Wind Energy Research at AAU - with focus on composite materials and wind turbine blades

Transcription

1 Wind Energy Research at AAU - with focus on composite materials and wind turbine blades Presented by Erik Lund, Professor in Computational Mechanics and Design Optimization Department of Mechanical and Manufacturing Engineering, Aalborg University Agenda: Overview of AAU and activities within wind energy Focus on wind turbine blades / composite materials June 19, 2012, NOVI Aalborg University Aalborg University has more than 17,000 students, ranging from students at preparatory courses through doctoral-level candidates Around 4,000 students are enrolled at the Faculty of Humanities, 5,000 students at the Faculty of Social Sciences, 7,000 at the Faculty of Engineering and Science and 1000 students at Faculty of Medicine 10% are international students from 100 different countries all over the world The university employs around 1300 faculty and 1000 administrative staff The research are organized into 4 faculties and 18 departments Aalborg University offer in total 65 different educational programmes organized in 10 schools Aalborg University have more than 60 master programmes taught in English

2 Campus Locations in DK Aalborg University Campus Aalborg

3 Aalborg University Campus Aalborg East Key figures 2011 (Engineering and Science) Revenue : 1.30 bill dkr Employees : Brutto area m2 Research m2 Education m2 Administration 2500 m2 Other 7500 m2 Departments : 10 Schools : 3 (Appr. 30 Bachelor, 60 Master programmes - English) Ph.D. : 500 Students : 7000

4 Revenue budget mio. dkr. (in whole mill dkr.) Education (34%) Research (25%) Ph.D/research education (9%) Public sector consultancy (2%) Sale of goods and services (3%) External funded research (26%) Departments Engineering and Science Civil Engineering Architecture, Media and Design Mechanical Engineering and Manufacturing Energy Technology Electronic Systems Mathematics and Statistics Computer Science Physics and Nano-technology Learning and Philosophy (cross faculty) Chemistry, Biotech and Life Science Planning Center for Industrial Production Campus Esbjerg Campus Copenhagen

5 Aalborg University - EXCELLENCE in wind energy Research areas in wind energy: Power electronics, Generators Power systems, Grid integration Control Blades, Composite materials and structures Support structures / Foundation Structural dynamics Offshore and on-shore wind turbines Reliability / Operation & Maintenance Logistics, production and design for manufacturing of wind turbines Energy planning Aalborg University - EXCELLENCE in wind energy Research projects focus on cooperation with industry and international partners - Examples: AEOLUS: Distributed Control of Large Scale Offshore Wind Farms Development of a secure, economic and environmentally-friendly modern power system Dynamic wind turbine model - from wind to grid Foundation of offshore wind turbines with suction buckets Blade King Composite shell foundations made of high-tension concrete and steel sheets Reliability-based analysis applied for reduction of cost of energy for offshore wind turbines Norwegian Centre for Offshore Wind Energy (NORCOWE) Vestas Power Programme

6 Aalborg University - Excellence in wind energy MSc programs : Wind Power Systems (electrical aspects) Offshore, Structural and Mechanical Engineering (mechanical aspects) Energy Planning and Sustainable Energy Continuing education: Master in wind energy: WindMaster PhD programs: More than 70 PhD students PhD courses Wind Energy - Aalborg University - Departments Department of Civil Engineering Department of Development and Planning Department of Energy Technology Department of Electronic Systems - Section for Automation & Control Department of Computer Science Department of Mechanical and Manufacturing Engineering

7 Number of Ph.D students within Wind energy Departments Active Ph.D. students Civil Engineering 14 Mechanical and Manufacturing Engineering 16 Electronic Systems 18 Energy Technology 25 Planning 2 Total 75 Department of Civil Engineering Wind energy activities: Loads and safety Operation and Maintenance Rotordynamics Foundations substructure design Wave and current loads - scour See more details on the following slides Professor John Dalsgaard Sørensen Professor Søren R.K. Nielsen Assoc. Prof. Peter Frigaard Professor Lars Bo Ibsen Assoc. Prof. Lars Andersen

8 Load & Safety Operation & Maintenance Reliability of wind turbines Planning of operation & maintenance Professor John Dalsgaard Sørensen Rotordynamics Multi-body dynamics of wind turbines Non-linear rotor dynamics Smart control Professor Søren R.K. Nielsen

9 Wave and current loads - Scour Environmental offshore loads: Waves; irregular breaking Currents; wave generated / tidal Loads from wave/current Loads from ice Erosion holes (Scour) Scour protection Assoc. Prof. Peter Frigaard pf@civil.aau.dk Assoc. Prof. Thomas L Andersen tla@civil.aau.dk Foundation Substructures and Geotechnics Mono-pile and jacket foundation for offshore wind turbines Bucket foundation for offshore wind-turbines Soil - Structure interaction of foundations for wind turbines Professor Lars Bo Ibsen lbi@civil.aau.dk Assoc. Prof. Lars Andersen la@civil.aau.dk

10 Offshore wind energy - project examples: UpWind: Integrated Wind turbine Design EU 6 rammeprogram: John D Sørensen, Institut for Byggeri og Anlæg Zhe Chen & Birgitte Bak-Jensen, Institut for Energiteknik Development of the Bucket foundation Lars Bo Ibsen, Institut for Byggeri og Anlæg Søren A. Nielsen, MBD Physical and numerical modeling of monopile in silt with focus on offshore wind turbines Lars Bo Ibsen, Institut for Byggeri og Anlæg Søren A. Nielsen, MBD Offshore wind energy - project examples: Time Development of Scour Around Offshore Monopiles Samfinansieret PhD project Peter Frigaard, Institut for Byggeri og Anlæg Wave Forces on Boat Landings Samfinansieret PhD projekt Lars Bo Ibsen & Thomas Lykke Andersen, Institut for Byggeri og Anlæg Probabilistic Design of Wind Turbines Det Strategiske Forskningsråd John D Sørensen, Institut for Byggeri og Anlæg

11 Offshore wind energy - project examples: Reliability-based analysis applied for reduction of cost of energy for offshore wind turbines Danish Council for Strategic Research (DSF) John D Sørensen, Lars Bo Ibsen, Lars Andersen, Institut for Byggeri og Anlæg Ole Thybo Thomsen and Erik Lund, Institut for Mekanik og Produktion Norwegian Centre for Offshore Wind Energy (NORCOWE) Norwegian Council for Strategic Research Zhe Chen, Frede Blaabjerg, Institut for Energiteknik Thomas Bak, Institut for Elektroniske Systemer John D Sørensen, Institut for Byggeri og Anlæg Department of Development and Planning Wind energy activities: Inter-disciplinary work on energy planning Technical energy systems analyses and GIS analyses of energy systems Primary focus is on the production of energy Professor Henrik Lund Assoc. Professor Poul A Østergaard

12 Department of Electronic Systems - Section for Automation & Control Wind energy activities: Control of wind turbines Control of floating wind turbine installations (NORCOWE) Distributed Control of Large Scale Offshore Wind Farms (AEOLUS): Professor Thomas Bak Professor Jakob Stoustrup Professor Rafal Wisniewski Department of Energy Wind energy activities: Energy production, distribution, consumption, and control Vestas Wind Power Program Grid Integration of Offshore Wind Farms (NORCOWE) Many other examples, see a few on the following slides Professor Frede Blåbjerg Professor Zhe Chen Professor Remus Teodorescu Professor Stig Munk-Nielsen Assoc. Prof. Birgitte Bak-Jensen

13 Key Words: Power Electronics converters Modern Generators Fluid power System New Systems Concepts Advanced Control Grid Connection HVDC transmision Wind farms Grid Codes Reliability Systems optimization Performance & cost Wind Turbine Systems Control System Rotor Gearbox Generator Wind Energy Mechanical Energy Power electronics Transformer Grid Electrical Energy Grid Requirements! Key Words: Smart Grid and Active Networks Distributed Power Renewable Sources New Grid Structures Grid Stability Grid Reliability Grid Control Grid Components Independency Micro Grids Self Organised Networks Storage Systems EU UNIFLEX-PM

14 Next: Department of Mechanical and Manufacturing Engineering Department of Mechanical and Manufacturing Engineering (M-Tech) (Merger of Department of Mechanical Engineering and Department of Production per 1 March 2010) Approx. 110 faculty/supporting staff/phd students Budget 2011: Approx. DKK 90 mill. Key professional areas: o Materials Science and Engineering (composites, polymers, ceramics, metals and alloys) o Mechanics / Solid mechanics / Structural mechanics (lightweight structures, composites, ) o Computational Mechanics & Computer-Aided Engineering Design (FE analysis, multi-criteria optimization, fluid structure interaction, acoustics, ) o Biomechanics (musculoskeletal modelling & ergonomics) o Manufacturing Engineering (processing technology, metals, polymers, welding, assembly, automation, ) o Robotics and Mechatronics o Management, operational analysis, logistics and production planning

15 M-Tech research groups 1. Materials Science and Engineering 2. Solid and Computational Mechanics 3. Mechanical Systems and Mechatronics 4. Biomechanics - The AnyBody Research Group 5. Materials Processing Group 6. Robotics and Automation 7. Applied Operations Research & Operations Management 8. Logistics - Centre for Logistics (CELOG) 9. Product Configuration 10. Construction Management At the moment all research activities related to wind energy are in the first two research groups listed. Materials Science and Engineering Key areas of research: Mechanics of materials Mesomechanics Polymers : characterization and processing Polymer based composites Nano phased/structured materials (nano composites) Metal alloys Ceramics and microcellular materials

16 Solid and Computational Mechanics Key areas of research: Fundamental mechanics and solid mechanics Machine design (transmissions, bearings, ) Dynamics and fluid structure interactions Finite element analysis and other numerical methods Computer-aided engineering design Multidisciplinary design optimisation Vibro acoustics Experimental characterisation of materials and structures Fibre reinforced polymer materials (FRP or composites ) Lightweigth composite and sandwich structures Processing/manufacturing of polymer composites Laboratories & Workshops Well-equipped laboratories and workshops Integrated part of the education, research and development activities Materials testing and characterisation Testing of structures and mechanical systems Prototype development and qualification

17 Laboratories & Workshops from Autumn 2012 Our laboratories and workshops are being completely refurbished for 70 mill DKK. Opening in September All facilities are moved to Fibigerstraede 14 which has been expanded. State-of-the-art laboratories and workshops within mechanical and manufacturing engineering. Materials Science and Engineering / Solid and Computational Mechanics Staff: 14 faculty members (professors, assoc. professors, assist. professors) 25 PhD students (including 10 industrial PhD students) 16 associated with wind energy 8 postdocs Project portfolio on polymers, composite materials and structures (most projects related to wind turbine industry): Total project turnover in excess of EURO 15 mill. More than 15 ongoing research projects with Siemens Wind Power, Vestas Wind Systems, LM Wind Power and Suzlon Wind Energy

18 Activities related to Wind Power Technology Teaching/education: Student projects typically 2nd, 3rd and 4th semester M.Sc. Curriculum: Vestas Wind Systems, LM Glasfiber, Siemens Wind Power, Suzlon Wind Energy (typically 3-6 M.Sc. projects every year related to wind power technology) Ad hoq courses and supervision of projects for industry Research: Mainly related to characterisation, modelling/analysis, design and optimization of advanced composite materials and sandwich structures for wind turbine blades A few projects concern modelling, design and validation of mechanical drive trains for wind turbines including gears and bearings with a special focus on wear and tribology. Several ongoing and recent projects with partners in wind energy sector (wind turbine blade manufacturers, material suppliers, research institutions, ) Projects within Wind Energy Ongoing large research projects (+50 mill. kr): HTF platform ( ) Blade King with LM Wind Power, Comfil ApS & DTU Wind Energy. (HTF: Højteknologifonden Advanced Technology Foundation) Large-scale integration project under EU-FP7 (FP7-NMP , Grant agreement no.: ): NanCore - Microcellular Nanocomposite for Substitution of Balsa Wood and PVC Core Materials. Many partners including LM Wind Power. DSF project ( ): Danish Centre for Composite Structures and Materials for Wind Turbines with DTU, AAU, LM Wind Power, Siemens Wind Power, DSF: Danish Council for Strategic Research. Nearly all key persons from Danish Universities working on composite materials and structures for wind turbines are involved in this center. AAU will have 7 Ph.D. students in relation to this center.

19 Projects within Wind Energy Examples of ongoing projects funded by FTP (the Danish Council for Technology and Innovation) and DSF: FTP ( ): Optimal Design of Composite Structures under Manufacturing Constraints - with DTU Wind Energy and Siemens Wind Power. FTP ( ): Thermal Degradation Effects in Foam Cored Sandwich Structures with LM Wind Power, DIAB AB, and Univ. Southampton. FTP ( ): Enhanced Performance of Sandwich Structures by Improved Damage Tolerance with DTU-MEK, Siemens Wind Power, LM Wind Power, and Univ. Southampton. FTP ( ): Mechanical Property Characterisation of Fibre Composites with Focus on Thermal Cure Conditions - with L Ecole Polytechnique Montreal, Canada, and Siemens Wind Power. DSF ( ): Reliability-Based Analysis and Design of Wind Turbine Blades with AAU-CIVIL, Vestas Wind Systems, DONG, and DTU Wind Energy. Ongoing Industrial Ph.D. Projects within Wind Energy : The Influence of Defects on the Failure of Wind Turbine Blades. Industrial Ph.D. project with Siemens Wind Power : Progressive Damage Simulation of Laminates in Wind Turbine Blades under Quasistatic and Cyclic Loading. Industrial Ph.D. project with Siemens Wind Power : Design of Sandwich Structures with Grid Scored Core Materials for Wind Turbine Blades. Industrial Ph.D. project with Suzlon Wind Energy : Dynamic Drive Train Simulation. Industrial Ph.D. project with Vestas Wind Systems : Optimal Design of Wind Turbine Drive Trains. Industrial Ph.D. project with Vestas Wind Systems : Development of a New Hydraulic Yaw System for Wind Turbines. Industrial Ph.D. project with Liftra Aps.

20 More information Prof. Ole Thybo Thomsen, Prof. Ryszard Pyrz, Prof. Erik Lund, On the following slides one example of a research project on wind turbine blades is presented. Structural Instability Phenomena in Wind Turbine Blades Improved design of large wind turbine blades EUDP 3&4: AAU, Risø-DTU, DTU, Vestas Wind Systems and LM Glasfiber Courtesy of Vestas Wind Systems A/S The test data, post mortem analysis and "standard" FE models suggested: Local buckling phenomenon and influence of initial geometric imperfections Local stiffness degradation, i.e. damage propagation (delamination) - probably interlaminar/delamination damage at biaxial interfaces Very difficult to capture and explain the sequence of events causing the progressive failure

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22 A method for progressive damage simulation of composite structures was developed, taking both geometric and material nonlinearities into account Adaptive mesh refinement and cohesive zone modeling (large scale) Progressive development of debonding/delamination (damage) and local instabilities

23 A method for progressive damage simulation of composite structures was developed, taking both geometric and material nonlinearities into account Adaptive mesh refinement and cohesive zone modeling (large scale) Progressive development of debonding/delamination (damage) and local instabilities Comparison between measured acoustic emission data (a) and finite element damage results (c)

24 A look inside the deformed main spar: (a) damage state 1 prior to the limit point and figure (b) damage state 2 after the crossing of the limit point. More information Prof. Erik Lund, el@m-tech.aau.dk Department of Mechanical and Manufacturing Engineering, AAU