The Department of Energy and the Sandia National Laboratories Wind Power Technology Department have initiated a
number of wind turbine blade sensing technology projects with a major goal of understanding the issues and challenges
of incorporating new sensing technologies in wind turbine blades. The projects have been highly collaborative with
teams from several commercial companies, universities, other national labs, government agencies and wind industry
partners. Each team provided technology that was targeted for a particular application that included structural dynamics,
operational monitoring, non-destructive evaluation and structural health monitoring. The sensing channels were
monitored, in some or all cases, during blade fabrication, field testing of the blade on an operating wind turbine, and lab
testing where the life of the blade was accelerated to blade failure. Implementing sensing systems in wind turbine blades
is an engineering challenge and solutions often require the collaboration with a diverse set of expertise. This report
discusses some of the key issues, challenges and lessons-learned while implementing sensing technologies in wind
turbine blades. Some of the briefly discussed topics include cost and reliability, coordinate systems and references, blade
geometry, blade composites, material compatibility, sensor ingress and egress, time synchronization, wind turbine
operation environments, and blade failure mechanisms and locations.
Rising energy prices and carbon emission standards are driving a fundamental shift from fossil fuels to alternative
sources of energy such as biofuel, solar, wind, clean coal and nuclear. In 2008, the U.S. installed 8,358 MW of new
wind capacity increasing the total installed wind power by 50% to 25,170 MW. A key technology to improve the
efficiency of wind turbines is smart rotor blades that can monitor the physical loads being applied by the wind and then
adapt the airfoil for increased energy capture. For extreme wind and gust events, the airfoil could be changed to reduce
the loads to prevent excessive fatigue or catastrophic failure. Knowledge of the actual loading to the turbine is also
useful for maintenance planning and design improvements. In this work, an array of uniaxial and triaxial accelerometers
was integrally manufactured into a 9m smart rotor blade. DC type accelerometers were utilized in order to estimate the
loading and deflection from both quasi-steady-state and dynamic events. A method is presented that designs an
estimator of the rotor blade static deflection and loading and then optimizes the placement of the sensor(s). Example
results show that the method can identify the optimal location for the sensor for both simple example cases and realistic
complex loading. The optimal location of a single sensor shifts towards the tip as the curvature of the blade deflection
increases with increasingly complex wind loading. The framework developed is practical for the expansion of sensor
optimization in more complex blade models and for higher numbers of sensors.
As electric utility wind turbines increase in size, and correspondingly, increase in initial capital investment cost, there is
an increasing need to monitor the health of the structure. Acquiring an early indication of structural or mechanical
problems allows operators to better plan for maintenance, possibly operate the machine in a de-rated condition rather
than taking the unit off-line, or in the case of an emergency, shut the machine down to avoid further damage. This paper
describes several promising structural health monitoring (SHM) techniques that were recently exercised during a fatigue
test of a 9 meter glass-epoxy and carbon-epoxy wind turbine blade. The SHM systems were implemented by teams from
NASA Kennedy Space Center, Purdue University and Virginia Tech. A commercial off-the-shelf acoustic emission (AE)
NDT system gathered blade AE data throughout the test. At a fatigue load cycle rate around 1.2 Hertz, and after more
than 4,000,000 fatigue cycles, the blade was diagnostically and visibly failing at the out-board blade spar-cap
termination point at 4.5 meters. For safety reasons, the test was stopped just before the blade completely failed. This
paper provides an overview of the SHM and NDT system setups and some current test results.
A project targeted at developing a low-cost fiber optic interrogator system for fiber Bragg grating (FBG) sensors has
been completed, and has resulted in a stand-alone system that can be used in multiple applications. The interrogator
system, tailored as a potential solution for embedded strain sensing in composite wind turbine blades, was recently tested
and its performance validated at the Infrastructure Assurance & Non-Destructive Inspection (NDI) department at Sandia
National Laboratories (SNL). The test specimen used to test the system consisted of a single fiber optic cable with six
FBG sensors embedded in a 36-ply fiberglass composite specimen. The FBG sensors were installed around a series of
known engineered flaws. Six foil type resistive strain gauges were bonded to the composite specimen surface and co-located
with the six embedded FBG sensors. The fiber optic interrogator was used to sample the FBG sensors and an
independent data acquisition system was used to sample the foil strain gauges. The test specimen was subjected to a
series of static loads and the results from both the foil strain gauges and the FBG sensors were compared. Results from
the analysis show a good correlation between the embedded FBG sensors and the foil strain gauges.
Conference Committee Involvement (1)
Second International Conference on Smart Materials and Nanotechnology in Engineering
Access to the requested content is limited to institutions that have purchased or subscribe to SPIE eBooks.
You are receiving this notice because your organization may not have SPIE eBooks access.*
*Shibboleth/Open Athens users─please
sign in
to access your institution's subscriptions.
To obtain this item, you may purchase the complete book in print or electronic format on
SPIE.org.
INSTITUTIONAL Select your institution to access the SPIE Digital Library.
PERSONAL Sign in with your SPIE account to access your personal subscriptions or to use specific features such as save to my library, sign up for alerts, save searches, etc.