ÉireComposites, the University of Galway, and Engineers Ireland hosted a hybrid seminar to disseminate the results of the REBLADE project. The event was well attended and the audience was eager to hear the findings presented by Conor Kelly, Tomás Flanagan, Dr. Yadong Jiang (University of Galway), and William Finnegan (University of Galway).
Highlights of the Event
During the event, Conor Kelly, the Engineering Team Lead at ÉireComposites, provided a detailed overview of the manufacturing processes and material testing conducted on both a demonstrator and a full-scale wind turbine blade. Dr. Yadong Jiang, a Lecturer in Civil Engineering at the University of Galway, discussed the structural testing of the full-scale wind turbine blade and explained how the results were used to validate the numerical models developed with BladeComp software for optimal blade design.
REBLADE Project Results
The REBLADE consortium successfully manufactured and tested two 5m wind turbine blade box spar demonstrators. One used conventional thermoset epoxy resin, while the other utilised an innovative, recyclable thermoplastic Elium resin. These tests validated the manufacturability and structural properties of the new recyclable Elium resin reinforced with glass fibre and confirmed the accuracy of the finite element models created using BladeComp software.
A new methodology was developed to optimise power production and extend the lifespan of existing wind turbines. Performance of the new, highly efficient rotor blade was improved through the optimisation of foil shape, size, and twist angle using a genetic algorithm.
Additionally, a full-scale sustainable and recyclable 13m wind turbine blade was designed, and manufactured successfully.
Full-Scale Testing
The full-scale recyclable wind turbine blade was rigorously de-risked through a series of structural tests:
- Static Series 1
- Fatigue Testing
- Static Series 2
- Test to Failure
Initially, the wind blade was loaded to 70% of its design load during Static Series 1 to evaluate its behaviour. The blade then underwent fatigue testing, reaching 500,000 cumulative fatigue cycles. Next, the blade was loaded to 100% of its design load in Static Series 2 to assess potential fatigue damage. Finally, the blade was subjected to a Test to Failure, reaching 165% of its design load. Throughout the testing campaign, the blade demonstrated minimal strain, confirming the viability of using thermoplastic resin to manufacture large-scale composite structures.
About ÉireComposites
ÉireComposites specialises in the design, manufacturing, and development of composite structures and technology. With over 25 years of expertise, ÉireComposites is a leader in sectors such as aviation, space, renewable energy, and mobility. The company is renowned for producing high-quality wind turbine blades and components for leading wind turbine OEMs. ÉireComposites is committed to pioneering research and development in new materials, designs, and manufacturing techniques for the renewable energy industry.
About University of Galway
The University of Galway is a leading research institution with extensive expertise in wind turbine blade design and testing. Home to the Sustainable & Resilient Structures Research Group within the SFI MaREI Research Centre, the university operates a world-class Large Structures Testing Laboratory. With a strong focus on innovation, the university developed advanced tools like the BladeComp software to optimize blade design and efficiency. Leveraging over a decade of experience in renewable energy projects, the university plays a pivotal role in driving the success of the REBLADE project.
About Engineers Ireland
Engineers Ireland is the voice of the engineering profession in Ireland. With over 25,000 members, the organisation is a community of creative professionals delivering sustainable solutions for society. By fostering knowledge sharing and professional development, Engineers Ireland plays a vital role in shaping the future of engineering in Ireland.
Funding and Support
This work has been funded by the Sustainable Energy Authority of Ireland under the SEAI Research, Development & Demonstration Funding Programme 2021, Grant number 21/RDD/630.
