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Search Results (764)

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Keywords = wind turbine production

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15 pages, 1835 KiB  
Article
Stress Development in Droplet Impact Analysis of Rain Erosion Damage on Wind Turbine Blades: A Review of Liquid-to-Solid Contact Conditions
by Quentin Laplace Oddo, Quaiyum M. Ansari, Fernando Sánchez, Leon Mishnaevsky and Trevor M. Young
Appl. Sci. 2025, 15(15), 8682; https://doi.org/10.3390/app15158682 (registering DOI) - 6 Aug 2025
Abstract
The wind energy sector is experiencing substantial growth, with global wind turbine capacity increasing and projected to expand further in the coming years. However, rain erosion on the leading edges of turbine blades remains a significant challenge, affecting both aerodynamic efficiency and structural [...] Read more.
The wind energy sector is experiencing substantial growth, with global wind turbine capacity increasing and projected to expand further in the coming years. However, rain erosion on the leading edges of turbine blades remains a significant challenge, affecting both aerodynamic efficiency and structural longevity. The associated degradation reduces annual energy production and leads to high maintenance costs due to frequent inspections and repairs. To address this issue, researchers have developed numerical models to predict blade erosion caused by water droplet impacts. This study presents a finite element analysis model in Abaqus to simulate the interaction between a single water droplet and wind turbine blade material. The novelty of this model lies in evaluating the influence of several parameters on von Mises and S33 peak stresses in the leading-edge protection, such as friction coefficient, type of contact, impact velocity, and droplet diameter. The findings provide insights into optimising LEP numerical models to simulate rain erosion as closely as possible to real-world scenarios. Full article
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33 pages, 6551 KiB  
Article
Optimization Study of the Electrical Microgrid for a Hybrid PV–Wind–Diesel–Storage System in an Island Environment
by Fahad Maoulida, Kassim Mohamed Aboudou, Rabah Djedjig and Mohammed El Ganaoui
Solar 2025, 5(3), 39; https://doi.org/10.3390/solar5030039 - 4 Aug 2025
Abstract
The Union of the Comoros, located in the Indian Ocean, faces persistent energy challenges due to its geographic isolation, heavy dependence on imported fossil fuels, and underdeveloped electricity infrastructure. This study investigates the techno-economic optimization of a hybrid microgrid designed to supply electricity [...] Read more.
The Union of the Comoros, located in the Indian Ocean, faces persistent energy challenges due to its geographic isolation, heavy dependence on imported fossil fuels, and underdeveloped electricity infrastructure. This study investigates the techno-economic optimization of a hybrid microgrid designed to supply electricity to a rural village in Grande Comore. The proposed system integrates photovoltaic (PV) panels, wind turbines, a diesel generator, and battery storage. Detailed modeling and simulation were conducted using HOMER Energy, accompanied by a sensitivity analysis on solar irradiance, wind speed, and diesel price. The results indicate that the optimal configuration consists solely of PV and battery storage, meeting 100% of the annual electricity demand with a competitive levelized cost of energy (LCOE) of 0.563 USD/kWh and zero greenhouse gas emissions. Solar PV contributes over 99% of the total energy production, while wind and diesel components remain unused under optimal conditions. Furthermore, the system generates a substantial energy surplus of 63.7%, which could be leveraged for community applications such as water pumping, public lighting, or future system expansion. This study highlights the technical viability, economic competitiveness, and environmental sustainability of 100% solar microgrids for non-interconnected island territories. The approach provides a practical and replicable decision-support framework for decentralized energy planning in remote and vulnerable regions. Full article
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25 pages, 7087 KiB  
Article
Production of Anisotropic NdFeB Permanent Magnets with In Situ Magnetic Particle Alignment Using Powder Extrusion
by Stefan Rathfelder, Stephan Schuschnigg, Christian Kukla, Clemens Holzer, Dieter Suess and Carlo Burkhardt
Materials 2025, 18(15), 3668; https://doi.org/10.3390/ma18153668 - 4 Aug 2025
Abstract
This study investigates the sustainable production of NdFeB permanent magnets using powder extrusion molding (PEM) with in situ magnetic alignment, utilizing recycled powder from an end-of-life (Eol) wind turbine magnet obtained via hydrogen processing of magnetic scrap (HPMS). Finite Element Method (FEM) simulations [...] Read more.
This study investigates the sustainable production of NdFeB permanent magnets using powder extrusion molding (PEM) with in situ magnetic alignment, utilizing recycled powder from an end-of-life (Eol) wind turbine magnet obtained via hydrogen processing of magnetic scrap (HPMS). Finite Element Method (FEM) simulations were conducted to design and optimize alignment tool geometries and magnetic field parameters. A key challenge in the PEM process is achieving effective particle alignment while the continuous strand moves through the magnetic field during extrusion. To address this, extrusion experiments were performed using three different alignment tool geometries and varying magnetic field strengths to determine the optimal configuration for particle alignment. The experimental results demonstrate a high degree of alignment (Br/Js = 0.95), exceeding the values obtained with PEM without an external magnetic field (0.78). The study confirms that optimizing the alignment tool geometry and applying sufficiently strong magnetic fields during extrusion enable the production of anisotropic NdFeB permanent magnets without post-machining, providing a scalable route for permanent magnet recycling and manufacturing. Moreover, PEM with in situ magnetic particle alignment allows for the continuous fabrication of near-net-shape strands with customizable cross-sections, making it a scalable approach for permanent magnet recycling and industrial manufacturing. Full article
(This article belongs to the Special Issue Advanced Materials and Processing Technologies)
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18 pages, 1156 KiB  
Review
Increased Velocity (INVELOX) Wind Delivery System: A Review of Performance Enhancement Advances
by Anesu Godfrey Chitura, Patrick Mukumba and Ngwarai Shambira
Wind 2025, 5(3), 19; https://doi.org/10.3390/wind5030019 - 4 Aug 2025
Abstract
Residential areas are characterized by closely packed buildings which disturb wind flow resulting in low wind speeds (below 2 m/s) with a high turbulence intensity (above 20%). In order to interface between off-the-shelf wind turbines and low-quality wind, the Increased velocity (INVELOX) wind [...] Read more.
Residential areas are characterized by closely packed buildings which disturb wind flow resulting in low wind speeds (below 2 m/s) with a high turbulence intensity (above 20%). In order to interface between off-the-shelf wind turbines and low-quality wind, the Increased velocity (INVELOX) wind delivery system is an attractive wind augmentation option for such regions. The INVELOX setup can harness more energy than conventional bare wind turbines under the same incident wind conditions. However, these systems also have drawbacks and challenges that they face in their operation, which amplify the need to review, understand, and expose gaps and flaws in pursuit of increased power production in low wind quality environments. This paper seeks to review and simplify the advances done by various scholars towards improving the INVELOX delivery system. It provides the mathematical foundation on which these advances are rooted and gives an understanding of how the improvements better the geometric properties of INVELOX. The article concludes by proposing future research directions. Full article
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21 pages, 4761 KiB  
Article
Enhanced Dynamic Game Method for Offshore Wind Turbine Airfoil Optimization Design
by Rui Meng, Jintao Song, Xueqing Ren and Xuhui Chen
J. Mar. Sci. Eng. 2025, 13(8), 1481; https://doi.org/10.3390/jmse13081481 - 31 Jul 2025
Viewed by 165
Abstract
The novel enhanced dynamic game method (EDGM) is proposed to advance game-based design approaches, with a focus on enhancing solution distribution, precision, and the ability to reveal the dynamic influence sensitivity of design variables on objective functions. An integrated mathematical model is developed [...] Read more.
The novel enhanced dynamic game method (EDGM) is proposed to advance game-based design approaches, with a focus on enhancing solution distribution, precision, and the ability to reveal the dynamic influence sensitivity of design variables on objective functions. An integrated mathematical model is developed by combining EDGM with PARSEC and CST parameterization methods, forming a systematic framework for offshore wind turbine airfoil optimization. Targeting airfoils with approximately 30% and 35% thickness, the study aims to improve annual energy production (AEP) and optimize the polar moment of inertia. Redesigned airfoils using the EDGM-integrated model exhibit significant enhancements in aerodynamic performance and anti-flutter capability compared to baseline airfoils DU97W300 and DU99W350. The methodology’s superiority is validated through analyses of pressure distributions, lift-to-drag ratios, and streamline patterns, as well as comparative evaluations using HV and Spacing metrics, demonstrating EDGM’s potential for broader engineering applications in complex multi-objective optimization scenarios. Full article
(This article belongs to the Section Coastal Engineering)
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34 pages, 6236 KiB  
Article
Factors Impacting Projected Annual Energy Production from Offshore Wind Farms on the US East and West Coasts
by Rebecca J. Barthelmie, Kelsey B. Thompson and Sara C. Pryor
Energies 2025, 18(15), 4037; https://doi.org/10.3390/en18154037 - 29 Jul 2025
Viewed by 172
Abstract
Simulations are conducted using a microscale model framework to quantify differences in projected Annual Energy Production (AEP), Capacity Factor (CF) and wake losses for large offshore wind farms that arise due to different input datasets, installed capacity density (ICD) and/or wake parameterizations. Differences [...] Read more.
Simulations are conducted using a microscale model framework to quantify differences in projected Annual Energy Production (AEP), Capacity Factor (CF) and wake losses for large offshore wind farms that arise due to different input datasets, installed capacity density (ICD) and/or wake parameterizations. Differences in CF (and AEP) and wake losses that arise due to the selection of the wake parameterization have the same magnitude as varying the ICD within the likely range of 2–9 MW km−2. CF simulated with most wake parameterizations have a near-linear relationship with ICD in this range, and the slope of the dependency on ICD is similar to that in mesoscale simulations with the Weather Research and Forecasting (WRF) model. Microscale simulations show that remotely generated wakes can double AEP losses in individual lease areas (LA) within a large LA cluster. Finally, simulations with the Coupled Ocean-Atmosphere-Wave-Sediment Transport (COAWST) model are shown to differ in terms of wake-induced AEP reduction from those with the WRF model by up to 5%, but this difference is smaller than differences in CF caused by the wind farm parameterization used in the mesoscale modeling. Enhanced evaluation of mesoscale and microscale wake parameterizations against observations of climatological representative AEP and time-varying power production from wind farm Supervisory Control and Data Acquisition (SCADA) data remains critical to improving the accuracy of predictive AEP modeling for large offshore wind farms. Full article
(This article belongs to the Section A3: Wind, Wave and Tidal Energy)
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23 pages, 5229 KiB  
Review
The Key Constituents, Research Trends, and Future Directions of the Circular Economy Applied to Wind Turbines Using a Bibliometric Approach
by Luis Zanon-Martinez and Conrado Carrascosa-Lopez
Energies 2025, 18(15), 4024; https://doi.org/10.3390/en18154024 - 29 Jul 2025
Viewed by 212
Abstract
The concept of the circular economy aims to develop systems for reusing, recovering, and recycling products and services, pursuing both economic growth and sustainability. In many countries, legislation has been enacted to create frameworks ensuring environmental protection and fostering initiatives to implement the [...] Read more.
The concept of the circular economy aims to develop systems for reusing, recovering, and recycling products and services, pursuing both economic growth and sustainability. In many countries, legislation has been enacted to create frameworks ensuring environmental protection and fostering initiatives to implement the circular economy across various sectors. The wind energy industry is no exception, with industries and institutions adopting strategies to address the forthcoming challenge of repowering or dismantling a significant quantity of wind turbines in the coming years reaching a total of global wind power capacity by 2024. This also involves managing the resulting waste, which includes materials with high economic value as well as others that have considerable environmental impacts but that can be reused, recycled, or converted. In parallel, the research activity in this field has increased significantly in response to this challenge, leading to a vast body of work in the literature, especially in the last three years. The aim of this paper is to conduct a bibliometric study to provide a global perspective on the current literature in the field, covering the period from 2009 to 2024. A total of 670 publications were retrieved from Web of Science and Scopus, with 57% of them published in the last three years, highlighting the growing interest in the field. This study analyzes the research product, the most relevant journal, the most cited authors and institutions, their collaborative patterns, emerging trends, and gaps in the literature. This contribution will provide an up-to-date analysis of the field, fostering better understanding of the direction of the research and establishing a solid foundation for future studies Full article
(This article belongs to the Section A3: Wind, Wave and Tidal Energy)
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25 pages, 3279 KiB  
Review
Current State of Development of Demand-Driven Biogas Plants in Poland
by Aleksandra Łukomska, Kamil Witaszek and Jacek Dach
Processes 2025, 13(8), 2369; https://doi.org/10.3390/pr13082369 - 25 Jul 2025
Viewed by 463
Abstract
Renewable energy sources (RES) are the foundation of the ongoing energy transition in Poland and worldwide. However, increased use of RES has brought several challenges, as most of these sources are dependent on weather conditions. The instability and lack of control over electricity [...] Read more.
Renewable energy sources (RES) are the foundation of the ongoing energy transition in Poland and worldwide. However, increased use of RES has brought several challenges, as most of these sources are dependent on weather conditions. The instability and lack of control over electricity production lead to both overloads and power shortages in transmission and distribution networks. A significant advantage of biogas plants over sources such as photovoltaics or wind turbines is their ability to control electricity generation and align it with actual demand. Biogas produced during fermentation can be temporarily stored in a biogas tank above the digester and later used in an enlarged CHP unit to generate electricity and heat during peak demand periods. While demand-driven biogas plants operate similarly to traditional installations, their development requires navigating regulatory and administrative procedures, particularly those related to the grid connection of the generated electricity. In Poland, it has only recently become possible to obtain grid connection conditions for such installations, following the adoption of the Act of 28 July 2023, which amended the Energy Law and certain other acts. However, the biogas sector still faces challenges, particularly the need for effective incentive mechanisms and the removal of regulatory and economic barriers, especially given its estimated potential of up to 7.4 GW. Full article
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12 pages, 1597 KiB  
Article
Effects of Anthropogenic Vibratory Noise on Plant Development and Herbivory
by Estefania Velilla, Laura Bellato, Eleanor Collinson and Wouter Halfwerk
Acoustics 2025, 7(3), 45; https://doi.org/10.3390/acoustics7030045 - 25 Jul 2025
Viewed by 289
Abstract
Anthropogenic infrastructure, such as inland wind turbines commonly found in agricultural fields, has substantially increased subterranean vibratory noise in the past decades. Plants, being rooted in soil, are continuously exposed to these vibrations, yet we have little understanding of how vibrational noise affects [...] Read more.
Anthropogenic infrastructure, such as inland wind turbines commonly found in agricultural fields, has substantially increased subterranean vibratory noise in the past decades. Plants, being rooted in soil, are continuously exposed to these vibrations, yet we have little understanding of how vibrational noise affects plant development and, consequently, plant–insect interactions. Here, we examine the impact of windmill-like vibrational noise on the growth of Pisum sativum and its full-factorial interaction with the generalist herbivore Spodoptera exigua. Plants were exposed to either high or low vibrational noise from seed germination to the seed production stage. We recorded germination, flowering, fruiting time, and daily shoot length. Additionally, we measured herbivory intensity by Spodoptera exigua caterpillars placed on a subset of plants. Plants exposed to high vibrational noise grew significantly faster and taller than those in the low-noise treatment. Additionally, we found a marginally significant trend for earlier flowering in plants exposed to high noise. We did not find a significant effect of vibrational noise on herbivory. Our results suggest that underground vibrational noise can influence plant growth rates, which may potentially have ecological and agricultural implications. Faster growth may alter interspecific competition and shift trade-offs between growth and defense. Understanding these effects is important in assessing the broader ecological consequences of renewable energy infrastructure. Full article
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18 pages, 1941 KiB  
Article
Design of Virtual Sensors for a Pyramidal Weathervaning Floating Wind Turbine
by Hector del Pozo Gonzalez, Magnus Daniel Kallinger, Tolga Yalcin, José Ignacio Rapha and Jose Luis Domínguez-García
J. Mar. Sci. Eng. 2025, 13(8), 1411; https://doi.org/10.3390/jmse13081411 - 24 Jul 2025
Viewed by 197
Abstract
This study explores virtual sensing techniques for the Eolink floating offshore wind turbine (FOWT), which features a pyramidal platform and a single-point mooring system that enables weathervaning to maximize power production and reduce structural loads. To address the challenges and costs associated with [...] Read more.
This study explores virtual sensing techniques for the Eolink floating offshore wind turbine (FOWT), which features a pyramidal platform and a single-point mooring system that enables weathervaning to maximize power production and reduce structural loads. To address the challenges and costs associated with monitoring submerged components, virtual sensors are investigated as an alternative to physical instrumentation. The main objective is to design a virtual sensor of mooring hawser loads using a reduced set of input features from GPS, anemometer, and inertial measurement unit (IMU) data. A virtual sensor is also proposed to estimate the bending moment at the joint of the pyramid masts. The FOWT is modeled in OrcaFlex, and a range of load cases is simulated for training and testing. Under defined sensor sampling conditions, both supervised and physics-informed machine learning algorithms are evaluated. The models are tested under aligned and misaligned environmental conditions, as well as across operating regimes below- and above-rated conditions. Results show that mooring tensions can be estimated with high accuracy, while bending moment predictions also perform well, though with lower precision. These findings support the use of virtual sensing to reduce instrumentation requirements in critical areas of the floating wind platform. Full article
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60 pages, 1535 KiB  
Review
Renewable Energy Communities (RECs): European and Worldwide Distribution, Different Technologies, Management, and Modeling
by Sandra Corasaniti, Paolo Coppa, Dario Atzori and Ateeq Ur Rehman
Energies 2025, 18(15), 3961; https://doi.org/10.3390/en18153961 - 24 Jul 2025
Viewed by 487
Abstract
Renewable energy communities (RECs) are increasingly recognized as pivotal instruments in the global energy transition, offering decentralized, participatory, and sustainable solutions for energy management, specifically regarding energy production and consumption. The present review provides a comprehensive examination of the REC concept, tracing its [...] Read more.
Renewable energy communities (RECs) are increasingly recognized as pivotal instruments in the global energy transition, offering decentralized, participatory, and sustainable solutions for energy management, specifically regarding energy production and consumption. The present review provides a comprehensive examination of the REC concept, tracing its regulatory evolution, particularly within the European Union through the renewable energy directives (RED II and RED III) and by analyzing its practical implementation across various countries. This paper explores the diverse technologies integrated into REC projects, such as photovoltaic systems, wind turbines, biogas, hydroelectric, and storage solutions, while also considering the socioeconomic frameworks, management models, and local engagement strategies that underpin their success. Key case studies from Europe, Asia, Africa, and Australia illustrate the various approaches, challenges, and outcomes of REC initiatives in different geographic and policy contexts. The analysis also highlights barriers to implementing RECs, including regulatory uncertainty and market integration issues, and identifies the best practices and policies that support REC scalability. By synthesizing current trends and lessons learned, this review aims to inform policymakers, researchers, and practitioners about the transformative role of RECs in achieving decarbonization goals and accomplishing resilient energy systems. Full article
(This article belongs to the Section B: Energy and Environment)
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15 pages, 2186 KiB  
Article
Supply Chain Design Method for Introducing Floating Offshore Wind Turbines Using Network Optimization Model
by Taiga Mitsuyuki, Takahiro Shimozawa, Itsuki Mizokami and Shinnosuke Wanaka
Systems 2025, 13(7), 598; https://doi.org/10.3390/systems13070598 - 17 Jul 2025
Viewed by 251
Abstract
This paper presents a method to model and optimize the supply chain processes for floating offshore wind turbines using a network model based on Generalized Multi-Commodity Network Flows (GMCNF). The proposed method represents production bases, base ports, installation sites, component transfer areas, and [...] Read more.
This paper presents a method to model and optimize the supply chain processes for floating offshore wind turbines using a network model based on Generalized Multi-Commodity Network Flows (GMCNF). The proposed method represents production bases, base ports, installation sites, component transfer areas, and transportation routes as nodes and arcs within the network. The installation process is modeled using three transport concepts: assembling components at the base port, direct assembly and installation at the installation site, and transferring components to the installation vessel at a nearby port. These processes are expressed as a linear network model, with the objective function set to minimize total transportation and assembly costs. The optimal transportation network is derived by solving the network problem while incorporating constraints such as supply, demand, and transportation capacity. Case studies demonstrate the method’s effectiveness in optimizing the supply chain and evaluating potential new production site locations for floating foundations, considering overall supply chain optimization. Full article
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21 pages, 447 KiB  
Article
Aerodynamic Design of Wind Turbine Blades Using Multi-Fidelity Analysis and Surrogate Models
by Rosalba Cardamone, Riccardo Broglia, Francesco Papi, Franco Rispoli, Alessandro Corsini, Alessandro Bianchini and Alessio Castorrini
Int. J. Turbomach. Propuls. Power 2025, 10(3), 16; https://doi.org/10.3390/ijtpp10030016 - 16 Jul 2025
Viewed by 304
Abstract
A standard approach to design begins with scaling up state-of-the-art machines to new target dimensions, moving towards larger rotors with lower specific energy to maximize revenue and enable power production in lower wind speed areas. This trend is particularly crucial in floating offshore [...] Read more.
A standard approach to design begins with scaling up state-of-the-art machines to new target dimensions, moving towards larger rotors with lower specific energy to maximize revenue and enable power production in lower wind speed areas. This trend is particularly crucial in floating offshore wind in the Mediterranean Sea, where the high levelized cost of energy poses significant risks to the sustainability of investments in new projects. In this context, the conventional approach of scaling up machines designed for fixed foundations and strong offshore winds may not be optimal. Additionally, modern large-scale wind turbines for offshore applications face challenges in achieving high aerodynamic performance in thick root regions. This study proposes a holistic optimization framework that combines multi-fidelity analyses and tools to address the new challenges in wind turbine rotor design, accounting for the novel demands of this application. The method is based on a modular optimization framework for the aerodynamic design of a new wind turbine rotor, where the cost function block is defined with the aid of a model reduction strategy. The link between the full-order model required to evaluate the target rotor’s performance, the physical aspects of blade aerodynamics, and the optimization algorithm that needs several evaluations of the cost function is provided by the definition of a surrogate model (SM). An intelligent SM definition strategy is adopted to minimize the computational effort required to build a reliable model of the cost function. The strategy is based on the construction of a self-adaptive, automatic refinement of the training space, while the particular SM is defined by the use of stochastic radial basis functions. The goal of this paper is to describe the new aerodynamic design strategy, its performance, and results, presenting a case study of a 15 MW wind turbine blades optimized for specific deepwater sites in the Mediterranean Sea. Full article
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18 pages, 4099 KiB  
Article
Numerical Study of the Effect of Unsteady Aerodynamic Forces on the Fatigue Load of Yawed Wind Turbines
by Dereje Haile Hirgeto, Guo-Wei Qian, Xuan-Yi Zhou and Wei Wang
Machines 2025, 13(7), 607; https://doi.org/10.3390/machines13070607 - 15 Jul 2025
Viewed by 288
Abstract
The intentional yaw offset of wind turbines has shown potential to redirect wakes, enhancing overall plant power production, but it may increase fatigue loading on turbine components. This study analyzed fatigue loads on the NREL 5 MW reference wind turbine under varying yaw [...] Read more.
The intentional yaw offset of wind turbines has shown potential to redirect wakes, enhancing overall plant power production, but it may increase fatigue loading on turbine components. This study analyzed fatigue loads on the NREL 5 MW reference wind turbine under varying yaw offsets using blade element momentum theory, dynamic blade element momentum, and the converging Lagrange filaments vortex method, all implemented in OpenFAST. Simulations employed yaw angles from −40° to 40°, with turbulent inflow generated by TurbSim, an OpenFAST tool for realistic wind conditions. Fatigue loads were calculated according to IEC 61400-1 design load case 1.2 standards, using thirty simulations per yaw angle across five wind speed bins. Damage equivalent load was evaluated via rainflow counting, Miner’s rule, and Goodman correction. Results showed that the free vortex method, by modeling unsteady aerodynamic forces, yielded distinct differences in damage equivalent load compared to the blade element method in yawed conditions. The free vortex method predicted lower damage equivalent load for the low-speed shaft bending moment at negative yaw offsets, attributed to its improved handling of unsteady effects that reduce load variations. Conversely, for yaw offsets above 20°, the free vortex method indicated higher damage equivalent for low-speed shaft torque, reflecting its accurate capture of dynamic inflow and unsteady loading. These findings highlight the critical role of unsteady aerodynamics in fatigue load predictions and demonstrate the free vortex method’s value within OpenFAST for realistic damage equivalent load estimates in yawed turbines. The results emphasize the need to incorporate unsteady aerodynamic models like the free vortex method to accurately assess yaw offset impacts on wind turbine component fatigue. Full article
(This article belongs to the Special Issue Aerodynamic Analysis of Wind Turbine Blades)
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17 pages, 984 KiB  
Article
Optimizing Wind Turbine Blade Manufacturing Using Single-Minute Exchange of Die and Resource-Constrained Project Scheduling
by Gonca Tuncel, Gokalp Yildiz, Nigar Akcal and Gulsen Korkmaz
Processes 2025, 13(7), 2208; https://doi.org/10.3390/pr13072208 - 10 Jul 2025
Viewed by 402
Abstract
This paper aims to enhance operational efficiency in the labor-intensive production of composite wind turbine blades, which are critical components of renewable energy systems. The study was conducted at a wind energy facility in Türkiye, integrating the Single-Minute Exchange of Die (SMED) methodology [...] Read more.
This paper aims to enhance operational efficiency in the labor-intensive production of composite wind turbine blades, which are critical components of renewable energy systems. The study was conducted at a wind energy facility in Türkiye, integrating the Single-Minute Exchange of Die (SMED) methodology with a Multi-Mode Resource-Constrained Project Scheduling Problem (MRCPSP) model to reduce production cycle time and optimize labor utilization. An operational time analysis was used to identify and classify non-value-adding activities. SMED principles were then adapted to the fixed-position manufacturing environment, enabling the conversion of internal setup activities into external ones and facilitating task parallelization. These improvements significantly increased productivity and labor efficiency. Subsequently, a scheduling model was developed to optimize the sequence of operations while accounting for activity precedence and resource constraints. As a result, the proposed approach reduced cycle time by 28.6% and increased average labor utilization from 68% to 87%. Scenario analyses confirmed the robustness of the model under varying levels of workforce availability. The findings demonstrate that integrating lean manufacturing techniques with optimization-based scheduling can yield substantial efficiency gains without requiring major capital investment. Moreover, the proposed approach offers practical insights into workforce planning and production scheduling in renewable energy manufacturing environments. Full article
(This article belongs to the Special Issue Design, Control, Modeling and Simulation of Energy Converters)
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