After designing the blade structure in the Netherlands, InDutch Composites Technology produced the mold for the prototype that Suzlon Group subsequently tested for load and fatigue. The results met the IEC61400-5:2020 certification, the production standard for engineering integrity of wind turbine blades.
Eight months of design and engineering work preceded the final validation testing and included blade structure design and the infusion process for the materials – carbon fibres and epoxy resin - as well as training for the production of two molds and one complete rotor blade prototype. Passing these validation tests, the new rotor blade is ready for serial production.
“From an engineering perspective, this result is motivating” said Arnold Timmer, managing director, We4Ce. “We had a very tight schedule of just eight months, which is a challenge, especially for the production of mold and prototype. In the end, the successful TÜV certification proved that our engineering design will work in practice.”
The standard IEC 61400-5:2020, issued by independent test service provider, TÜV Rheinland, specifies the requirements for the engineering integrity of wind turbine blades and operational safety and includes aerodynamic, structural design and material selection, We4Ce’s competence. The certification provides the technical reference for designers and manufacturers among others.
We4Ce’s rotor blades engineers designed the 2.5-3MW rotor blade at its headquarters in Almelo, Netherlands. InDutch Composites Technology produced the molds and prototype at its facility in Vadodara, Gujarat, India where also Suzlon’s testing centre is located.
The company trained technicians from the blade manufacturer and InDutch Composites Technology to use its infusion method for the prototype production, whereby carbon fibers and epoxy resin are placed in the mold and then vacuum processed for uniform distribution. Following prototype production, Suzlon performed static load tests, dual-axis fatigue and post fatigue test, simulating 20-year lifecycle performance.
Offering full service from documentation, drawings, static to fatigue testing requirements, We4Ce supports training blade manufacturers worldwide during prototype blade production on-site. Currently, 40 customised rotor blade engineering designs have resulted, from 900 kW 23-m to 14 MW 108-m blade length.
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