A key consideration that goes behind blade design and manufacturing is related to coming up with a reliable efficient power generation.
This means low maintenance of machinery, low variation in weight and mechanical performance of blades to reduce variable results and of course high power output in lower wind speeds to optimise the power curve.
Yet, blade failure, which is one of the main reasons behind wind turbine accidents, can arise due to numerous reasons or from possible sources, and results in either whole blades or pieces of blade being thrown from the turbine.
There are far too many blade failures, or blades in need of repair, replacement or a remedy, says David Cripps, Strategic Account Manager - Wind Energy, Gurit USA Inc.
“The work going on now in this respect is due to either manufacturing defects or design defects. In many cases, the defect has been caused by a valid design, but one that just proved impractical to manufacture to the tolerance level or accuracy required,” said Cripps.
Commenting on how much one can relate to the pressure to rapidly grow output from blade factories, Cripps said a lot has to do with the difficulty that new manufacturing teams can have with building to the accuracy, or defect level required, whilst it being driven to lower costs and increased production throughput.
“Also with the rapid rate of introduction of new blade designs, it is always possible that design errors creep in,” acknowledged Cripps.
According to experts from the industry, structural flaws have been encountered, particularly with the blades. Cracks sometimes appear soon after manufacturing. Mechanical failure, due to alignment and assembly errors, is common. Electrical sensors frequently fail because of the power surges. Non-hydraulic brakes tend to be reliable, but hydraulic braking systems often cause problems.
Manufacturing flaws can cause problems during normal operation. For example, it has been pointed out that blades can develop cracks at the edges, near the hub or at the tips. Fibre glass rotor blades have been considered to be the most susceptible components of a wind turbine. Typical manufacturing flaws in case of the blades may be summarised as delaminations, adhesive flaws and resin-poor areas.
This means low maintenance of machinery, low variation in weight and mechanical performance of blades to reduce variable results and of course high power output in lower wind speeds to optimise the power curve.
Yet, blade failure, which is one of the main reasons behind wind turbine accidents, can arise due to numerous reasons or from possible sources, and results in either whole blades or pieces of blade being thrown from the turbine.
There are far too many blade failures, or blades in need of repair, replacement or a remedy, says David Cripps, Strategic Account Manager - Wind Energy, Gurit USA Inc.
“The work going on now in this respect is due to either manufacturing defects or design defects. In many cases, the defect has been caused by a valid design, but one that just proved impractical to manufacture to the tolerance level or accuracy required,” said Cripps.
Commenting on how much one can relate to the pressure to rapidly grow output from blade factories, Cripps said a lot has to do with the difficulty that new manufacturing teams can have with building to the accuracy, or defect level required, whilst it being driven to lower costs and increased production throughput.
“Also with the rapid rate of introduction of new blade designs, it is always possible that design errors creep in,” acknowledged Cripps.
According to experts from the industry, structural flaws have been encountered, particularly with the blades. Cracks sometimes appear soon after manufacturing. Mechanical failure, due to alignment and assembly errors, is common. Electrical sensors frequently fail because of the power surges. Non-hydraulic brakes tend to be reliable, but hydraulic braking systems often cause problems.
Manufacturing flaws can cause problems during normal operation. For example, it has been pointed out that blades can develop cracks at the edges, near the hub or at the tips. Fibre glass rotor blades have been considered to be the most susceptible components of a wind turbine. Typical manufacturing flaws in case of the blades may be summarised as delaminations, adhesive flaws and resin-poor areas.
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