Publications

Mandell et al. have recently presented an updated constant-life diagram (CLD) for a fiberglass composite that is a typical wind turbine blade material. Their formulation uses the MSU/DOE fatigue data base to develop a CLD with detailed S-N information at 13 R-values. This diagram is the most detailed to date, and it includes several loading conditions that have been poorly represented in earlier studies. Sutherland and Mandell have used this formulation to analyze typical loads data from operating wind farms and the failure of coupons subjected to spectral loading. The detailed CLD used in these analyses requires a significant investment in materials testing that is usually outside the bounds of typical design standards for wind turbine blades. Thus, the question has become: How many S-N curves are required for the construction of a CLD that is sufficient for an "accurate" prediction of equivalent fatigue loads and service lifetimes? To answer this question, the load data from two operating wind turbines and the failure of coupons tested using the WISPERX spectra are analyzed using a nonlinear damage model. For the analysis, the predicted service lifetimes that are based on the CLD constructed from 13 R-values are compared to the predictions for CLDs constructed with fewer R-values. The results illustrate the optimum number of R-values is 5 with them concentrated between R-values of -2 and 0.5, or -2 and 0.7. Copyright © 2005 by ASME.

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This report addresses the effects of spectrum loading on lifetime and residual strength of a typical fiberglass laminate configuration used in wind turbine blade construction. Over 1100 tests have been run on laboratory specimens under a variety of load sequences. Repeated block loading at two or more load levels, either tensile-tensile, compressive-compressive, or reversing, as well as more random standard spectra have been studied. Data have been obtained for residual strength at various stages of the lifetime. Several lifetime prediction theories have been applied to the results. The repeated block loading data show lifetimes that are usually shorter than predicted by the most widely used linear damage accumulation theory, Miner's sum. Actual lifetimes are in the range of 10 to 20 percent of predicted lifetime in many cases. Linear and nonlinear residual strength models tend to fit the data better than Miner's sum, with the nonlinear providing a better fit of the two. Direct tests of residual strength at various fractions of the lifetime are consistent with the residual strength models. Load sequencing effects are found to be insignificant. The more a spectrum deviates from constant amplitude, the more sensitive predictions are to the damage law used. The nonlinear model provided improved correlation with test data for a modified standard wind turbine spectrum. When a single, relatively high load cycle was removed, all models provided similar, though somewhat non-conservative correlation with the experimental results. Predictions for the full spectrum, including tensile and compressive loads were slightly non-conservative relative to the experimental data, and accurately captured the trend with varying maximum load. The nonlinear residual strength based prediction with a power law S-N curve extrapolation provided the best fit to the data in most cases. The selection of the constant amplitude fatigue regression model becomes important at the lower stress, higher cycle loading cases. The residual strength models may provide a more accurate estimate of blade lifetime than Miner's rule for some loads spectra. They have the added advantage of providing an estimate of current blade strength throughout the service life.

This report presents the major findings of the Montana State University Composite Materials Fatigue Program from 1997 to 2001, and is intended to be used in conjunction with the DOE/MSU Composite Materials Fatigue Database. Additions of greatest interest to the database in this time period include environmental and time under load effects for various resin systems; large tow carbon fiber laminates and glass/carbon hybrids; new reinforcement architectures varying from large strands to prepreg with well-dispersed fibers; spectrum loading and cumulative damage laws; giga-cycle testing of strands; tough resins for improved structural integrity; static and fatigue data for interply delamination; and design knockdown factors due to flaws and structural details as well as time under load and environmental conditions. The origins of a transition to increased tensile fatigue sensitivity with increasing fiber content are explored in detail for typical stranded reinforcing fabrics. The second focus of the report is on structural details which are prone to delamination failure, including ply terminations, skin-stiffener intersections, and sandwich panel terminations. Finite element based methodologies for predicting delamination initiation and growth in structural details are developed and validated, and simplified design recommendations are presented.

In support of two major SNL programs, the Long-term Inflow and Structural Test (LIST) program and the Blade Manufacturing Initiative (BMI), three Micon 65/13M wind turbines have been erected at the USDA Agriculture Research Service (ARS) center in Bushland, Texas. The inflow and structural response of these turbines are being monitored with an array of 60 instruments: 34 to characterize the inflow, 19 to characterize structural response and 7 to characterize the time-varying state of the turbine. The primary characterization of the inflow into the LIST turbine relies upon an array of five sonic anemometers. Primary characterization of the structural response of the turbine uses several sets of strain gauges to measure bending loads on the blades and the tower and two accelerometers to measure the motion of the nacelle. Data are sampled at a rate of 30 Hz using a newly developed data acquisition system. The system features a time-synchronized continuous data stream and telemetered data from the turbine rotor. This paper documents the instruments and infrastructure that have been developed to monitor these turbines and their inflow.

The Long-term Inflow and Structural Test (LIST) program is collecting long-term, continuous inflow and structural response data to characterize the extreme loads on wind turbines. A heavily instrumented Micon 65/13M turbine with SERI 8-m blades is being used as the first test turbine for this program. This turbine and its two sister turbines are located in Bushland, TX, a test site that exposes the turbines to a wind regime that is representative of a Great Plains commercial site. The turbines and their inflow are being characterized with 60 measurements: 34 to characterize the inflow, 19 to characterize structural response, and 7 to characterize the time-varying state of the turbine. The primary characterization of the inflow into the LIST turbine relies upon an array of five sonic anemometers. Primary characterization of the structural response of the turbine uses several sets of strain gauges to measure bending loads on the blades and the tower and two accelerometers to measure the motion of the nacelle. Data from the various instruments are sampled at a rate of 30 Hz using a newly developed data acquisition system that features a time-synchronized continuous data stream that is telemetered from the turbine rotor. The data, taken continuously, are automatically divided into 10-minute segments and archived for analysis. Preliminary data are presented to illustrate the operation of the turbine and the data acquisition and analysis system.

Over the past several years, extensive databases have been developed for the S-N behavior of various mate&& used in wind turbine blades, primarily fiberglass composites. These data are typically presented both in their "raw" form and curve fit to define their average properties. For design, confidence limits must be placed on these descriptions. In particular, most designs call for the "95195" design values; namely, with a 95 percent level of confidence, thedesiguerisassuredthat95percentofthematerial will 'meet or exceed the design value. For such material properties as the ultimate streng& the procedures for estimating its value at a particular confidence level is wellffiedifthemeasured values follow a normal or a log-normal distribution. Namely, based upon the number of sample points and their standard deviation, a commonly-found table may be used to determine the survival percentagea t a particular confidencel evel with respect to its mean value. The same is true for fatigue data at a constaut stress level (the number of cycles to failure N at stress level SI). However, when the stress level is allowed to vary, as with a typical S-N fatigue curve, the proceduresf or determmingc onfidencel imits are not as well delked. This paper outlines techn.iques for determimng confklence limits of fatigue data Different approachesto estimating the 95195l evel are compared. Data from the MSUIDOE and the FACT fatigue databam are used to illustrate typical results.

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Modern wind turbines are fatigue critical machines that are typically used to produce electrical power from the wind. The materials used to construct these machines are subjected to a unique loading spectrum that contains several orders of magnitude more cycles than other fatigue critical structures, e.g., an airplane. To facilitate fatigue designs, a large database of material properties has been generated over the past several years that is specialized to materials typically used in wind turbines. In this paper, I review these fatigue data. Major sections are devoted to the properties developed for wood, metals (primarily aluminum) and fiberglass. Special emphasis is placed on the fiberglass discussion because this material is current the material of choice for wind turbine blades. The paper focuses on the data developed in the U.S., but cites European references that provide important insights.

Modern wind turbines are fatigue critical machines that are typically used to produce electrical power from the wind. Operational experiences with these large rotating machines indicated that their components (primarily blades and blade joints) were failing at unexpectedly high rates, which led the wind turbine community to develop fatigue analysis capabilities for wind turbines. Our ability to analyze the fatigue behavior of wind turbine components has matured to the point that the prediction of service lifetime is becoming an essential part of the design process. In this review paper, I summarize the technology and describe the ''best practices'' for the fatigue analysis of a wind turbine component. The paper focuses on U.S. technology, but cites European references that provide important insights into the fatigue analysis of wind turbines.

The NWTC (National Wind Technology Center) Variable-Speed Test Bed turbine is a three-bladed, 10-meter, downwind machine that can be run in either fixed-speed or variable-speed mode. In the variable-speed mode, the generator torque is regulated, using a discrete-stepped load bank to maximize the turbine`s power coefficient. At rated power, a second control loop that uses blade pitch to maintain rotor speed essentially as before, i.e., using the load bank to maintain either generator power or (optionally) generator torque. In this paper, the authors will use this turbine to study the effect of variable-speed operation on blade damage. Using time-series data obtained from blade flap and edge strain gauges, the load spectrum for the turbine is developed using rainflow counting techniques. Miner`s rule is then used to determine the damage rates for variable-speed and fixed-speed operation. The results illustrate that the controller algorithm used with this turbine introduces relatively large load cycles into the blade that significantly reduce its service lifetime, while power production is only marginally increased.

This report presents a detailed analysis of the results from fatigue studies of wind turbine blade composite materials carried out at Montana State University (MSU) over the last seven years. It is intended to be used in conjunction with the DOE/MSU composite Materials Fatigue Database. The fatigue testing of composite materials requires the adaptation of standard test methods to the particular composite structure of concern. The stranded fabric E-glass reinforcement used by many blade manufacturers has required the development of several test modifications to obtain valid test data for materials with particular reinforcement details, over the required range of tensile and compressive loadings. Additionally, a novel testing approach to high frequency (100 Hz) testing for high cycle fatigue using minicoupons has been developed and validated. The database for standard coupon tests now includes over 4,100 data points for over 110 materials systems. The report analyzes the database for trends and transitions in static and fatigue behavior with various materials parameters. Parameters explored are reinforcement fabric architecture, fiber content, content of fibers oriented in the load direction, matrix material, and loading parameters (tension, compression, and reversed loading). Significant transitions from good fatigue resistance to poor fatigue resistance are evident in the range of materials currently used in many blades. A preliminary evaluation of knockdowns for selected structural details is also presented. The high frequency database provides a significant set of data for various loading conditions in the longitudinal and transverse directions of unidirectional composites out to 10{sup 8} cycles. The results are expressed in stress and strain based Goodman Diagrams suitable for design. A discussion is provided to guide the user of the database in its application to blade design.

Time-domain simulations of the loads on wind energy conversion systems have been hampered in the past by the relatively long computational times for nonlinear structural analysis codes. However, recent advances in both the level of sophistication and computational efficiency of available computer hardware and the codes themselves now permit long-term simulations to be conducted in reasonable times. Thus, these codes provide a unique capability to evaluate the spectral content of the fatigue loads on a turbine. To demonstrate these capabilities, a Micon 65/13 turbine is analyzed using the YawDyn and the ADAMS dynamic analysis codes. The SNLWIND-3D simulator and measured boundary conditions are used to simulate the inflow environment that can be expected during a single, 24-hour period by a turbine residing in Row 41 of a wind farm located in San Gorgonio Pass, California. Also, long-term simulations (up to 8 hours of simulated time) with constant average inflow velocities are used to better define the characteristics of the fatigue load on the turbine. Damage calculations, using the LIFE2 fatigue analysis code and the MSU/DOE fatigue data base for composite materials, are then used to determine minimum simulation times for consistent estimates of service lifetimes.

Under the auspices of the {open_quotes}Government/Industry Wind Technology Applications Project{close_quotes} [{open_quotes}Letter of Interest{close_quotes} (LOI) Number RC-1-11101], Flo Wind Corp. has successfully developed, tested, and delivered a high-energy rotor upgrade candidate for their 19-meter Vertical Axis Wind Turbine. The project included the demonstration of the innovative extended height-to-diameter ratio concept, the development of a continuous span single-piece composite blade, the demonstration of a continuous blade manufacturing technique, the utilization of the Sandia National Laboratories developed SNLA 2150 natural laminar flow airfoil and the reuse of existing wind turbine and wind power plant infrastructure.

The analysis of component fatigue lifetime for a wind energy conversion system (WECS) requires that the component load spectrum be formulated in terms of stress cycles. Typically, these stress cycles are obtained from time series data using a cycle identification scheme. As discussed by many authors, the matrix or matrices of cycle counts that describe the stresses on a turbine are constructed from relatively short, representative samples of time series data. The ability to correctly represent the long-term behavior of the distribution of stress cycles from these representative samples is critical to the analysis of service lifetimes. Several techniques are currently used to convert representative samples to the lifetime cyclic loads on the turbine. There has been recently developed a set of fitting algorithms that is particularly useful for matching the body of the distribution of fatigue stress cycles on a turbine component. Fitting techniques are now incorporated into the LIFE2 fatigue/fracture analysis code for wind turbines. In this paper, the authors provide an overview of the fitting algorithms and describe the pre- and post-count algorithms developed to permit their use in the LIFE2 code. Typical case studies are used to illustrate the use of the technique.

This paper demonstrates a methodology for predicting the service lifetime of wind turbine blades using the high-cycle fatigue data base for typical U.S. blade materials developed by Mandell, et al. (1995). The first step in the analysis is to normalize the data base (composed primarily of data obtained from specialized, relatively small coupons) with fatigue data from typical industrial laminates to obtain a Goodman Diagram that is suitable for analyzing wind turbine blades. The LIFE2 fatigue analysis code for wind turbines is then used for the fatigue analysis of a typical turbine blade with a known load spectrum. In the analysis, a linear damage model, Miner`s Rule, is used to demonstrate the prediction of the service lifetime for a typical wind turbine blade under assumed operating strain ranges and stress concentration factors. In contrast to typical European data, the asymmetry in this data base predicts failures under typical loads to be compressive.

Modern wind turbines are fatigue critical machines used to produce electrical power. To insure long term, reliable operation, their structure must be optimized if they are to be economically viable. The fatigue and reliability projects in Sandia`s Wind Energy Program are developing the analysis tools required to accomplish these design requirements. The first section of the paper formulates the fatigue analysis of a wind turbine using a cumulative damage technique. The second section uses reliability analysis for quantifying the uncertainties and the inherent randomness associated with turbine performance and the prediction of service lifetimes. Both research areas are highlighted with typical results.

The torque loads on two classes of wind turbine gearboxes are analyzed using a time-at-torque technique and a rainflow counting technique to determine the cyclic loads on the gear teeth. The two techniques are compared and contrasted to one another using representative samples of the time histograms from a Micon 65 and the Sandia/DOE Test Bed wind turbines. To place these differences in perspective, Miner’s Rule is used to determine the damage produced by each of the distributions. The damage analyses illustrate that the differences in the distributions are minimal.

The fatigue analysis of a wind turbine component typically uses representative samples of cyclic loads to determine lifetime loads. In this paper, several techniques currently in use are compared to one another based on fatigue life analyses. The generalized Weibull fitting technique is used to remove the artificial truncation of large-amplitude cycles that is inherent in relatively short data sets. Using data from the Sandia/DOE 34-m Test Bed, the generalized Weibull file technique is shown to be excellent for matching the body of the distribution of cyclic loads and for extrapolating the tail of the distribution However, the data also illustrate that the fitting technique is not a substitute for an adequate data base.

NonDestructive Testing (NDT), also called NonDestructive Evaluation (NDE), is commonly used to monitor structures before, during, and after testing. This paper reports on the use of two NDT techniques to monitor the behavior of a typical wind turbine blade during a quasi-static test-to-failure. The two NDT techniques used were acoustic emission and coherent optical. The former monitors the acoustic energy produced by the blade as it is loaded. The latter uses electron shearography to measure the differences in surface displacements between two load states. Typical results are presented to demonstrate the ability of these two techniques to locate and monitor both high damage regions and flaws in the blade structure. Furthermore, this experiment highlights the limitations in the techniques that must be addressed before one or both can be transferred, with a high probability of success, to the inspection and monitoring of turbine blades during the manufacturing process and under normal operating conditions.

The paper discusses two aspects of Sandia`s Wind Energy Program. The first section of the paper presents a case study of fatigue in wind turbines. This case study was prepared for the American Society of Testing Material`s (ASTM) Standard Technical Publication (STP) on fatigue education. Using the LIFE2 code, the student is lead through the process of cumulative damage summation for wind turbines and typical data are used to demonstrate the range of life estimates that will result from typical parameter variations. The second section summarizes the results from a workshop held by Sandia and the National Renewable Energy Laboratory (NREL) to discuss fatigue life prediction methodologies. This section summarizes the workshop discussions on the use of statistical modeling to deduce the shape and magnitude of the low-probability-of-occurrence, high-stress tail of the load distribution on a wind turbine during normal operation.

The LIFE2 computer code is a fatigue/fracture analysis code that is specialized to the analysis of wind turbine components. The numerical formulation of the code uses a series of cycle count matrices to describe the cyclic stress states imposed upon the turbine. However, many structural analysis techniques yield frequency-domain stress spectra and a large body of experimental loads (stress) data is reported in the frequency domain. To permit the analysis of this class of data, a Fourier analysis is used to transform a frequency-domain spectrum to an equivalent time series suitable for rainflow counting by other modules in the code. This paper describes the algorithms incorporated into the code and their numerical implementation. Example problems are used to illustrate typical inputs and outputs.

The LIFE2 computer code is a fatigue/fracture analysis code specifically designed for the analysis of wind turbine components. It is a PC-compatible Fortran code that is written in a top-down modular format. In this numerical formulation, an S-n'' fatigue analysis is used to describe the initiation, growth and coalescence of micro-cracks into macro-cracks. A linear, da/dn'' fracture analysis is used to describe the growth of a macro-crack. This paper presents the numerical formulations used to implement these analyses. 16 refs., 2 tabs.