VASTWind: Virtual and Scaled Testing Methods for Mechanical Components of Large Wind Turbines

At a glance

• As turbine dimensions continue to grow, the offshore wind energy sector is faced with the challenge of exponentially increasing costs for full-scale testing and a foreseeable greater demand for such tests.
• Scaled, hybrid, and multi-rig test methods represent a solution, yet tried-and-tested and reliable methods are still lacking.
• In the VASTWind research project, the partners are developing methodologies and strategies adapted specially to the wind industry for the scaled, hybrid, and multi-rig testing of central components of an offshore wind turbine.

The challenge

The continuous growth in the capacity of new offshore wind turbines is presenting a demanding situation for established full-scale test methods. For one thing, larger components translate to disproportionately higher costs, which have an impact on the levelized cost of energy (LCOE). At the same time, however, innovative technologies and lightweight construction materials employed in the larger turbines render testing even more essential to guarantee reliable operation.

Scaled, hybrid, and multi-rig test methods, as already employed in other sectors, represent a promising alternative to full-scale testing:

• Scaling: A scaled-down test object is derived from the original design and produced to lower testing costs.
• Hybrid tests: The results of physical tests up to the load limits of the test bench are combined with virtual tests for the load stages beyond the test bench limits.
• Multi-rig testing: These test setups are combined on different test benches to investigate the same components or subsystems.

For the current state of the art, the required, tried-and-tested, and reliable methods for this approach are lacking. As such, they are yet to find widespread acceptance in commercial scenarios.

The solution

This is where the VASTWind research project comes into play. The partners are developing methodologies and strategies for scaled, hybrid, and multi-rig tests adapted to the wind industry. The scientists focus on three integral components of a wind turbine: rotor blade bearings, complete drive trains, and journal bearings. The objective is to further develop the methods in collaboration with key partners from the wind industry. The work will pursue different approaches in order to anticipate design trends as well as future test requirements and, at the same time, document different forms of damage and detailed test setups for the different components.

Fraunhofer IWES will be contributing its experience in full-scale testing to the project. Additionally, its leading network in the wind industry will help make it possible to reach a broad spectrum of stakeholders.

The added value

The new test methods will make a considerable contribution to the reliability of future turbine generations. VASTWind will not only increase the efficiency of test campaigns but also extend the service life of the existing, tried-and-tested, and validated test infrastructure. In this way, the project will contribute to reducing the LCOE and ensuring reliable energy supply.

VASTWind can rely on the support of an advisory board featuring key members from the wind industry. The funding is intended to further the international collaboration of Fraunhofer institutes with other institutions.