Integration Team

1. Integration Team

2. Background Peter Sensing Eric~Nate Actuation Jon Data Acquisition Jon Manufacturing and Testing Jon Recommendations Jon ~Eric~Nate Outline:

3. Background Wind Power 1926 Betz Limit (~59%) Wind Velocity Blade Length

4. Background Current Sensors Ground Support Power Generation Housing

5. Background Current Issues Tower Strikes Reliability of Components limited actual data of the wind loading for design Design and Manufacturing

6. Background Need Smart Structure Sensors Control Actuators Blade Health Monitoring Reliability Wind Loading Profile

7. Sensing Failure Modes De-lamination of the composite Base Webs Blade tip Buckling of the blade Near the base Tower strikes Tip damage

8. Sensing Areas 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

9. Sensing Major 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

10. 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

11. 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

12. Actuation Ultimately some force will cause a separation of the boundary layer on the top surface of the wing There are many schemes to accomplish this goal

13. Actuation The false wall compressed air is a very simple form for providing a means for boundary layer separation. The means for this type of actuation were very easy to manufacture. The tube containing the perforations and necessary tubes can be seen in the right of this photo.

14. Actuation The control surface is presently powered by an electric linear actuating motor. This is attached to the control surface with a hinge connection This particular motor is fast acing enough to accommodate the need for deployment time under 500 mS from time of sensing

15. Actuation For implementation on and industrial scale either linear motors or pneumatic actuators are needed. For pneumatic actuators a larger support system is needed Including a storage tank And an air compressor to refill the tank All of this support system needs to be mounted in the rotor hub.

16. Manufacturing for Testing I am heading up the linear actuator and wing integration. Integration into a flat plate for testing. Integration into a wing for Computational fluid dynamics and wind tunnel testing at U.C. Davis. The blades we are focusing on are 9 meters These blades are the ones that Sandia National labs uses for their research. They are for a 65 kW turbine

17. 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

18. Manufacturing for Testing Presently the blade we have to work 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) is one component of success. Placement of control surface for different loading conditions is desired Variable location on blade Variable height of control surface

19. Manufacturing for Industry Wings would have to be entirely redesigned to encompass the control surface scheme in a reasonable manor Large sections of wings would have to be modified to make the control surfaces work Pneumatic boundary separation schemes are more feasible as a retro fit for present turbines Holes can be drilled in existing wings and tubes for the compressed air and be mounted securely without severe damage to the blades

20. Data Acquisition The interrogators that we would use for testing would probably be the Wx interrogator from Smart Fibres.

21. 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

22. 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

23. 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_elements_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