R&D Test Systems, a Danish engineering company, has successfully delivered a state-of-the-art wind turbine blade testing bench to the Massachusetts Clean Energy Center's Wind Technology Testing Center (WTTC) based in the United States. This cutting-edge bench is capable of testing wind turbine blades that measure up to an impressive 130 meters in length.
One of the major advantages of this new full-scale multi-axis fatigue blade test system is its ability to reduce testing time. The WTTC can now perform both flap-wise and edge-wise fatigue tests using the same setup, eliminating the need for frequent changes in the testing process.
The blade exciter, a crucial component of the system, is composed of two units. These units possess the remarkable capacity to deliver individual force and power of up to 120kN and 210kW, respectively. The accompanying software allows users to easily configure the test system for different types of tests.
The two exciter units can be operated either in combination for parallel or dual-axis testing or independently on other areas of the bench. By utilizing the dual-axis operation, original equipment manufacturers (OEMs) can save valuable time during blade testing. They can now conduct flap-wise and edge-wise fatigue tests using a single test system, eliminating the time-consuming process of switching between different tests. Furthermore, the multi-axial setup enables the simulation of entirely new test scenarios that closely replicate the challenging offshore wind conditions experienced by the blades.
Following its assembly in Denmark, the test bench was shipped to Boston, United States, and subsequently installed and commissioned on-site by R&D Test Systems in April. After a successful commissioning process, the system was handed over to the WTTC, which has already commenced the initial test cycles using the blade exciter.
WTTC acknowledges that the development of larger and more advanced wind turbines is progressing at an unprecedented pace. Consequently, it emphasizes the importance of an agile and responsive supply chain capable of anticipating the needs of OEMs to accelerate development and reduce time-to-market. In line with this objective, WTTC, which specializes in large wind turbine blade testing, secured the acquisition of this new test bench, ensuring it possesses the size and power necessary to test the next generation of wind turbine blades.
The procurement of the test bench was made possible through a $4 million grant from the US Department of Energy and the Massachusetts Clean Energy Center (MassCEC). These funds were allocated to upgrade the blade testing equipment, enabling it to accommodate the longer and more advanced blades required for larger offshore turbine models.
Niels Pedersen, Key Account Manager for R&D Test Systems, expressed his enthusiasm for this milestone achievement: “Delivering the first blade test setup of this magnitude to the United States is a significant accomplishment for R&D Test Systems. This represents our inaugural commercial dual-axis system that we have successfully provided. As an American-owned company under MTS and ITW, expanding our activities in the United States is a strategic goal for us.”
Rahul Yarala, Executive Director at WTTC, emphasized the importance of remaining prepared for the innovative developments OEMs will introduce in the future: “As a testing facility, we must anticipate what the OEMs will develop next. With this advanced test equipment, we will possess the necessary setup to meet their requirements, enhance testing quality, and significantly reduce testing time.”
