Abstract. This work investigates the conceptual design and the aeroservoelastic performance of land-based wind turbines whose blades can be transported on rail via controlled bending. The turbines have a nameplate power of 5 MW and a rotor diameter of 206 m, and they aim to represent the next generation of land-based machines. Three upwind designs and two downwind designs are presented, combining different design goals together with conventional glass and pultruded carbon fiber laminates in the spar caps. One of the five blade designs is segmented and serves as a benchmark to the state of the art in industry. The results show that controlled flexing requires a reduction in the flapwise stiffness of the blades, but it represents a promising pathway for increasing the size of land-based wind turbine rotors. Given the required stiffness, the rotor can be designed either downwind with standard rotor preconing and nacelle uptilt angles or upwind with higher-than-usual angles. A downwind-specific controller is also presented, featuring a cut-out wind speed reduced to 19 m s−1 and a pitch-to-stall shutdown strategy to minimize blade tip deflections toward the tower. The flexible upwind and downwind rotor designs equipped with pultruded carbon fiber spar caps are found to generate the lowest levelized cost of energy, 2.9 % and 1.3 %, respectively, less than the segmented design. The paper concludes with several recommendations for future work in the area of large flexible wind turbine rotors.

Abstract. Increasing growth in land-based wind turbine blades to enable higher machine capacities and capacity factors is creating challenges in design, manufacturing, logistics, and operation. Enabling further blade growth will require technology innovation. An emerging solution to overcome logistics constraints is to segment the blades spanwise and chordwise, which is effective, but the additional field-assembled joints result in added mass and loads, as well as increased reliability concerns in operation. An alternative to this methodology is to design slender flexible blades that can be shipped on rail lines by flexing during transport. However, the increased flexibility is challenging to accommodate with a typical glass-fiber, upwind design. In a two-part paper series, several design options are evaluated to enable slender flexible blades: downwind machines, optimized carbon fiber, and active aerodynamic controls. Part 1 presents the system-level optimization of the rotor variants as compared to conventional and segmented baselines, with a low-fidelity representation of the blades. The present work, Part 2, supplements the system-level optimization in Part 1 with high-fidelity blade structural optimization to ensure that the designs are at feasible optima with respect to material strength and fatigue limits, as well as global stability and structural dynamics constraints. To accommodate the requirements of the design process, a new version of the Numerical Manufacturing And Design (NuMAD) code has been developed and released. The code now supports laminate-level blade optimization and an interface to the International Energy Agency Wind Task 37 blade ontology. Transporting long, flexible blades via controlled flapwise bending is found to be a viable approach for blades of up to 100 m. The results confirm that blade mass can be substantially reduced by going either to a downwind design or to a highly coned and tilted upwind design. A discussion of active and inactive constraints consisting of material rupture, fatigue damage, buckling, deflection, and resonant frequencies is presented. An analysis of driving load cases revealed that the downwind designs are dominated by loads from sudden, abrupt events like gusts rather than fatigue. Finally, an analysis of carbon fiber spar caps for downwind machines finds that, compared to typical carbon fibers, the use of a new heavy-tow carbon fiber in the spar caps is found to yield between 9 % and 13 % cost savings.

Abstract. This work investigates the conceptual design and the aeroservoelastic performance of land-based wind turbines whose blades can be transported on rail via controlled bending. The turbines have a nameplate power of 5 MW and a rotor diameter of 206 m, and they aim to represent the next generation of land-based machines. Three upwind designs and two downwind designs are presented, combining different design goals together with conventional glass and pultruded carbon fiber laminates in the spar caps. The results show that controlled flexing requires a reduction in the flapwise stiffness of the blades, but it represents a promising pathway to increase the size of land-based wind turbine rotors. Given the required stiffness, the rotor can be designed either downwind with standard rotor preconing and nacelle uptilt angles or upwind with higher-than-usual angles. A downwind-specific controller is also presented, featuring a cut-out wind speed reduced to 19 m per second and a pitch-to-stall shutdown strategy to minimize blade-tip deflections toward the tower. The flexible upwind and downwind rotor designs equipped with pultruded carbon fiber spar caps are found to generate the lowest levelized cost of energy, 2.9 % and 1.3 %, respectively, less than the segmented design. The paper concludes with several recommendations for future work in the area of large flexible wind turbine rotors.

This report is available at no cost from the National Renewable Energy Laboratory at www.nrel.gov/publications.3. Completed research-and-development opportunity screening 4. Performed model improvements and detailed design studies 5. Assessed low-cost carbon fiber.The remainder of this report focuses on the findings from each task and includes excerpts and citations from previously published work.

Predicting the effective electromechanical properties for piezoelectric fiber composite patches is crucial for analysis of smart structures equipped with such patches. In particular, analytical homogenization models are attractive but are limited by the complexity of the microstructure and the multiphysics involved. The macro-fiber composite (MFC) has emerged as the most popular piezoelectric fiber composite. But typical reports of its effective properties provide layerwise homogenization with low-order mechanical plate theories. This approach discards most of the out-of-plane properties and may introduce significant error from the assumptions about the plate kinematics. Moreover, the effective permittivities of the transducer are not available analytically. In an attempt to overcome these limitations, a new analytical scheme for homogenizing all layers in the MFC patch is proposed. Based on the newly discovered mechanics of structure genome, we avoid all kinematical assumptions and obtain an exact analytical solution for a periodic, multi-layered, linear-piezoelectric material. In doing so, we prove that in any such multi-layered composite, the in-plane strains and the transverse stresses are equal in each layer and the in-plane electric fields and transverse electric displacement are constant between the electrodes. Using this knowledge, a hybrid rule of mixtures is developed to homogenize all the MFC layers to obtain the complete set of properties of the full MFC. In doing the new analytical framework can homogenize any layered piezoelectric medium. Finally, since we were able to avoid the plate-kinematics assumptions, we present studies on their effect on the properties they obtain. We find that the in-plane elastic properties are not affected but the transverse shear moduli are overpredicted from 100% to 300%. What is more, studies are presented on how using the ubiquitous plane-stress-like assumptions to homogenize the fiber layers causes an 8% underprediction of the lateral elastic modulus of the MFC.