SCAMORSA-1: a camber-morphing wind turbine blade with sliding composite skin

Abstract

Wind turbines form an increasingly important source of renewable and sustainable energy. Traditional rigid wind turbine blades are unable to control the flow of air over their surfaces, resulting in higher loads and lower aerodynamic efficiency at non-optimal wind speeds and angles of attack. This paper presents the design of SCAMORSA-1 (“Sliding CAmber- MORphing Skin Action”), a camber-morphing turbine blade in a Horizontal Axis Wind Turbine (HAWT) for increased aerodynamic efficiency and improved extreme load alleviation. The blade is linearly tapered and comprises three sections: a conventional rigid section, a morphing section, and a fixed blade tip, all covered by functionally graded composite skin. Measured from the root, the rigid section spans 0%-60% of the total blade length and its profile transitions at 20% from SD7062 thick airfoil to the thinner SD7037 airfoil. The rigid section includes carbon fiber composite spars that resist flap-wise bending. The morphing section occupies the next 30% of the span with SD2030 airfoil profile and can seamlessly change camber angle up to 10°. This section is composed of three hybrid ribs connected via two leading-edge composite spars and a trailing-edge synchronizing rod. Each hybrid rib has a solid leading-edge segment connected to a flexible trailing-edge segment via T-slots. The trailing-edge segment, where morphing occurs, is an enhanced version of the corrugated FishBAC design, with hexagonal honeycomb infill that increases the out-of-plane stiffness and allows for morphing deformation without internal buckling. Two of these hybrid ribs have servomotors housed in the leading-edge segment. These integrated actuators in the hybrid ribs actuate flexible carbon fiber ribbons that run through slits in the trailing-edge segment to morph it. At the trailing-edge portion of the morphing section, the composite skin transitions to a thin flexible layer that can slide over the deforming trailing-edge segment via skin sliders. Computational simulations were performed to quantify the performance gains and ensure safe operation of all components. A proof-of-concept model of SCAMORSA-1’s morphing section was manufactured and tested to demonstrate the effectiveness of the design.