at a slight angle to each other so that
an optimum angle of attack can be maintained to get the maximum Lift force.
Urel is, in effect, the wind that appears to interact with blade as the rotor is
rotating. If the blade were stationary, the direction and magnitude of the Urel
would be the same as the incident velocity of the air.
p (Section Pitch Angle) is the angle between the chord line of the section under
consideration and the plane of rotation. p, o is the angle between the chord line
of the section of the blade at the blade tip (r = R) and the plane of rotation. The
difference in these two angles is because of the twist in the blade as mentioned
earlier. t is then a measure of the twist in the section under consideration.
Equations Derived from Figure.16 are as follow:
By using geometrical relationships and vector algebra the following equations can be
derived from Figure.16
xvi.
xvii.
xviii.
=
= +
= ( )
xix.
()
(+ )
(+ )
Re-writing the equations for the Lift and Drag forces for the element under
consideration:
xx.
26
xxi.
Substituting (xx) and (xxi) into (xvii) and calculating dFN for the same blade section for all
the blades by multiplying it with the number of blades B we get:
=
( + )
xxii.
xxiii.
=
( ) )
=
The value of Cp can be approximated as a little less than 0.59 and is the efficiency
combined efficiency of the gearbox and the generator.
Once the approximate length of the blade has been determined, a reasonable tip speed
ratio should be selected based on the application. For example; for power generation a
tip speed ratio of 4 to 10 should be selected [16]. After selecting the tip speed ratio the
desired number of blades for the turbine should be selected based on the tip speed ratio.
For example; if the tip speed ratio is greater than 4, three or less blades should be used
on the rotor.
The next step is to define the shape of the blade which requires the values of and the
chord length.
As explained in the beginning of this section an iterative approach needs to be used for
this part of the design.
Since the iterative procedure does not apply to a continuous domain of length of the
blade, the blade needs to be divided into different sections. The procedure need to be
repeated on each section of the blade to determine the values on those air-foil sections.
Generally around 12 to 20 sections are needed for an accurate design [16]. It is a good
idea to make smaller sections along the length of the blade closer to the root as these
are the sections that experience the most dramatic change of twist and chord length.
Once the sections of the blade have been decided the iterative procedure can be used.
Following flow chart explicitly shows the procedure:
28
Note:
Subscript i refers to the guess values of the parameters and j refers to the
iteration number.
Subscript 1 points out that the procedure is being carried out for the first
section of the blade.
be determined by = 2). The drag force in this case is taken to be zero which is a
reasonable estimate since most airfoils are made to have very low values of Cd. This
procedure is done to refine the value of a by evaluating it for the known design
parameters Cl,design and l,design.
The consequent value of a for a given value of a can be found by equation mentioned
in the third step of the flow chart. This equation is obtained for maximum value of Cp by
solving (Equation xi) and replacing with its definition in terms of the induction factors.
This value of a insures that maximum aerodynamic efficiency is obtained from the rotor.
This completes the process for obtaining the guess values for a and a.
The next procedure (starting from 4th box) is to refine the values of a and a. Firstly a
value for is obtained from the new values of a a and r for the section.
The new value of is used to calculate the tip loss factor and the coefficient of Thrust
force CT. This expression for CT is derived from the fact that the normal force and the
thrust force are the same for a HAWT so (Equation xvii) can be used in (Equation v) by
substituting an expression for the area of the rotor and expression for the lift and drag
forces. The drag force in this case is again taken to be zero.
The new values of a can then be found using Glauert empirical relation [16] for both
windmill state (CT<0.96) and turbulent wake state (CT>0.96). The discussion of how these
equations are derived is beyond the scope of this work.
When the values of pitch angular, angular induction factor and linear induction factor
are converged to a satisfactory level then the value of chord length is evaluated from the
following equation
=
= (
(
)
)[
)
(
) ]
Repeat the procedure if the power output turns out to be less than the expected.
30
Chord
Length
(m)
0.50
1.50
2.50
3.50
4.50
5.50
6.50
7.75
9.25
11.00
13.00
15.50
18.50
21.50
24.50
27.50
30.50
33.50
2.0000
3.4000
3.8933
4.1455
4.0939
3.9020
3.6574
3.3923
2.9933
2.6445
2.3190
1.9997
1.7097
1.4898
1.3184
1.1815
1.0313
0.5723
Pitch
Angle
(degree)
Tip
Speed
Ratio
Relative
Drag Force Fd
velocity(m/x) (N)
52.4602
418.9
255.2412
0.1000
10.0499
45.4658
1320.0
923.6587
0.3000
10.4403
42.2900
2260.0
1671.8327 0.5000
11.1803
36.6720
3220.0
2583.7816 0.7000
12.2066
32.0000
4200.0
3561.8031 0.9000
13.4536
28.1825
5160.0
4548.2714 1.1000
14.8661
25.0457
6130.0
5553.5996 1.3000
16.4012
21.8852
7340.0
6811.0259 1.5500
18.4459
18.9300
8800.0
8324.0583 1.8500
21.0297
16.3000
10500.0 10077.9563 2.2000
24.1661
14.0300
12400.0 12030.0953 2.6000
27.8568
11.9200
14800.0 14480.8674 3.1000
32.5730
10.1000
17700.0 17425.7068 3.7000
38.3275
8.7279
20600.0 20361.4547 4.3000
44.1475
7.6898
23400.0 23189.5650 4.9000
50.0100
6.8699
26100.0 25912.6106 5.5000
55.9017
6.0938
27500.0 27379.7501 6.1000
61.8142
4.3305
18000.0 17948.6115 6.7000
67.7422
Figure 18: Table for detailed results of iteration process
31
4.6278
8.4904
11.1494
14.1510
16.9762
19.7563
22.5398
26.4434
30.3280
35.3819
41.2276
48.6077
57.5396
66.5219
75.5416
84.5880
90.2791
60.1682
32
33
Thickness of upper skin , lower skin , spar caps , and the shear web is assumed to
be 7mm throughout the span of the blade
Wind loadings and other aerodynamic parameters have been determined from
the aerodynamic model ( as described in last chapter)
II.
III.
IV.
V.
Initially, 18 XY planes were created at different locations along the span of the
blade. Following table shows the name of blade (as specified in Abaqus model)
and its distance from origin.
18 airfoils of varying chord length were created on their respective planes (values
of chord lengths were taken from the aerodynamic module). Each airfoil was
drawn by plotting 100 points. Afterwards they were connecting by a spline
command.
Two shear webs were drawn at each cross section at 15% and 50 % of chord length
respectively.
Each cross section was rotated by Rotate sketch up tool in Abaqus 6.10. Rotations
are given according to blade pitch angle calculated previously in aerodynamic
model.
After wards each section is joined by Shell lofting feature in Abaqus 6.10
36
37
Load: Since Lift force is varying along the span of the blade so different Pressure loads
are applied on 18 different segments of the blade. Values of these loads are given in the
following table:
Surface
Name
Surf 1
0.151
Surf 2
0.36
Surf 3
0.528
Surf 4
0.737
Surf 5
0.99
Surf 6
1.29
Surf 7
1.3
Surf 8
1.4
Surf 9
1.69
Surf 10
2
Surf 11
2.19
Surf 12
2.5
Surf 13
3.9
Surf 14
4.65
Surf15
5.94
Surf 16
7.47
Surf17
9.016
Surf18
8.03
Figure 22: Pressure loads acting on surfaces of HAWT rotor blade
38
Elements used in meshing are S8R: An 8-node doubly curved thick shell, reduced
integration. These elements account for shear flexibility in laminated composites and
are suitable for thick shells.
Meshing:
Meshing has been carried out on seed size of 500 mm, assigned along the span of the
blade.
Note that the negative sign in this case shows the blade deflects downwards as the
pressure force is applied on the upper surface of the blade.
The next part of the post processing is highly important. The figure above shows only the
contours along the length of the blade. This is because the differences in the chord-wise
39
deflections are small compared to the flap-wise deflections. This deflection information
cannot be directly obtained from the diagram so another approach will have to be taken.
For an isotropic material model with uniform material thickness the stresses in the blade
can serve as a tool for predicting the critical areas of deflection. Since the material is
assumed to be show a linear relationship between the stress and strain, we can imply
that the areas with the highest stresses will directly cause the greatest deflections. The
following figure shows the Von misses stresses for the blade:
The first observation that can be made from the diagram is the stress concentrations
around the areas where the skin contacts the shear webs make contact with the skin.
The shear webs being the main load bearing members keep the skin from deforming.
The aerodynamic lift force which is the main load acting on the blade tends to compress
the shear webs. The shear webs also bear the loading which causes the flap-wise tip
deflections. This defines the goal for the composite design. The shear webs being the
main load bearing components of the blade should have the greatest strength and it will
experience compressive and shear loading.
The area near the root of the blade has higher stresses as compared to the areas away
from the root. Hence, the areas closer to the root should have higher strength.
The spar caps transmit the loads to the shear webs hence they need to be stronger than
the remaining skin of the blade.
40
The skin is the part which bears the least stresses and so it requires the least structural
performance. However, the skin should be strong enough to maintain an aerodynamic
shape and should not flutter due the turbulence of the wind.
A better idea of the stresses which are directly related to the flap-wise tip deflections
can be had from the S-22 stresses. The figure below shows the variation of the stresses.
The figure above shows almost the same trend as Figure.24. The stress concentrations
are again in the root sections and along the regions where the shear webs are connected.
One anomaly in the trend which is quite visible in Figure.25 occurs at z=6500mm where
the stresses are reasonably low at the point where the spar at 15% of the chord length
meets the skin. This is due to a geometric anomaly which occurs while creating the CAD
model of the blade. The spar at 15% chord length in the 7th section occurs at the 14 point
used to create the airfoil and in the 8th section the spar created joins the skin at the 15th
point and continues for the subsequent sections. This could very well be the reason for
the anomaly.
With the goals defined for the composite layup and the critical areas identified, the next
step in FEA would be to design the composite layup.
41
4 Analytical Modeling
4.1 Introduction
The objective of this section is to analytically model the behavior of the blade under the
lift force experienced by it. The limiting parameter for this study is the tip deflection of
the blade. The agreement of the results of this model with those of the FE model is of
significant importance as well.
Analytical formulation requires the actual solution of the governing equations in a
continuous domain; however, some discrete mathematics may be required to
approximate certain parameters for which the actual information is not available.
The purpose of this analytical model is not to serve as a substantial design aid for the
blade but to confirm, with a reasonable level of certainty, the accuracy of the FE model.
The analytical model can also be used as a first guess to study the behavior of the blade
to narrow down the design parameters in an acceptable range for FE modeling in the
case where parametric study is not an objective.
The results obtained from the analytical model may be inaccurate, to some extent, due
to the lack of complexity that can be incorporated in the model. The complexity,
however, is a subject to the requirement of the designer and the object of designing.
43
4.2.1 Theory
The basic equation for finding the tip deflection is derived from the expression for the
curvature of a cantilever beam:
2
= 2
Where
= Internal moment experienced by the beam as a force is applied on the beam
= Youngs Modulus
= Moment of Inertia about an axis transverse to length of the beam
In this case the internal moment and moment of inertia are both functions of x so the
equation can be written as:
2
() = () 2
Integrating the expression twice will yield the expression for the transverse deflection of
the beam at any point along the length of the beam.
This happens to be an initial value problem with the two conditions observed at the fixed
end of the beam such that:
(0 ) = 0
(0 ) = 0
4.2.2 Procedure
The construction of the analytical model consists of the following steps:
Construction of expression for the variation of internal moment along the length of the
beam
As only the aerodynamic loading is considered for this section, the significant internal
moment will be only be caused by the lift force on the blade. To obtain the equation for
the internal moment, the lift force experiences was plotted on 19 airfoil sections and
44
then curve fitted. The moment equation is obtained by integrating the force equation
and calculating the constant of integration on any of the 19 known points of the curve.
The equation obtained is:
= 31.036767 3 1337.985 2 + 214095 7.9 107
Construction of expression for the width and height of the section
The data for the width and height of the box section is taken from the existing CAD model
in ABAQUS for 19 airfoil sections which were interpolated using EES.
A box section will consist of two sets of equation for the distribution of height and two
sets of equations for the width owing to the thickness of the box section i.e.0 .007m. The
reason for doing so is that these equations will later be used to calculate the moment of
inertia which will be obtained from subtracting the moment of inertia of the inside box (
consisting of hollow space) from the outside box.
As mentioned previously, two cases for the distribution of the height and width have
been considered which are as follows
4.2.2.1
In this case the data from the 19 airfoil sections was interpolated using a 5th degree
polynomial.
The equations obtained are:
= 0.460302 + 0.27071 0.0455494 2 + 0.002785 3 0.000074 4
+ 7.2 107 5
= 0.449974 + 0.26965 0.0454459 2 + 0.002781 3 0.000074 4
+ 7.2 107 5
= 0.7005 + 0.4289 0.07410 2 + 4.6 103 3 1.24 104 4
+ 1.22 106 5
= 0.68555 + 0.4293 0.07416 + 4.6 103 3 1.24 104 4
+ 1.22 106 5
45
Following figures show the curve fit for the dimensions of the box:
Figure 29: height of the outside box section curve fitted against length of the beam
Figure 30: height of the inside box section curve fitted against length of the beam
46
Figure 31: width of the outside box section curve fitted against length of the beam
Figure 32: width of the inside box section curve fitted against length of the beam
47
4.2.2.2
While making the equations for the analytical model, it is important to realize the effects
and sensitivity of different parameters on the desired parameter.
The object of making equations of height and width of the box is to use them in the
expression for calculating the variation of the moment of inertia (Izz) of the box section
along the length of the beam, about a transverse axis z. While making the equations for
the width and height of the box section in terms of x, the following should be noted:
The height of the box section h is much more sensitive than the width w of the
box section in the expression for Izz.
An overestimation of Izz will result in less tip deflections of the beam and the
opposite is true as well.
An underestimation of Izz closer to the root will result in more deflections as
compared to the same level of underestimation closer to the tip region.
Underestimation in regions of high forces will result in more deflections.
4.2.3.1
The expression formed from the 5th degree polynomial interpolation of the parameters
gives a significant 20-degree polynomial expression for the moment of inertia which is
not mentioned here because it is not directly related to any actual calculations.
Since this expressions is a result of an interpolation it is not necessary that it will the
required number of real roots needed to make the expression. It is indeed the case the
expression does not have a root in the range that we are interested in i.e. 0-36 m. To
avoid imaginary roots the expression for Izz was interpolated using an exponential
function.
48
Figure below shows the graph for the actual expression obtained and the graph for the
interpolated exponential function overlapped.
Figure 33: Moment of inertia of the box section interpolated with an exponential function
It can be seen from the graph that there is an overestimation of results from 0 - 3m and
an underestimation from 3 - 12.5 m. The large moment of inertia at the root will result
in under estimation of tip deflections and over prediction of beam strength.
The equation of the exponential interpolation is shown below:
= 6.84261 103 .144501
4.2.3.2
As discussed above the equations for the width w and the height h of the box section
were determined by taking the average of the first four airfoil section dimensions and
using it for the initial section for the beam in the analytical model. The last section of the
beam corresponds to the dimensions of the last airfoil section.
49
The width and the height of the section were interpolated linearly which has its
advantages; Using a higher order might increase an R2 percentage for the particular
curve fit but it does not account for the sensitivity of the curve sections to errors. As
discussed earlier, errors in the values of parameters closer to the root section will
account for a larger error in obtaining the tip deflection of the beam. One should choose
the more conservative approach when such errors are plausible.
The second advantage for choosing a linear function to interpolate the parameters is
that a function close to a negative exponential function is obtained for the moment of
inertia which is favorable for interpolation.
The figure below shows the graph of Izz and its interpolation with exponential function.
Again, the choice of exponential function is obvious in this case as the function for Izz
does not have a root in the required range of values of x
50
The graph highlights one of the shortcomings of EES as a tool for interpolation. EES does
not provide the user with the option of specifying the starting point of interpolation. The
region closer to the root is in this case an over estimation but since the height and the
width were underestimated to begin with, this model would produce reasonable results.
The original equation for Izz is as follows:
1.02844 1077
2.70432 1063
5.0706 1045
1.41771 1026
2.11405 1012
+
6.7554 1029
6.4 1014
(0) = 0
(0 ) = 0
Izz and Mz are functions and E is a constant. The equation can be integrated twice to
obtain an expression an equation for y in terms of x, where y is a measure of tip
deflection of the beam.
The values of the constants of integration can be obtained by employing the boundary
conditions.
51
The final tedious equations for the tip deflection are not mentioned for both cases in this
report but they can be obtained from following the procedure and using an equation
solver. MATLAB was used for this purpose.
Material used in this case is steel (E=200x109)
The values of the tip deflection can be found out by using a value of 36 for x for both
the cases
The value of the tip deflection obtained for Case1 is 85.626cm
The value of tip deflection obtained for Case2 is 1.45m
The value of tip deflection obtained from the CAE model is 4.138m
4.3 Discussion
As it can be seen, the tip deflections from the analytical model are in agreement with
the CAE model. However the analytical model under predicts the tip deflections for the
blade. There are a number of reasons for this;
Firstly, analytical calculations which involve curve fitting and involvement of higher
power of those equations will have an amplifying effect on the errors. The calculation of
the moment of inertia is one of those quantities which are very sensitive to this kind of
error.
The over prediction of the moment of inertia in the root region is a source of the under
prediction of tip deflections as the area closer to the root decreases deflections a lot
more than the area near the tip of the blade with the same level of increase in stiffness.
The difference in the loadings for the analytical model and the CAE model also has an
effect on the tip deflections obtained. For the CAE model the aerodynamic forces are
applied as pressure forces while in the analytical model the aerodynamic forces are
assumed to be line forces. Abaqus takes different boundary conditions for the two
loadings applied. A more fair comparison with the analytical model would be to apply
the line force on the CAE model in Abaqus with the equation of the force defined but
since in Abaqus the mesh is made on an area for shells, concentrated forces produce
stress concentrations and produce results far from the actual when the area are big and
the mesh is fine.
52
The equation used to predict the deflections of the blade is actually an approximated
equation which originated from a Taylor series expansion. The differential terms have
been truncated so the equation can be integrated.
53
In above figure, spar caps and the shear webs is the main load bearing components. So
spar caps and the shear webs are always the regions with greater thickness as compared
to upper and lower skin. Spar caps are placed at 15% and 50% of the chord length from
the leading edge to give an appropriate stiffness values [20].
On a typical HAWT rotor blade, following are some forces acting on it,
Lift force
Drag Force
Gravity loadings
Centrifugal Forces
54
Following is the figure showing loadings induced in a typical cross sectional blade as a
result of above mentioned forces:
55
56
Figure 37: Figure showing difference between balanced and unbalanced layup sequence
Due to such layup coupling between in plane normal and shear behavior is removed.
Figure 38: Room temperature ultimate tension strength for high strength graphite epoxy laminates
57
Figure 39: Room temperature ultimate shear strength for high strength graphite epoxy laminates
58
5.6.2 Meshing
Meshing has been carried out on seed size of 500, 700 and 830 mm mesh sizes.
5.7 Loadings
5.7.1 Lift force
Lift force has been applied by the same procedure as described in previous chapter.
Following are the values of normal pressure forces:
Surface
Name
0.09706
0.253
0.391
0.59112
0.84
1.14
1.18
1.27
1.57
1.902
2.105
2.43
3.43
4.58
5.87
7.41
8.965
8.03
Surf 1
Surf 2
Surf 3
Surf 4
Surf 5
Surf 6
Surf 7
Surf 8
Surf 9
Surf 10
Surf 11
Surf 12
Surf 13
Surf 14
Surf15
Surf 16
Surf17
Surf18
Figure 40: Pressure Loads on Various Cross-Sections of the Blade
60
Cd = Coefficient of Drag
P = density of air assumed to be 1.1433 kg/m^3
U = Relative velocity of air
C = Chord length
Fd/l = Drag force per unit length
For chosen airfoil ie. NACA 64-618 coefficient of drag is 0.03 [24]. Values of relative
velocity are calculated in aerodynamic modal for every cross section of blade. On
average drag force has been applied after every 2 meters so value of length has assumed
to be 2000mm.
After calculating drag force, it has been decomposed in vertical component and
horizontal component. Following are the equation used,
=
=
Where is the angle of relative velocity.
Drag force has been applied in terms of concentrated force in Abaqus 6.10
61
Horizontal
Component
F dx
Vertical
Component
F dy
Drag1
4200
-5400
Drag2
8920
-9000
Drag3
12200
-11200
Drag4
17000
-12660
Drag5
21600
-13400
Drag6
26120
-13980
Drag7
30620
-14300
Drag8
36800
-14780
Drag9
43020
-14740
Drag10
50920
-14880
Drag11
59980
-14980
Drag12
71330.9
-15060
Drag13
84960
-15120
Drag14
98620
-15140
Drag15
125960
-15160
Drag16
134640
-14360
Drag17
90000
-6800
Drag18
78560
-5400
62
At this point it is important to note that the sections closer to the root have almost no
deflections while the sections closer to the root have larger deflections. However, this
result should not be misinterpreted, as the less deflections near the root are section a
result of the boundary condition applied. A better macroscopic observation at this point
would be the curvature of the blade. A uniform curvature shows that the different
sections of the blade have deflected uniformly if the deflections of the previous sections
are ignored.
The next result to be displayed is the flap-wise deflections of the blade. This is the limiting
factor in the elastic response of the blade. The flap-wise deflections should be less than
the length of the nacelle for the blade to avoid making contact with the supporting
tower. The figure below shows the distribution of the flap-wise deflections of the blade.
63
The maximum flap-wise deflections for the blade are 4.165m. This is well within the safe
range for the blade of a 1.2MW HAWT which is [25]. A negative sign shows the downward
deflection of the blade in the global y-axis as the aerodynamic lift force (which is
responsible for the deflection) has been applied on the low pressure-top surface of the
blade. This is a conservative approach as the area of the low pressure surface is less than
the high-pressure bottom surface of the blade.
Another important result to consider is the span-wise deflections of the blade to ensure
that the shape of the airfoil has not distorted due to the application of drag force on the
airfoil. The following figure shows the span-wise deflections of Blade in the edge-wise
direction.
64
It can be seen from the figure that the maximum deflections are of the order of 6.9cm
on the leading edge of the blade in the sections closer to the root which is reasonable
for a section with a minimum chord length of about 800cm. There are two trends that
can be seen in the above figure. The first trend is the increase in the span-wise
deflections from root to tip. This is because of the centrifugal forces applied to the blade.
As we move away from the root of the blade the magnitude of the centrifugal force
increases. Since the direction of the centrifugal forces is along the global-z direction
(along the length of the blade) the sections closer to the root region tend to be the most
affected by these forces. The 2nd trend to observe is the variation of the edge-wise
deflections. The trend is governed by the application of drag force which causes a
bending about the global x-axis (along the chord). Since the drag force is applied in the
x-direction, it generates a bending moment about the x-axis so the leading edge is under
tension and the trailing edge is under compression.
With all the deflections in reasonable range, the next step would be to study the stress
distribution within the blade.
The figure below shows the contour plot for the Von misses stresses in the blade:
Figure 45: Von misses stress distribution for the blade, viewing from the low pressure surface
The first verification from the plot is the range of stresses experienced in the blade to
validate the assumption of the linear elastic response. The maximum stresses
experienced are of the order of 0.3162GPa which is within the linear range [26]
65
The maximum stress occurs in the shear webs which act as the main load bearing
components in the blade.
Another important observation is the distribution of stresses within the skin. Note that
there is an improvement in this regard compared to the case where the isotropic
material is used. This is due the greater thickness of the spar caps and an excess of plies
which 0-degree fibers.
The principal stresses are in the linear behavior range as well. Figure.5 shows the
maximum principal stresses in the blade.
The trend is quite close to that of the Von misses stress distribution with the maximum
stresses acting on the shear webs. A cutaway section will reveal the stresses in the shear
webs.
66
Figure 47: Cutaway section of the blade viewing from the blade root end
As can be seen from the Figure.6 the maximum stresses occur in the shear webs at the
root section. This is the result of the applied boundary condition.
The next step would be analyzing the strains in the blade. Determination of strains serves
as a good tool for the initial prediction of fatigue based failure for the wind turbine blade
[27].
In the above figure, the maximum stresses are of the order of 6.092E-3. If we refer to
[27] this gives us a life cycle of above 10,000,000 cycles.
67
A cutaway section when viewed from the root end reveals that maximum strains occur
at the root section of the blade. The maximum strains are shared equally by the spar
caps and the shear webs alike.
The compressive strains are much lower than the tensile strains which are a good result
as composites are weaker in compression as compared to when they are loaded in
tension.
Figure 49: Cut-away section viewed from the root end showing Maximum in plane Principal stresses
68
4.15
4.1
4.05
500
700
830
3.95
3.9
3.85
5.10 Conclusions
The linear elastic response gives an idea about the stress, strain and deflections
distributions of the model. It is a very useful analysis in determining the critical areas of
a structure and the load bearing members of a part or an assembly.
Designing a composite layup is a not trivial task. An in-depth understanding of the forces
is required for weight saving. Some guidelines are necessary to make a long-lasting and
durable composite in addition to one that satisfies the loading conditions. These
guidelines can only be developed with experience and real world thinking. A poorly
designed composite material for the job would not be of much help in reducing the
weight of the component.
The aim of designing a composite layup is to analyze the elastic response of the blade
and to satisfy the loading conditions with the material properties in the most material
saving manner.
In case of a wind turbine blade it is important to take into account the various types of
loadings and the result of these forces. It is also important to realize the purpose of the
different components in the blade: The skin should be stiff enough to maintain the
69
aerodynamic profile; the spar caps channel the forces to the shear webs, the shear webs
provide the bending stiffness to the structure and hence are the main load bearing
component of the blade. Evidently, the shear webs are the most effected component
from the in plane shear stresses so they need to be strong in shear as well.
As far as the direction along the length of the blade is concerned the root is the most
critical area as it bears the most loading as well as it is the most sensitive area in terms
of deflections. Varying the composite thickness along the length of the blade can also act
as a weight saving tool.
For the edge-wise deflections of the blade, the leading edge is the most critical area as
it bears the most drag forces and its frontal deformation can greatly affect the shape of
the airfoil.
5.11 Recommendations
Following are the recommendations for future work:
Incorporation of turbulent flows while calculating the performance parameters for
the blade with the help from CFD analysis
Calculation of wind loads distribution along the chord of the airfoil. This will help
in determining the effects of the chord-wise bending
Wind load calculations should be done with the help of computational software
as it is less time taking and a more accurate approach.
Analytical model should be developed for the composite material.
Analysis for prevention of buckling and fatigue should be done.
On the basis of developed model a parametric model of the blade may be
prepared to
Investigate the effect of changing Spar configurations, Lamina configuration and
Airfoil shape
70
6 REFERENCES
[1] Presentation to the press London (2011), International Energy agency World Energy
outlook 2011
[2]Parker, J.G. (2011).Renewables 2011: Global Status Report, pp. 35
[3]Guhptha, R.G.(2009). Indias solar mission, how it is harnessing unlimited energy.
[4] Information retrieved from http://www.owdcc.org/
[5] United Nations Statistics Division, Millennium Development Goals indicators,
collected
by
CDIAC.
Information
retrieved
from
http://mdgs.un.org/unsd/mdg/SeriesDetail.aspx?srid=749&crid=,
[6], [7] Government and private sector role in energy crisis .Information retrieved from:
http://www.pakistanenergyconference.com/
[8]Strengthening Americas Energy Security with Offshore Wind. U.S. Department of Energy.
February 2011.
[9] Wind Vision 2025: Powering Canada's
fromhttp://www.canwea.ca/windvision_e.php
Future
(2008).Information
retrieved
[10] Latin America wind power market and strategies: 20102025 (2011). Information
Retrieved
fromhttp://www.emergingnergy.com/uploadDocs/LatinAmericaWindPowerMarketsandStrategies.pdf
[11] Massive interest shown in Brazil wind energy tender (2009). Retrieved from:
http://www.rechargenews.com/business_area/politics/article183932.ece
[12] Communication from the Commission to the European Parliament, the Council, the
European Economic and Social Committee and the Committee of the Regions - Offshore
Wind Energy: Action needed to deliver on the Energy Policy Objectives for 2020 and
beyond.
Information
retrieved
from:
http://eurlex.europa.eu/LexUriServ/LexUriServ.do?uri=CELEX:52008DC0768:EN:NOT
[13] Masdar plan for $200m pioneering wind farm. Information retrieved from:
http://www.thenational.ae/business/energy/masdar-plan-for-200m-pioneering-windfarm
71
[16] Manwell J.F. McGowan J.G. Rojers A.L.(2002). Wind Energy Explained: Theory Design
and Application
[17] Liu Wenzhi, Wu Jianxin, ZHangFuhai and Liu Changzeng (2009) 3D Modeling
Methods of Aerodynamic Shape for Large-Scale Wind Turbine Blades in 200. In
precedence of International Conference on Information Technology and Computer
Science 2009
[18] Peter Fuglsang, Stefano Bove and LM Glasfiber(2000). WindTunnel Testing Of
Airfoils Involves More Than Just Wall Corrections.
[19] NaeemMemon ( 2002). Analysis of Data of AEDB-UNDP (WEP) Wind Masts Installed
in Gharo-Keti Bandar Wind Corridor
[20] Parametric Study for Large Wind Turbine Blades Sand2002-2519 TPI Composites. Inc
[21] M. Grujicic, G. Arakere, E. Subramanian, V. Sellappan, A. Vallejo, and M. Ozen [2009].
Structural-Response Analysis, Fatigue-Life Prediction,and Material Selection for 1 MW
Horizontal-AxisWind-Turbine Blades , Journal ASM International.
[22] Hogg P. ( 2010) Manufacturing challenges for wind turbines, pp. 23
[23] J. A. Bailie,A. Pasricha, A. Pasricha ( 1997) A summary and review of composite
laminate design guidelines
[24] Peter Fuglsang, Stefano Bove and LM Glasfiber(2000). WindTunnel Testing Of
Airfoils Involves More Than Just Wall Corrections
[25] Parametric Study for Large Wind Turbine Blades Sand2002-2519 TPI Composites. Inc
[26] Ilan Juran and Uri Komornik (2006). Behavior of Fiber-Reinforced Polymer (FRP)
Composite Piles under Vertical Loads Geotechnical Engineering U.S Department of
transportation
[27] Teresa Wagner (2008). High Performance Reinforcements for the Wind Energy
Market.
72
7 Appendix
7.1 Aerodynamic calculations in Matlab code:
clear
omega=2; % Angular Velocity in rad/s
r= 0.5;
U=10; % Wind velocity
B=3; % Number of blades in wind turbine
i=1;
R=36; % Radius of Blade
N=18; % Number of Sections of Blade
lambda=(omega)*(R)/U; % Tip speed Velocity
lambda_r=(omega)*r/U % local tip speed ratio
phi=(2/3)*atand(1/lambda_r); % Angle of relative wind
C_l=1.4;
% Lift Coefficient
phi_1=phi*3.14159/180;
% Angle of relative wind in radians
c=(8*3.14159*r/(B*C_l))*(1-cos(phi_1)); % Chord length
solidity=(B*c)/(2*3.14159*r);
% solidity of wind turbine
a(i)=1/(1+((4*(sin(phi_1))^2)/(solidity*C_l*cos(phi_1)))); % axial induction factor
a_o(i)=(1-3*a(i))/((4*a(i))-1); % Angular induction factor
i=2;
j=1;
density=1.1455; % Density of air
while(j<100)
phi=atand((1-a(i-1))/((1+a_o(i-1))*lambda_r));
phi=phi*(3.14159/180);
F=(2/3.14159)*(3.14159 /180)*acosd(exp((-1.5*(1-r/36))/((r/36)*sin(phi))));
a_o(i)=1/((4*F*cos(phi)/(solidity*C_l))-1);
a(i)=1/((4*F*(sin(phi))^2/(solidity*C_l*cos(phi)))+1);
if (a(i)-a(i-1)<.01)
j=1000;
end
i=i+1;
j=j+1;
end
U_relative=(U*(1-a(i-1))/(sin(phi))) % Relative wind magnitude
c=(8*3.14159*r/(B*C_l))*(1-cos(phi))
73
74
%power coefficient
%Thrust
%