Efficient and realistic tests of large wind turbine blades

The standard certification tests, that blades are tested against today, are not representing the actual conditions the blades will be exposed to when taken in use.  In reality, blades are exposed to torsion and bending in different directions at the same time. Therefore, better and more realistic fatigues testing methods has been crucial – and Blatigue’s testing method which uses multiple axes simultaneously is exactly such a testing method.

Large blades that can extend past 100 meters today can then through this method be tested under more realistic conditions with simultaneous twisting in different directions. Aside from being more realistic the testing method is also faster and more efficient than existing test methods.

At the projects conclusion, Kim Branner, DTU, stated that the Blatigue project culminated in the successful demonstration of the test method and test equipment on a 75 meter blade at Blaest in Aalborg. Another main result that the project has shown is that a blade can be tested much better in half the time compared to a traditional certification test, Branner says.

Optimisation through digitalisation

The EUDP funded project was finalised in 2021. The same year, the project partners received approval of funding for a second part of the project, BLATIGUE-2:  Fast, Smart and Efficient Fatigue Testing of Large Wind Turbine Blades. The project aims to improve test methods and make fatigue tests smarter through the integration of load equipment and software. The project will also develop and test methods that significantly reduce the time for the fatigue testing of the blades.

By using digital image correlation techniques, drone technology and image analysis techniques the project will develop contactless measurements and automated inspection systems and reduce the time and labor consuming operations currently included in fatigue testing. Through automation and digitisation, the developed methods of fatigue testing will provide added value for manufacturers and operators.

The project, led by DTU, is supported by EUDP with almost DKK 33 mill.