Innovative blade root joint
The project concerns the development of a demonstration prototype of a component for the mounting of a wind turbine blade. The strength, a key feature of the component, is to be experimentally characterized in cooperation with DTU Mechanical Engineering. Furthermore, a pilot plant for the machining of the component will be designed to demonstrate the quality capability of the proposed technology.
The overall aim of the project is to develop a demonstration model of an innovative root joint solution for wind turbine blades using the integral pultrusion process of fiber glass composites. The project is divided in 3 major technical work packages followed up by documentation and definition of marketing strategy. The 3 work packages are (i) component design, (ii) mechanical test and characterization and (iii) development of a pilot machine line. The idea has achieved considerable attention among leading blade manufacturers which confirm the need for the root joint solution and the feasibility of its application. However, to move forward in the actual application development, a finished component with documented characteristics must be presented. The aim is to develop, demonstrate and document such a root joint solution. A successful solution enables the following areas of focus: 1) Optimizing part of the blade production through increased automation 2) Higher mould production cycles 3) Cost effective manufacturing concept on component level 4) Longer blades 5) Reduced costs for installation per energy unit 6) QA at lower costs and minimize safety risks.
Furthermore the project covers the development, design and production of test and prototype manufacturing equipment, with which a number of prototype units have been produced. The extensive test program includes pull-out test of bushes at component level, material characterizing test of the pultruded composite material, test and optimizing of the attachment between the steel bush and the composite, and test of the attachment between the pultruded unit and the blade laminate. Several variants of prototype units and test units have been produced, and after the static and fatigue tests, the most promising variant has been selected. This variant has undergone additional tests for the purpose of a component certificate of the pultruded root elements. According to the test results, the strength of the developed blade root elements is on level with the best solutions on the market. The selected manufacturing process, the design, and choice of material make it possible to reach a most competitive selling price. By means of the produced manufacturing equipment, it has been possible to produce prototype units for a blade root display, and units for testing – all of expected quality. A production plant for the manufacturing of smaller amounts of units for 0-series blades have been developed, which reduced the extent of manual handling and the risk of unlike quality.
Key figures
Category
Participants
| Partner | Subsidy | Auto financing |
|---|---|---|
| FIBERLINE A/S | 3,21 mio. DKK | 3,21 mio. DKK |
| Danmarks Tekniske Universitet (DTU) |
Contact
Fiberline Composites A/S
Barmstedt Allé 5
DK-5500 Middelfart
www.fiberline.dk
Kratmann, Kasper K. , 70137713, fiberline@fiberline.com
Øvr. Partnere: Danmarks Tekniske Universitet. Institut for Mekanisk Teknologi (DTU Mekanik)
