Net Shape Fabricated Low Cost MHK Pass-Through the Hub Turbine Blades with Integrated Health Management Technology

Description

The primary objective of this project is to develop a three-blade MHK rotor with low manufacturing and maintenance costs. The proposed program will design, fabricate and test a novel half-scale low cost, net shape fabricated single piece three-blade MHK rotor with integrated health management technology to demonstrate significant Capital Expenditures (CAPEX) and Operational Expenditures (OPEX) cost reductions due to the novel design and manufacturing process. The proposed project is divided into three major tasks: Task 1: Single Piece Three-blade Kinetic Hydropower System (KHPS) Rotor Full-Scale and Half-Scale Design; Task 2: Composite Manufacturing Trials and Half-Scale Prototype Rotor Fabrication; and Task 3: Material Characterization and Half-Scale Prototype Test and Evaluation. These three tasks include design and analysis of full-scale and half-scale three-blade rotor prototypes using computational fluid dynamics (CFD) and finite-element analysis (FEA), demonstration of a novel half-scale net shape fabrication process, determination of a fatigue threshold composite strain allowable, three-blade rotor mold design, manufacture of half-scale rotor clam shell mold, three-blade rotor test fixture design and fabrication, development of final manufacturing and test plans, manufacture of the half-scale net shape composite single blade and three-blade prototypes, and test and evaluation of the half-scale rotor.

Resources

Name Format Description Link
36 Rotor Design Assessment with initial FE model, FEA of single full-scale blade, rotor FE model assembly, and principal strains and stress https://mhkdr.openei.org/files/324/8.1%20Full-scale%20Rotor%20Design%20FEA%20Assessment.pptx
0 CAD model of three blade rotor assembly https://mhkdr.openei.org/files/324/8.2%20Full_scale_3_Blade_Rotor%20CAD%20Model.stp
0 Solid CAD model of quarter-scale single blade rotor https://mhkdr.openei.org/files/324/8.3%20QS%20Single_Blade_CAD_Solid_model.stp
53 Geometry inspection of the quarter scale single-blade clam shell tool https://mhkdr.openei.org/files/324/8.4%20Geometry%20inspection%20of%20Q.S.%20Single%20Blade%20clam-shell%20tool.xlsx
53 Geometric inspection results of the as-fabricated single blade rotor https://mhkdr.openei.org/files/324/8.6%20Geometry%20inspection%20results%20of%20as%20fab%20single%20blade.xlsx
53 Quarter-Scale 3-blade composite fatigue test results https://mhkdr.openei.org/files/324/8.7%2010M%20Cycle%20Threshold%20Fatigue%20Test%20Data.xlsx
36 Single-blade 1/2 scale fabrication demonstration from ply development, mold construction, curing, and de-molding https://mhkdr.openei.org/files/324/8.8%20Single_blade_fabrication_demo.pptx
53 Inspection of the QS 3-Blade Clam-Shell Mold https://mhkdr.openei.org/files/324/9.3%20Geometric%20inspection%20of%20QS%203-blade%20clam-shell%20mold.xlsx
53 First of three estimates of capital and operational expenditures https://mhkdr.openei.org/files/324/9.1%20CAPEX%20OPEX%20First%20Estimate.xlsx
36 Test Fixture and Instrumentation for the QS Three Blade Composite Rotor https://mhkdr.openei.org/files/324/9.4%20QS%20Fixture%20Design%20and%20Instrumentation%20Suite.pptx
10 Testing and Validation Plan describing static and fatigue test setup and procedures https://mhkdr.openei.org/files/324/9.5%20Testing%20and%20Validation%20Plan.docx
0 QS 3-Blade Rotor Test Fixture CAD Model https://mhkdr.openei.org/files/324/9.7%20QS%203-blade%20Rotor%20Test%20Fixture.stp
53 Second of three estimates of capital and operational expenditures https://mhkdr.openei.org/files/324/10.1%20CAPEX%20OPEX%20Estimate%202.xlsx
53 Comparison of Predicted and Actual Strains https://mhkdr.openei.org/files/324/10.3%20Comparison%20of%20Measured%20abd%20Predicted%20%20QS%203-Blade%20Rotor%20Test%20Data.xlsx
53 Third of three estimates of capital and operational expenditures https://mhkdr.openei.org/files/324/10.5%20Final%20CAPEX%20OPEX.xlsx
53 Costs for Single Blade, 3-Blade Rotor and Additional Prototypes https://mhkdr.openei.org/files/324/10.6%20Actual%20Cost%20to%20Fab%20Single%20Blade%203-Blade%20Rotor%20and%20Prototypes.xlsx
53 Updated Metrics Table https://mhkdr.openei.org/files/324/10.7%20Updated%20Metrics_Table.xlsx
10 Final Test Report including quasi-static coupon testing, in-plane coupon fatigue, and sub-scale rotor-blade fatigue https://mhkdr.openei.org/files/324/10.4%20Final%20Test%20Report.docx
10 Interim design report including CFD steady state and transient solutions and 3-blade rotor design and analysis https://mhkdr.openei.org/files/324/9.2%20Interim%20Design%20Report.docx
57 Images of as-fabricated single blade rotor https://mhkdr.openei.org/files/324/8.5%20as_fabricated_single_blade.zip
57 Images of Quarter Scale 3-blade rotor before and after removal of slight mold flash https://mhkdr.openei.org/files/324/9.6%20Images%20QS%203-blade_rotor.zip
57 U_surf archive containing files for CFD steady-state and transient simulations https://mhkdr.openei.org/files/324/7.1%20U_surf.zip
10 Component Design Report including flow visualization, CFD and FE analyses, half-scale 3-blade rotor design and fabrication, fatigue test analyses, and experimental results https://mhkdr.openei.org/files/324/10.2%20Component%20Design%20Report.docx
57 Images of fully-fixtured quarter-scale as-fabricated rotor test assembly and fixture plate fastened to Instron servo-hydraulic test frame https://mhkdr.openei.org/files/324/9.8%20Image%20of%20As-Fab%20QS%20Test%20Fixture.zip

Tags

  • khps
  • cec
  • transient
  • strain
  • kinetic-hydropower-system
  • rite
  • hydrokinetic
  • fatigue-test
  • modeling
  • composite-materials
  • capex
  • over-rel
  • cad
  • fast
  • three-blade
  • visualization
  • axial-flow-turbine
  • flow
  • adv
  • verdant-power
  • health-management
  • net-shape-fabrication
  • fabrication
  • as-fabricated
  • fea
  • threshold-fatigue
  • rotor
  • steady-state
  • cfd
  • gen5d
  • economics
  • stress
  • test-and-evaluation
  • vp
  • simulation
  • opex

Topics

Categories