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This paper presents the design and analysis for a spar cap for a wind turbine rotor blade. The cap is formed of an integral, unitary 3D woven material (3WEAVE®) having constant thickness; spar cap weight is varied and controlled by appropriately tapering the cap width from the blade root to tip. This analysis is employed for 24-m and 37-m rotor blades. These studies are conducted parametrically, examining a range of 3WEAVE® materials incorporating varying fractions of glass and carbon fibers, and hence exhibiting a range of structural properties and material costs. These parametric studies are used to determine the impact on blade weight and cost resulting from the various materials studied. Detailed results are presented in the form of tables to enable candidate materials to be evaluated as they are developed.

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Yarn tension during air-jet filling insertion is analyzed experimentally and theo retically for drum and loop storage systems. In the case of drum storage, yarn tension is higher and more even. The model for drum storage shows that the yarn tension depends on the frictional force between the drum surface and the yarn, the mass linear density of the yam, and the unwinding speed. A set-up is developed for air friction coefficient measurements, and friction coefficients for two different yarns are deter mined.