OptiCore

Challenge

Current state of the art design processes requires 5 – 8 trial and error iterations for a proper core kit design and do not take into account the considerations for an optimized flow pattern through the core material as well as the effect to material properties. Consequences are relative long development lead-time, increased weight of blade structure, risk of reduced material properties and extended use of resources for prototypes.

Solution

The optimization dilemma for the OptiCore Platform is to design a robust core kit ensuring proper resin flow for full wetting of sandwich components and good material properties with a minimum amount of grooves/channels in the foam structure, as these will add weight to the blade.

The OptiCore Platform has an overall Technology Readiness Level (TRL) of 3 at start and will be developed to TRL7 at the end of the 3-year project. For this development, the main project activities include:

Resin flow characterization and modelling and influence of groove pattern in core material.
Mechanical properties of infused sandwich material, e.g., specific stiffness.
Improved core kit design based on optimization.
Evaluation of design tool and Prototype realization at end users.

Effect

The expected outcome of a successfully OptiCore project is an improved competitiveness due to significant better understanding of the complexity of how core materials mechanical and flow properties are affected by grooves/channels in the core material. A shorter lead time and less material usage during the design phase will be achieved.

Outmost important will the reduced blade weight allow a 2% extended blade length corresponding to 4% increase in swept area and increase of annual energy. The OptiCore Platform is directly integrable with the rest of the digital design and production chain of a wind turbine blade. Expected impact is therefore a better competitiveness by reduction of cost for wind turbine blades and thereby reduced LCOE for wind energy.