Durability and Reliability of Wind Turbine Composite Blades Using Robust Design Approach

Abstract

The paper describes a computational simulation approach for durability, damage tolerance (D&DT) and reliability of composite wind turbine blade structures in presence of uncertainties in material properties. This computer-based prediction methodology combines composite mechanics with finite element analysis, damage and fracture tracking capability, probabilistic analysis and a robust design algorithm to reduce weight of turbine bales without loss in structural durability and reliability. A composite turbine blade was first assessed with finite element based multi-scale progressive failure analysis to determine failure modes and locations as well as the fracture load. Analysis D&DT results were validated with static test performed at Sandia National Laboratories. The work was followed by detailed weight analysis to identify contribution of various materials to the overall weight of the blade. The methodology ensured that certain types of failure modes, such as delamination progression, are contained to reduce risk to the structure. Probabilistic analysis indicated that composite shear strength has a great influence of the blade ultimate load under static loading. Weight was reduced by 12% with robust design without loss in reliability or D&DT. It was achieved by replacing a small volume of key materials with foam.