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Effect of Spar Design Optimization on the Mass and Cost of a Large-Scale Composite Wind Turbine Blade

Author

Listed:
  • Khazar Hayat

    (Department of the Mechanical Engineering, Main Campus, The University of Lahore (UoL), 1-km Defense Road, Lahore 54590, Pakistan)

  • Shafaqat Siddique

    (Department of the Mechanical Engineering, Main Campus, The University of Lahore (UoL), 1-km Defense Road, Lahore 54590, Pakistan)

  • Tipu Sultan

    (Department of the Mechanical Engineering, School of Engineering (SEN), University of Management and Technology (UMT), C-II, Johar Town, Lahore 54770, Pakistan)

  • Hafiz T. Ali

    (Department of Mechanical Engineering, College of Engineering, Taif University, Taif 21944, Saudi Arabia)

  • Fahed A. Aloufi

    (Department of Environmental Science, Faculty of Meteorology, Environment and Arid Land Agriculture, King Abdulaziz University, Jeddah 21589, Saudi Arabia)

  • Riyadh F. Halawani

    (Department of Environmental Science, Faculty of Meteorology, Environment and Arid Land Agriculture, King Abdulaziz University, Jeddah 21589, Saudi Arabia)

Abstract

Mass and cost tradeoffs by deploying three optimized spars, made of all-glass, hybrid and all-carbon composites, applied to a publicly available large-scale composite blade of 100 m in length for a 13.2 MW wind turbine, are explored. The blade mass and cost minimizations are calculated for two design load cases, generating the worst aerodynamic loads for parked and rotating rotor blades, while meeting the stiffness, strength, stability and resonance design requirements, as recommended by the wind turbine standards. The optimization cases are formulated as a single-objective, multi-constraint optimization problem, while taking into account the manufacturability of hybrid spars in particular, and it is solved using a genetic algorithm method. The blade mass lowers in the range of 8.1–13.3%, 18.5–20.7% and 25.7–26.4% for the optimized all-glass, hybrid and all-carbon spars, respectively, while the cost decreases for the optimized all-glass spars only. The cost increases in a range of 1.2–13.6% and 24.5–31.5% when the optimized hybrid and all-carbon spars are used. Further, the hybrid spar optimization using the blade mass and cost objective functions, as well as the effects of spar optimization on the blade’s structural performance in terms of tip deflection, strength, buckling resistance and first natural frequency, are discussed.

Suggested Citation

  • Khazar Hayat & Shafaqat Siddique & Tipu Sultan & Hafiz T. Ali & Fahed A. Aloufi & Riyadh F. Halawani, 2022. "Effect of Spar Design Optimization on the Mass and Cost of a Large-Scale Composite Wind Turbine Blade," Energies, MDPI, vol. 15(15), pages 1-17, August.
    • Handle: RePEc:gam:jeners:v:15:y:2022:i:15:p:5612-:d:878735
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    References listed on IDEAS

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    1. Jie Zhu & Xin Cai & Pan Pan & Rongrong Gu, 2014. "Multi-Objective Structural Optimization Design of Horizontal-Axis Wind Turbine Blades Using the Non-Dominated Sorting Genetic Algorithm II and Finite Element Method," Energies, MDPI, vol. 7(2), pages 1-15, February.
    2. Xin Cai & Jie Zhu & Pan Pan & Rongrong Gu, 2012. "Structural Optimization Design of Horizontal-Axis Wind Turbine Blades Using a Particle Swarm Optimization Algorithm and Finite Element Method," Energies, MDPI, vol. 5(11), pages 1-14, November.
    3. Murray, Robynne E. & Beach, Ryan & Barnes, David & Snowberg, David & Berry, Derek & Rooney, Samantha & Jenks, Mike & Gage, Bill & Boro, Troy & Wallen, Sara & Hughes, Scott, 2021. "Structural validation of a thermoplastic composite wind turbine blade with comparison to a thermoset composite blade," Renewable Energy, Elsevier, vol. 164(C), pages 1100-1107.
    4. Jie Zhu & Xin Cai & Rongrong Gu, 2016. "Aerodynamic and Structural Integrated Optimization Design of Horizontal-Axis Wind Turbine Blades," Energies, MDPI, vol. 9(2), pages 1-18, January.
    5. Fischer, Gunter Reinald & Kipouros, Timoleon & Savill, Anthony Mark, 2014. "Multi-objective optimisation of horizontal axis wind turbine structure and energy production using aerofoil and blade properties as design variables," Renewable Energy, Elsevier, vol. 62(C), pages 506-515.
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    Cited by:

    1. Hui Li & Xiaolong Lu & Wen Xin & Zhihui Guo & Bo Zhou & Baokuan Ning & Hongbing Bao, 2023. "Repair Parameter Design of Outer Reinforcement Layers of Offshore Wind Turbine Blade Spar Cap Based on Structural and Aerodynamic Analysis," Energies, MDPI, vol. 16(2), pages 1-24, January.

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