Rapid questions rapid prototyping rapid answers: 3d printing in small wind turbine tests

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1 Rapid questions rapid prototyping rapid answers: 3d printing in small wind turbine tests Maciej Karczewski, Michal Kulak, Damian Kadrowski Michal Lipian, Filip Grapow, Malgorzata Stepien, Katarzyna Telega, Dominika Raszewska, Piotr Baszczynski, Jeremiasz Czarnecki, Rafal Skalski, Pawel Rogowski, Lukasz Pokrzywka, Marcin Miller, Karol Zawadzki Bloomington, MN, USA, 04/10/2018

2 2016 Our people behind the success 2017

3 3d printing in lab scale Question: How to conduct load tests for a 3d printed wind turbine blade? Prototype: Small scale prototype 1:6 scale bench and force platform Answer:. It s coming!

4 Blade testing standard BS EN :2014 Test procedure Mass/COG of the blade Y Natural frequencies of the blade Z X Static load test Fatigue load test

5 Static test design load case Characteristics of a wind turbine 18 m/s wind speed Rotational speed range 300 rpm to 7100 rpm Increment of 200 rpm between each test 5

6 Static test design load case Power (W) Characteristics of a wind turbine stage Maximum load at 3900 wind speed of 18 m/s Rotational speed (rpm) 1st flapwise at 4980 rpm

7 Moment (N.m) Power (W) Shear force (N) Static test design load case Characteristics of a wind turbine stage Maximum load at 3900 wind speed of 18 m/s Rotational speed (rpm) Shear force distributions rpm 3,0 2,5 2,0 1,5 1,0 0,5 0,0 0,3 0,2 0,1 0,0-0,1-0,2 Shear Z (N) Shear X (N) 0 0,025 0,05 0,075 0,1 0,125 0,15 0,175 Radial distance (m) Moment distributions rpm 0 0,025 0,05 0,075 0,1 0,125 0,15 0,175 Radial distance (m) Mx (Nm) Mz (Nm) My (Nm) 1st flapwise at 4980 rpm

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9 Static test design load case Whiffle-tree design 2nd stage beam Ø0,4 mm nylon strings 3D printed blade Holder 1st stage beams

10 Static test design load case Whiffle-tree design Turnbuckle: to level the beam 2nd stage beam Turnbuckle Ø0,4 mm nylon strings 1st stage beams 3D printed blade Holder

11 Static test design load case Whiffle-tree design Turnbuckle: to level the beam Counter-weight: to balance the beam 2nd stage beam Turnbuckle 1st stage beams 3D printed blade Ø0,4 mm nylon strings Counter-weights Holder

12 Static test design load case 3d printing turnbuckle bolts and frame Whiffle-tree design Turnbuckle: to level the beam

13 Static test design load case 3d printing turnbuckle bolts and frame Whiffle-tree design Turnbuckle: to level the beam Counter-weight: to balance the beam Easy: rope slides into the channel Secure: pin is locked between the holders Design with channels and holders for 3d printing Fast: pin is knotted to the rope before assembly

14 Static test design load case Blade testing Design load case Nylon string was torn apart while 3d printed blade returned to its original shape! Mass (g) Primary load (N) 78 0, , , , , , , , , , , , , , ,6

15 Static test design load case Blade deflection (cm) Test results (deflection) Deflection 5 4,5 4 3,5 3 2,5 2 1,5 1 0,5 0 Tip Saddle 4 Saddle 3 Saddle Primary mass (g)

16 Static test design load case Stress (Mpa) Stress (Mpa) Test results (deflection) Stress Saddle 2 12 y = 1870x ,002 0,004 0,006 deflection (m) Stress deflection@ Saddle 3 y = 904x 0 0,005 0,01 0,015 0,02 deflection (m)

17 Static test design load case Primary Load (N) E (Gpa) Test results (Young modulus) Radial distance (m) 0,11 0,14 0,16 10,2 1,34 1,02 0,99 11,1 1,48 0,94 0,88 12,2 1,34 1,11 1,10 13,4 1,43 1,04 1,00 14,7 1,32 1,10 1,09 15,1 1,45 1,07 1,03 15,9 1,40 1,15 1,14 17,9 1,35 1,23 1,25 19,9 1,67 1,18 1,13 21,3 1,69 1,33 1,30 Average (GPa) 1,45 1,12 1,09 1,6 1,4 1,2 1 0,8 0,6 0,4 0,2 0 Young modulus evolution y = -7,4226x + 2,2341 R² = 0,90 0 0,05 0,1 0,15 0,2 Radial distance (m) E=1,95 GPa Young modulus of ABS according to Zortrax

18 Nowadays Rapid question: How much does a winglet increase power output of a small wind turbine? Rapid prototype: Small scale prototype 1:6 scale wind tunnel Rapid answer: By about 2-3%

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25 3d printing for lab test 3d printed rotor, torquemeter and generator housings Rotor Bearing unit Torquemeter Generator

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27 Cp 0,4 0,2 EXP WT IMP 12.5 m/s Qblade BEM 12.5 m/s Cp vs TSR 0 TSR

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29 Power [W] Open field test to quantify real data Cp avg = 0.65, AF=99% OPEN FIELD TEST Cp avg = 0.75, AF=100% 3D CFD TSR avg = 6.76, Vavg=3.1 m/s TSR avg = 6.00, Vavg=5.0 m/s Wind speed [m/s]

30 Concept Aerodynamic numerical model Empirical model WT correction Validation No Yes ISO/IEC standard Aeroelastic numerical model Verification No No Empirical test Verification WT correction Yes Yes ISO/IEC standard Design Exploration Product Algorithm for the innovative product development in the field of aerodynamics using multiple levels of numerical-experimental research integration

31 Maciej Karczewski, Ph.D. GUST project supervisor Lodz University of Technology 219/223 Wolczanska St., Lodz, Poland