Wind Turbine Blade Testing Solutions

Wind Turbine Blade Testing SolutionsOptimize the reliability of your designs and the overall effectiveness of your test facility

MTS’ wind turbine blade testing solutions are engineered to address the complete range of full-scale structural static and fatigue testing required for certification to International Electrotechnical Commission (IEC) Technical Specification 61400-23.

Before you can begin specifying mechanical test solutions, however, a series of critical questions must be answered regarding the costly and complex facility that will support your testing. The facilities-related decisions you make today will either enable you or limit you in the future.

» Will you initially conduct static tests, fatigue tests, or both?

» How many tests will you run per year?

» Will you apply forces and motions flap-wise, edge-wise, or in both directions simultaneously?

» How long are the blades you will initially test, and how long may they become in the future?

» How many tests do you need to run in parallel, and how might this number change over time?

These are just some of the many questions every wind turbine blade manufacturer must face at the preliminary stages of their test program. MTS offers the advanced solutions and facilities planning expertise it takes to set your wind turbine blade testing program on the best course possible from the outset. Our experience helping test professionals evaluate large, expensive test articles translates perfectly to ensuring a successful wind turbine blade test program for you—now and well into the future.

Benefits

» Comprehensive turnkey test systems

and components for both static and

fatigue blade evaluations

» Scalable solutions designed to

expand with your evolving needs

» Test blades up to 100 meters in length

» Complete facilities planning ensures

successful, sustainable laboratories

» Advanced systems integration helps

you get it right the first time

Wind turbine blade static testing is employed to confirm required load profiles and validate blade designs, commonly subjecting blades to 150% of their rated loads. Accurately testing blades to failure requires high-force, high-precision and impact-worthy test equipment.

MTS static test solutions apply tightly controlled static loading to blades, for performing the stiffness and strength tests that are required for certification and FEM model validation. Leveraging proven technology for subjecting wings and other large aerospace components to massive

Static Test Solutions

» Used for performing stiffness and strength

measurements

» Conduct tests for blade certification and

FEM model validation

» Leverage control tools similar to those used

in aerospace static structural testing

» Employ robust hydraulic winch and linear

actuator technologies

» Exert multiple pull points on blade

simultaneously

» Feature tightly integrated control and

data acquisition

loads, these solutions combine robust hydraulic winch and/or linear actuation technologies (commonly employed in tandem) to achieve coordinated, precision loading at multiple pull points along a blade. These technologies can be used either together or individually based on your testing needs.

State-of-the-art FlexTest® digital controls combine with MTS Model 793.00 software, MultiPurpose TestWare® (MPT™) software and optional AeroPro™ software to provide a tightly integrated control and data acquisition solution.

Linear Actuator Assembly

Hydraulic Winch Assembly

Reaction Block

Blade

Loading Fixture

Loading Fixture

Reaction Block



Blade

3


The MTS hydraulic winch assembly configuration is ideally suited for large-deflection, high-load static blade tests. It integrates test-quality winches and articulating pulley assemblies to apply static loading near the blade tip where force requirements are relatively low (below 200 kN), and where displacements are at their highest. The winch assembly control manifold features a low-flow/low-pressure manual mode for setup and automatic mode for testing.

MTS winch assemblies are available in 100 kN and 200 kN configurations, and are composed of a drum, gear reduction, hydraulic motor, control manifold, and cable with inline load cell and load fuse. They are sized for 50% overload and work in conjunction with pullies attached to the strong floor and load cell affixed to the blade. The control manifold connects to the main controller and is equipped with simple, local controls to either release or take in cable during test setup.

The winch system includes integral position feedback. Winch modules are removable from winch stands to facilitate reconfiguration and fixation to the strong floor for downward pull tests. Our engineers will help you make sound winch system fixturing decisions at the earliest possible stage of test program development. Whether you want to outsource this process or receive expert guidance in doing it yourself, you can count on MTS to deliver precisely the support you need.


The MTS linear actuation assembly configuration is designed for testing sections of the blade near the root where smaller displacements (less than two meters) and higher loads (above 200 kN) are required. The actuator can also be mounted in a frame for side-pull applications.

Linear actuator assemblies use a single-ended, fatigue-rated MTS hydraulic actuator with a two-meter stroke and tension range of 400 kN – 800 kN. They also include a 400 kN-rated load cell, 15gpm servovalve, integrally-mounted Temposonics® displacement transducer, mechanical fuse, and the appropriate force-rated wire. Maximum velocity is 2.5 meters per minute.

High-quality, non-metallic bearings maximize actuator service life and are highly resistant to bearing-to-rod galling failures. The assembly’s local control manifold features manual mode for setup and automatic mode for testing, and allows the actuator to extend and retract as needed.

100 kN Hydraulic Winch Station

Force capacity (at blade) 100 kN

Stroke (at blade) 30 m

Speed max 8.6 m/min

Oil consumption (setup) 110 gpm

Oil consumption (test) 57 gpm

Dimensions (LxWxH) 2.1x1.7x1.5 m

Weight 2900 kg

200 kN Hydraulic Winch Station



Speed max 4.3 m/min



Dimensions (LxWxH) 2.1x1.7x1.5 m

Weight 2915 kg

400 kN Linear Actuator Station (short stroke)



Speed max 2.5 m/min



Dimensions (LxWxH) .4x.4x3.1 m

Weight 990 kg

400 kN Linear Actuator Station (long stroke)



Speed max 2.2 m/min



Dimensions (LxWxH) .6x.6x3.1 m

Weight 1900 kg

Hose Stands

IREX Loading Devices

Blade

Fatigue Test Solutions

MTS wind turbine blade fatigue test solutions apply automated cyclic loading to wind turbine blades at resonant frequency to excite the blade and achieve the desired strain rate. This offers a productive and accurate means for meeting the fatigue testing demands of International Electrotechnical Commission (IEC) Technical Specification 61400-23.

Cyclic loads are applied to blades at resonant frequency for flap-wise (typically 0.5 Hz to 2.0 Hz) or edge-wise (typically 2.0 Hz to 5.0 Hz) fatigue blade testing. The attached mass is adjustable in 50 kg increments up to 1000 kg on each of the two actuators.

» Used for performing fatigue testing required

for blade certification

» Employ compact, energy-efficient Inertial

Resonance Excitation (IREX) System

» Feature automated control of test end-levels

and test frequency

» Perform both flap-wise and edge-wise

fatigue testing

» Capable of performing time-saving dual-axis

resonant tests

» Feature integrated control and data

acquisition

IREX System (Blade Fatigue)

Frame

IREX

Insert

5

Reaction Block

IREX Systems

MTS fatigue testing solutions employ compact, energy-efficient IREX (Inertial Resonance Excitation) systems, developed through a Cooperative Research & Development Agreement (CRADA) between the U.S. DOE National Renewable Energy Laboratory (NREL) and MTS. Each IREX system integrates two double-ended, fatigue-rated MTS 244 hydraulic actuators, linear side bearings, a hose stand, and adjustable masses to accurately apply both flap-wise and edge-wise resonant-frequency cyclic loads.

IREX systems feature easy installation, setup and operation and minimal energy consumption. A compact design helps to uphold test data integrity by minimizing the introduction of improper overturning moments.

Next-generation FlexTest control technology and blade resonant fatigue test control software allow you to control each IREX device as a single channel. Linear motion control includes adjustable amplitude and frequency, and advanced dual mode Inertial Resonance Excitation (IREX) System

Standard Specifications

Force capacity 50 kN

Moving mass range 160-1010 kg

Moving mass increment 50 kg

Stationary mass (typ) 170-230 kg

Total mass (typ) 330-390 kg

Dimensions 1.42x.53x.48 m

Stroke 0.15 m

Velocity 1.37 m/sec

Servovalve 120 lpm

Hose sizes -16P, -16R, -8D JIC

Special Options

Tilt angle range +/- 10 deg

Tilt angle increment 2 deg

Accumulation required 2 L (normal)

control allows efficient programming of blade acceleration, displacement or strain. A controlled stop protects operators and test articles from harm in the event of a power loss or mechanical malfunction.

Drawing on decades of test expertise, MTS design consultants can also assist you in specifying the right frame and insert configurations for your application.

Complete tests faster with dual-axis configuration

Accelerate your blade fatigue evaluations with an innovative MTS dual-axis resonant testing configuration. This setup combines multiple IREX systems to enable both flap-wise and edge-wise testing concurrently, allowing you to generate meaningful blade fatigue test results in a fraction of the time.

Technology and Expertise for a Successful Test Program

» A full complement of advanced software

» State-of-the-art controls

» Quality components

» Global service, support and facilities

planning will help you achieve your wind

turbine development objectives faster.

Multipurpose TestWare® (MPT™) Software

MPT (Model 793.10) software provides a flexible, easy-to-use, “drag-and-drop” environment for creating, managing and executing command sequences for both static and fatigue blade tests. It features powerful load, displacement and other control modes, along with a broad range of data acquisition options. An intuitive, easy-to-use “drag-and-drop” feature enables test engineers to link basic processes, including function generation, data acquisition, events, and triggers, to quickly define even the most complex tests. MPT software also works seamlessly with a variety of leading spreadsheet programs and analysis packages to facilitate efficient plotting, analysis and reporting of test data.

FlexTest Controllers

Blade Resonant Fatigue Test Control Software

Available as a module through Multipurpose TestWare® (Model 793.10) software, Blade Resonant Fatigue Test Control (Model 793.86) software automatically adjusts amplitude and phase to hold wind turbine blades in resonance during blade fatigue tests. Feedback can come from blade acceleration, displacement or strain. Calculated channels also lend flexibility to matrix control algorithms, enabling advanced users to adapt readily to changing test demands.

AeroPro™ Software (Optional)

AeroPro Control and Data Acquisition Software is the world’s preferred aerospace structural testing platform. It also offers an ideal optional solution for leveraging advanced data acquisition (DAC) with your wind turbine blade dynamic testing. AeroPro software offers the industry’s most extensive DAC functionality, including support for a variety of data acquisition hardware. It facilitates easy setup and display of channels, and creates a highly precise digital connection to MTS FlexTest® controller data.

FlexTest® Controllers

State-of-the-art FlexTest digital control systems deliver high speeds and channel densities to keep pace with the evolving demands of your wind turbine test program. These controllers share common conditioners, hardware boards and user interface tools, simplifying test standardization and optimization. They are also multi-box scalable, meaning you can connect several FlexTest control systems together to support multiple user workstations and create a single control platform that supports your entire test facility.

Other FlexTest capabilities that are particularly useful for wind turbine blade testing include:

» Limit detectors that initiate a controlled shutdown when user-defined limits are exceeded.

» Dual-mode control, which allows the test system to run in displacement control for stability, while performing tests based on the specimen acceleration or strain conditions being achieved.

» Multi-station capabilities, which enables controller resources to be allocated efficiently across several tests simultaneously

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Unrivaled Service, Support and Facilities Planning

MTS fields one of the largest and most experienced worldwide service, support and consulting staff of any mechanical testing solutions provider. This global team can provide facilities planning expertise to meet both your current and future wind turbine testing needs, equipping you at the outset with the configuration capabilities and adaptability necessary to support your program over the long term.

This consulting spans a wide range of disciplines, including:

» Hydraulic power supply and distribution

» Foundation and strong floor design

» Floor plan efficiency

» Hose and cabling schemes

» Electrical power management

» Materials and equipment handling strategies

Upon facility completion, MTS will coordinate the installation and integration of your test systems, and we will train your laboratory personnel to operate the equipment safely and efficiently. Once your laboratory is fully operational, MTS lifecycle management programs can help maximize your system uptime and productivity, equipping you to complete testing and get new turbine blade designs to market as quickly as possible.

Reaction Blocks

Blade Fatigue Test

Hydraulic Distribution

Blade Static Test

Strong Floors

Control Room

Hydraulic Power Supply

MTS Systems Corporation 14000 Technology Drive Eden Prairie, MN 55344-2290 USA

Telephone: 1-952-937-4000 Toll Free: 1-800-328-2255 Fax: 1-952-937-4515

E-mail: [email protected] www.mts.com

ISO 9001 Certified QMS

Specifications subject to change without notice.

MTS is a trademark of MTS Systems Corporation within the United States. This trademark may be protected in other countries. RTM No. 211177.

© 2012 MTS Systems Corporation. 100-234-441a WindTurbine Printed in U.S.A. 11/12

SilentFlo HPU Specifications

Model 505.60 Model 505.90 Model 505.120 Model 505.150 Model 505.180

Flow rates (for 60 Hz models) 227 lpm (60 gpm) 340 lpm (90 gpm) 454 lpm (120 gpm) 568 lpm (150 gpm) 681 lpm (180 gpm)

Flow rates (for 50 Hz models) 200 lpm (53 gpm) 300 lpm (80 gpm) 400 lpm (106 gpm) 500 lpm (133 gpm) 600 lpm (160 gpm) Noise level* 68 dB (A) 68 dB (A) 70 dB (A) 71 dB (A) 72 dB (A)

Reservoir capacity (maximum) 950 L (250 gal) 950 L (250 gal) 1,893 L (500 gal) 1,893 L (500 gal) 1,893 L (500 gal Width 100 cm (39 in) 100 cm (39 in) 100 cm (39 in) 100 cm (39 in) 100 cm (39 in) Height 200 cm (79 in) 200 cm (79 in) 200 cm (79 in) 200 cm (79 in) 200 cm (79 in) Length 287 cm (113 in) 287 cm (113 in) 457 cm (180 in) 457 cm (180 in) 457 cm (180 in)

Weight with maximum oil 1,907 kg 2,134 kg 2,338 kg 2,542 kg 2,747 kg (4,200 lb) (4,700 lb) (5,150 lb) (5,600 lb) (6,050 lb)

Motor starter configuration Wye-Delta Wye-Delta Wye-Delta Wye-Delta Wye-Delta Motor size 45 KW (60 Hp) 45 KW (60 Hp) 45 KW (60 Hp) 45 KW (60 Hp) 45 KW (60 Hp) Number of Motor/pump units 2 3 4 5 6

Heat exchanger Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel plate style plate style plate style plate style plate style

Hydraulic connections Pressure & Return: SAE 2 inch C61 Flange Pressure & Return: SAE 2 inch C61 Flange Drain: JIC -16 Drain: JIC -16 Drain: JIC -16 Drain: JIC -16 Drain: JIC –16

Cooling water connection 3.8 cm (1.5 in) 3.8 cm (1.5 in) 3.8 cm (1.5 in) 3.8 cm (1.5 in) 3.8 cm (1.5 in)

Operating pressure: 210 bar (3,000 psi) Pump type: Variable displacement pumps Filtration: 3 micron on the return sideMaximum ambient operating temperature: 40° C (104° F)Minimum ambient operating temperature: 5° C (40° F)

* Sound levels [dbA] are expressed as a free field value. Readings may vary with acoustic environment. Specifications subject to change without notice. Please contact MTS for specifications critical to your application.

Hydraulic Distribution Solutions

MTS offers an extensive portfolio of components, systems and consultation designed to maximize safety, reliability and energy-efficiency of hydraulic power generation and distribution. These solutions produce minimal ambient noise levels while delivering exceptionally well-controlled power across a wide range of testing environments.

The MTS hydraulic distribution offering includes:

»» SilentFlo™»Hydraulic»Power»Units»(HPUs), offering the cleanest and quietest hydraulic power supply available.

»» Model»293»Hydraulic»Service»Manifolds»(HSMs) that facilitate the efficient control, isolation, and distribution of hydraulic fluid between test stations, while also ensuring smooth pressure transitions.

»» Hardline»Services: Based on decades of experience in the field, MTS can assist you in the engineering, fabrication and installation of hydraulic hardline and distribution systems, for applications ranging from simple piping to highly complex networking distributions.

Wind Turbine Blade Testing Solutions

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