Modeling, Simulation, and Optimization of Large‚ÄêScale Wind Turbine Blade Manufacturing
Bob Minaie, Ph.D.
bob.minaie@wichita.edu
The long‚Äêterm goal of this research is to reduce the cost of wind energy and improve
the durability of turbine blades through better manufacturing processes. The one‚Äêyear
goal of this research is to model, simulate, and optimize the manufacturing process
of transverse-section wind turbine blades with the aim at reducing prototyping time
and trial-and-error fabrication.
Thus far, the manufacturability of hybrid carbon-glass fiber-reinforced composite
wind turbine blades using Vacuum-Assisted Resin Transfer Molding (VARTM) was investigated.
The objective of this investigation was to study the VARTM process and its parameters
to manufacture cost-effective wind turbine blades with no defects (mainly eliminate
dry spots and reduce manufacturing time). A 2.5-dimensional model and a 3-dimensional
model were developed to simulate mold filling and part curing under different conditions.
These conditions included isothermal and non-isothermal filling, curing of the part
during and after filling, and placement of injection gates at different locations.
Results from this investigation reveal that the process can be simulated and also
that manufacturing parameters can be optimized to eliminate dry spot formation and
reduce the manufacturing time.
Using computer-based models is a cost-effective way to simulate manufacturing of wind turbine blades. The approach taken herein allows the design of the wind blade manufacturing processes without physically running trial-and-error experiments that are expensive and time-consuming; especially for larger blades needed for more demanding environmental conditions. This will benefit the wind energy industry by reducing initial design and manufacturing costs which can later be passed down to consumers and consequently make the wind energy industry more competitive.