Fraunhofer Institute for Wind Energy and Energy System Technology. Directors

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1 F R A U N H O F E R I N S T I T U T E F O R W I N D E N E R G Y A N D E N E R G Y S Y S T E M T E C H N O L O G Y I W E S ANNUAL REPORT 2010 /

2 Fraunhofer Institute for Wind Energy and Energy System Technology Directors Prof. Dr.-Ing. Andreas Reuter IWES Bremerhaven Am Seedeich Bremerhaven Germany Phone Fax Prof. Dr.-Ing. Jürgen Schmid IWES Kassel Königstor Kassel Germany Phone Fax

3 ANNUAL REPORT 2010 / 2011

4 INHALT 6 Foreword Institute s overview 8 Brief portrait of Fraunhofer IWES 10 The Fraunhofer-Gesellschaft 12 Fraunhofer IWES in figures 14 Key area of the future: Wind energy 16 Key area of the future: Energy system technology 18 Expertise and contact persons 20 Test centers and laboratories 24 Research departments 24 Competence center rotor blade 26 Support structures 27 Technical reliability 28 Simulation and assessment of wind turbines 29 Fluid and system dynamics 30 Systems technology and grid integration 32 Energy economy and grid operation 34 Energy meteorology and system integration 35 Bioenergy system technology 36 Control engineering and energy storage systems 4

5 I N H A L T Research Highlights 38 Rotor blade testing on a new scale 40 Material tests offshore 42 Maintenance strategies for offshore wind turbines 44 Optimized design of jacket structures via simulation 46 Optimized simulation of ice loads 48 Site assessment based on geophysical measurements 50 Measurement of swell and currents 52 Characterization of site conditions 54 Control of wind turbines and wind farms 56 Control of marine current turbines and wave energy converters 58 Integration of bioenergy into energy supply structures 60 Integration of photovoltaic systems 62 Analyses and tools for grid integration 64 Bi-directional energy management 66 E-energy: model regions for smart grids 68 Electromobility and renewable energy 70 Power-to-gas renewable gas connects energy networks 72 Transformation of energy systems Documentation 74 Events and distinctions 82 Research and development projects 87 Publications 101 Lectures at universities 102 Dissertations, diploma, and master thesis 103 Patents and other property rights 106 Memberships 107 Standardization bodies 107 Guideline committees 109 Publications 111 Funding 112 Editorial notes 5

6 FOREWORD Well positioned The importance of renewable energy for sustainable supply systems is reflected in the energy plan of the German government: By the middle of this century 80 percent of electricity must be produced from renewable sources, with wind energy being designated a dominant player. In addition to further developing the individual energy sources with respect to cost reduction and efficiency improvement, a key aspect of the energy plan and hence an important area for research is the integration of these sources into supply structures. Indeed, both these major areas wind energy utilization and energy system integration are at the fore of the work of Fraunhofer IWES. It is hence expected that the growth we have experienced over the last two years will continue unabated in the future. Much of the required infrastructure for this research has been put in place in the last year: For example, at the Bremerhaven site there is now a facility for testing rotor blades having lengths up to 90 meters. Such large blades will be used for future offshore wind turbines in the over 10 MW class. In Wolfhagen near Kassel a test center is being built for studying onshore wind flow conditions at great heights. This includes a 200 meter high measuring mast. The Test Center for Smart Grids and Electromobility (SysTec), situated in Fuldatal-Rothwesten near Kassel will focus on grid integration, and at the Eichhof training and research center in Bad Hersfeld Fraunhofer IWES has an external facility, the Bioenergy Research Center, for optimizing the utilization of bioenergy in order to offset fluctuations in wind and solar energy usage. These facilities further enhance the position of Fraunhofer IWES as a leading European energy research organization, including research on matters relating to the grid integration of renewable energies. Collaboration with universities has also been greatly intensified: For example, the Fluid and System Dynamics work group under the leadership of Prof. Peinke in Oldenburg and the Support Structures work group under the leadership of Prof. Rolfes and Prof. Schaumann in Hanover have been set up. Fraunhofer IWES employees are working at the University of Bremen on offshore site evaluation. Collaborative work has been agreed with the University of Stuttgart in the area of smart grids. The longstanding partnership with the University of Kassel is being expanded with the setting up of the Research Alliance for Vehicle Systems (FAST). 6

7 These measures mean that Fraunhofer IWES is in an excellent position to take on the R&D challenges in collaboration with industry that are necessary to transform global energy systems. We would like to thank the representatives of the federal government and representatives of the states of Bremen, Hesse, and Lower Saxony for their support during the establishment and further development of our institute. Appreciation is also extended to our partners and customers for the trust they have put in us and, last but by no means least, we wish to thank all our employees for their enthusiasm and devotion to developing sustainable energy systems. Prof. Dr. Andreas Reuter Director, Bremerhaven Prof. Dr. Jürgen Schmid Director, Kassel 7

8 BRIEF PORTRAIT OF FRAUNHOFER IWES Objectives and main areas of work The research activities of the Fraunhofer Institute for Wind Energy and Energy System Technology IWES cover all aspects of wind energy and the integration of renewable energies into energy supply structures. The main areas of research are: Technology and operational management of wind turbines and wind farms Dynamics of wind turbines and components Component development for rotors, drive trains, and foundations Test and evaluation methods for wind turbines and components Environmental analysis of wind, sea, and seabed for utilization of wind energy and marine energy Control and system integration of decentralized energy converters and storage systems Energy management and grid operation Energy supply structures and system analysis Development of Fraunhofer IWES Fraunhofer IWES was founded at the start of 2009 through the merger of the former Fraunhofer Center for Wind Energy and Maritime Engineering CWMT in Bremerhaven and the Institut für Solare Energieversorgungstechnik ISET e.v. in Kassel. By agreement with the Fraunhofer-Gesellschaft, the institute directors are linked to professorships at the universities in Hanover and Kassel. Fraunhofer IWES in Bremerhaven has been headed by Prof. Dr. Andreas Reuter since 1 October At that time he was also appointed Professor of Wind Energy Technology at the University of Hanover. He succeeded the acting director, Dr. habil. Hans-Gerd Busmann, who since 2006 had headed the CWMT. The Kassel site is led by Prof. Dr. Jürgen Schmid, who has been chairman of the ISET Executive Board since The institute continued to grow in 2010 and revenues were increased to approx. 22 million euros in total. The above average increase in industrial funding by about one third to a level of 3.7 million euros is a most gratifying development. To meet its new challenges, IWES started 2011 with over 230 employees as opposed to 200 in

9 1 2 Besides the continuing growth in Bremerhaven and Kassel, two new project groups were formed in 2010 covering the research areas of support structures (University of Hanover) and aerodynamics (University of Oldenburg). These groups will further enhance the national and international reputation of Fraunhofer IWES. Collaboration Fraunhofer IWES works very closely with the ForWind alliance (the universities of Hanover, Oldenburg, and Bremen) and with the University of Kassel. Contacts with the Bremerhaven Technical College and other technical colleges have been further strengthened. New collaborative work has been started with the University of Stuttgart following the appointment of Prof. Dr. Martin Braun as Junior Professor of Smart Power Grids. Within the Fraunhofer-Gesellschaft use is made of the expertise and experience of partner institutes. Fraunhofer IWES participates in the Fraunhofer Energy Alliance and in Fraunhofer networks in the area of Wind Energy and Smart Grids. At a national and international level the institute successfully collaborates with many public and industrial research organizations. The application-oriented work of Fraunhofer IWES is highlighted by the large number of direct projects and contracts with industry. Our research results are the basis for the participation of many IWES scientists in national and international bodies such as DKE, CENELEC, and IEC and the use of those results for standardization. With its technical expertise, Fraunhofer IWES is thus able to shape political and commercial boundary conditions, for example the drawing up of the Renewable Energy Act, development of offshore wind energy utilization, development of future energy supply structures, and participation in the German Advisory Council for Global Environmental Change (WBGU). 1 New institute building in Bremerhaven 2 Fraunhofer IWES in Kassel 9

10 THE FRAUNHOFER-GESELLSCHAFT 10

11 T H E F R A U N H O F E R - G E S E L L S C H A F T Research of practical utility lies at the heart of all activities pursued by the Fraunhofer-Gesellschaft. Founded in 1949, the research organization undertakes applied research that drives economic development and serves the wider benefit of society. Its services are solicited by customers and contractual partners in industry, the service sector and public administration. At present, the Fraunhofer-Gesellschaft maintains more than 80 research units in Germany, including 60 Fraunhofer Institutes. The majority of the more than 18,000 staff are qualified scientists and engineers, who work with an annual research budget of 1.65 billion. Of this sum, more than 1.40 billion is generated through contract research. More than 70 percent of the Fraunhofer-Gesellschaft s contract research revenue is derived from contracts with industry and from publicly financed research projects. Almost 30 percent is contributed by the German federal and Länder governments in the form of base funding, enabling the institutes to work ahead on solutions to problems that will not become acutely relevant to industry and society until five or ten years from now. Affiliated international research centers and representative offices provide contact with the regions of greatest importance to present and future scientific progress and economic development. With its clearly defined mission of application-oriented research and its focus on key technologies of relevance to the future, the Fraunhofer-Gesellschaft plays a prominent role in the German and European innovation process. Applied research has a knock-on effect that extends beyond the direct benefits perceived by the customer: Through their research and development work, the Fraunhofer Institutes help to reinforce the competitive strength of the economy in their local region, and throughout Germany and Europe. They do so by promoting innovation, strengthening the technological base, improving the acceptance of new technologies, and helping to train the urgently needed future generation of scientists and engineers. Carbon nanotubes are innovative materials of great promise. Nanotubes are being researched at Fraunhofer IWES for reinforcing rotor blades and improving the service life. As an employer, the Fraunhofer-Gesellschaft offers its staff the opportunity to develop the professional and personal skills that will allow them to take up positions of responsibility within their institute, at universities, in industry and in society. Students who choose to work on projects at the Fraunhofer Institutes have excellent prospects of starting and developing a career in industry by virtue of the practical training and experience they have acquired. The Fraunhofer-Gesellschaft is a recognized non-profit organization that takes its name from Joseph von Fraunhofer ( ), the illustrious Munich researcher, inventor and entrepreneur. 11

12 FRAUNHOFER IWES IN FIGURES Financing / Development of earnings Projection for 2010* in millions of euros Development of operating and investment budget Projection for 2010* in millions of euros * * up to 2008 CWMT since IWES merger of CWMT and ISET up to 2008 CWMT since IWES merger of CWMT and ISET Other funding Income from industry EU Operationg budget Investment expenditure Federal government / state Basic funding 12

13 F R A U N H O F E R I W E S I N F I G U R E S Finance structure IWES continued to grow in Based on projected figures, the total budget is approx. 22 million as opposed to 19.4 million in Compared to the previous year, the revenues from industry increased from 2.7 million to 3.7 million which is a significantly above-average increase of approx. one third. Public funding grew by 13 % to reach a total of 14.2 million. EU-Funding remained relatively constant at a level of 1.2 million, when compared with the previous year and constitutes approximately 6 % of total funding. The continuing successful development of IWES as a whole was mainly due to the increase in the operating budget of about 19 %. Investment funding, being 4.8 million, stayed at the same level as the previous year and constitutes approximately 22 % of total funding. The main areas of investment are in Bremerhaven the further development of the rotor blade test center, in Kassel the construction of the Test Center for Smart Grids and E-Mobility SysTec, and in Bad Hersfeld the development of bio-energy system technology. Personnel as at scientists technical staff administration / internal services assistants, trainees and students total

14 KEY AREA OF THE FUTURE: WIND ENERGY 14

15 T A R G E T E D C O L L A B O R A T I O N I N S T E A D O F I N D I V I D U A L A C T I O N S. T H E H I G H L Y N E T W O R K E D R E S E A R C H A L L I A N C E B E T W E E N F R A U N H O F E R I W E S A N D F O R W I N D I S A B L E T O C A R R Y O U T L O N G - T E R M, S T R A T E G I C A L L Y I M P O R T A N T P R O J E C T S I N T H E A R E A O F W I N D E N E R G Y R E S E A R C H. A P R I L W I L L M A R K T H E F I R S T A N N I V E R - S A R Y O F T H E O P E R A T I O N O F T H E A L P H A V E N T U S O F F S H O R E T E S T W I N D F A R M. F R A U N H O F E R I W E S I S C O O R D I N A T I N G T H E R A V E I N I T I A T I V E W H I C H I S C A R R Y - I N G O U T R E S E A R C H A C T I V I T I E S A T T H E T E S T W I N D F A R M. T H E F I N D I N G S W I L L B E N E F I T T H E W H O L E S E C T O R. T H E S E D E V E L O P M E N T S A R E B E I N G S U P P O R T E D B Y C R O S S - S Y S T E M R E S E A R C H A T F R A U N H O F E R I W E S. Wind energy has become an important factor for the economy (source: German Wind Energy Association & German Engineering Federation). In the first half of 2010 the turnover of wind turbine manufacturers in Germany was 6.4 billion euros, with 75 % of the turbines being exported. The competitiveness of German wind turbine manufacturers and suppliers is highly dependent on their ability to quickly implement new technological developments. Collaborative research projects with industry are allowing optimizations to be undertaken which are laying the foundation for serving new markets and customers. used offshore. At the Fraunhofer IWES facility in Hanover a test rig for support structures is under development. This will allow investigation of the dynamic behavior of the complete structure, via amongst other things near-reality simulation of seabed-support structure interactions. The experimental tests will be complemented by novel simulation models which will aid the development of innovative concepts for support structures. The opening of the 90 meter test stand for rotor blades in Bremerhaven means that there is now facility available for testing blades of increasing lenght. Improved economics and forecasting The challenges of offshore wind energy utilization require the close integration of the wind energy sector with maritime technologies. Enhancement of the technical reliability of turbines and improved logistics and operating concepts for the utilization of wind energy at demanding offshore sites can help reduce the cost of electricity generation and hence improve the economics of offshore wind energy. The adaptation of forecasting models for offshore wind energy optimizes the control of the power feed to the grid. Growing practical experience is improving the model for risk assessment which helps to reduce uncertainties on the investor side. Pioneering projects at deep water sites, such as the HiPRWind collaborative project, are expanding the knowledge base. Testing materials under offshore conditions Fraunhofer IWES is adapting its current development work to meet future needs. A climate chamber for testing the simultaneous effect of mechanical and climatic loads is aiding the development of protection strategies for materials that are Challenging offshore projects require new technical solutions. Greater certainty for operators and investors is achieved by using methods for system validation prior to the prototype phase. These methods also include computation of the wind potential, wind power forecasting, prediction of wind-rotor interactions, load determination, and calculation of shadowing. Aerodynamic system modeling is carried out at the Fraunhofer IWES facility in Oldenburg using detailed numerical methods. Concepts for large-scale utilization of wind energy Despite the ambitious plans for offshore turbines by 2020 it is planned to have some 10 GW of generation capacity installed the onshore sector still remains the bread and butter business of the wind energy sector. A hindrance to expansion of onshore wind energy is the increasingly united space available for new turbines, in connection with special designation of land in some German Länder. Regulations concerning distance and height limitations have proven to be hindrances. Acceptance being the key point here. The expansion of wind energy in accordance with the binding EU climate objectives is a task which involves the whole of society. By developing technical solutions, for example wind turbines with higher hub heights for forested areas and rotor blades optimized for lower noise, applied research makes a very important contribution. 15

16 KEY AREA OF THE FUTURE: ENERGY SYSTEM TECHNOLOGY 16

17 T H E F U R T H E R E X P A N S I O N O F R E G E N E R A T I V E E N E R G I E S A N D C O N S E Q U E N T R E - P L A C E M E N T O F C O N V E N T I O N A L G E N E R A T I N G C A P A C I T Y R E Q U I R E S S U S T A I N - A B L E R E O R G A N I Z A T I O N O F T H E E N E R G Y S U P P LY S T R U C T U R E S B Y U S I N G M O D E R N P O W E R E L E C T R O N I C S A N D T H E N E T W O R K I N G A N D C O O R D I N A T I O N O F G E N E R A - T O R S, G R I D S, S T O R A G E S Y S T E M S, A N D C O N S U M E R S. T H E O B J E C T I V E O F F U T U R E R & D W O R K M U S T B E T O D E S I G N S U P P LY S T R U C T U R E S S U C H T H A T G R I D S T A B I L I T Y A N D R E L I A B I L I T Y O F S U P P LY R E M A I N G U A R A N T E E D F O R T H E S I T U A T I O N W I T H A G R O W I N G N U M B E R O F F L U C T U A T I N G E N E R G Y G E N E R A T O R S, A N D E V E N W I T H O U T L A R G E C A P A C I T Y R E S E R V E S. Besides having the right energy mix, efficient communication structures, online and forecasting methods for planning grid usage, bidirectional energy management and energy trading systems for the dialog between energy generators, distributers and consumers will be very important. Interactive grids for electricity and gas (smart grids) and the integration of smart metering will allow flexible adaptation between energy generation and consumption via time-variable energy tariffs in the future. Close European collaboration In order to balance between the supply of renewable energies at times of over-generation and under-generation, a European high voltage direct current transmission network is required. This serves to supplement and safeguard the energy supply, for example by utilizing wind and solar energy from other European and non-european sites. This includes power stations (Desertec project) and photovoltaic energy and electricity from European onshore and offshore wind farms, and pumped-storage power stations and hydro-power stations in Scandinavia. In this regard, close European collaboration is a key prerequisite for stepwise increase of the share of renewable energies being fed to the electricity grid. In virtual power stations, the inclusion of electrically-thermally coupled generators and the production of hydrogen or methane from excess electricity generation provide further freedom for operational management. In such systems with power-heat coupling, the local capacities in buildings can be utilized to create urgently needed storage systems for grid operation and the integration of renewable energies. Information and communication technologies A decentralized energy supply system based on regenerative energy generators requires the large-scale use of modern technologies for the control and operational management of generators, grids, storage systems, and consumers, as well as efficient information and communication systems for all areas. There is still no structured communication network with standardized interfaces for providing decentralized energy generators with parameters from higher level control technology or even for controlling them online. In the future, reliable, effective, and favorable-cost data transfer must be developed for this. The costs incurred will in the medium term be paid back by the efficiency this brings in all areas. First successes In frame of a number of pilot projects, Fraunhofer IWES has already shown that the integration of distributed regenerative generators into virtual power stations opens up new options for operational management which allow system services such as frequency and voltage stabilization of the electricity network. For integrating wind and solar energy into the electricity supply, transmission network operators are using the powerful forecasting model of Fraunhofer IWES which allows the renewable energies balance perimeter mentioned in the Renewable Energies Act (EEG) to be balanced with balancing energy. An important prerequisite for the integration of wind farms into the energy management of virtual power stations is very accurate short-term forecasting by Fraunhofer IWES on a timescale of one hour to four days. Renewable energies require new supply structures 17

18 EXPERTISE AND CONTACT PERSONS Competence Center Rotor Blades Technical Reliability Rotor blade testing Component testing Material testing Climate chamber test New concepts for rotor blades Tests under offshore conditions Simulation of environmental loads Structural Health Monitoring and estimation of residual service life Dr.-Ing. Arno van Wingerde Phone Dr.-Ing. Holger Huhn Phone Drive Trains Simulation and Assessment of Wind Turbines Dynamic loading of drive trains and nacelles Load calculations with ADCoS-Offshore Holistic simulation platform Consulting on structural design Software development for simulation Dr.-Ing. Jan Wenske (deputy director, Fraunhofer IWES Bremerhaven) Phone Dipl.-Ing. Michael Strobel Phone Support Structures Fluid and System Dynamics Design and optimization of support structures Monitoring Risk analysis Wind physics Computational fluid dynamics (CFD) System dynamics Stochastics Prof. Dr.-Ing. habil. Raimund Rolfes Phone Prof. Dr.-Ing. Peter Schaumann Phone Prof. Dr. rer. nat. Joachim Peinke Phone

19 K O M P E T E N Z E N U N D A N S P R E C H P A R T N E R Systems Technology and Grid Integration Bioenergy System Technology Engineering and measuring technology Electricity distribution networks Hybrid systems and electromobility Decentralized energy management Decentralized ancillary services Converter integration und electrical drives Sustainable supply and disposal Biogas plant technology Biogas upgrading Dr.-Ing. Philipp Strauß philipp.strauss@iwes.fraunhofer.de Phone Dr.-Ing. Bernd Krautkremer bernd.krautkremer@iwes.fraunhofer.de Phone Energy Economy and Grid Operation Control Engineering and Energy Storage Systems Reliability and maintenance strategies Wind energy utilization Energy meteorology and wind power management Energy informatics Virtual power plants Energy economy and systems analysis Control of wind turbines Wind farm control systems Control of marine energy plants Fault prediction systems Energy storage systems Dr.-Ing. Kurt Rohrig (deputy director, Fraunhofer IWES Kassel) kurt.rohrig@iwes.fraunhofer.de Phone Dipl.-Ing. Peter Caselitz peter.caselitz@iwes.fraunhofer.de Phone Energy Meteorology and Systems Integration Marine Energy Utilization Wind, waves, currents, and seabed Characterization of environmental conditions Development of innovative measuring methods Analysis of measurement and model data Marine current turbines Wave energy converters Floating wind turbines Dr. rer. nat. Bernhard Lange bernhard.lange@iwes.fraunhofer.de Phone Dipl.-Phys. Jochen Bard jochen.bard@iwes.fraunhofer.de Phone

20 TEST CENTERS AND LABORATORIES Fraunhofer IWES possesses extensive testing and experimental facilities, laboratories, and state-of-the-art equipment. Our expertise has allowed us to develop and introduce new testing facilities and test methods. These facilities, coupled with the know-how of our scientists and engineers, enable Fraunhofer IWES to offer its customers and partners world class research and development services and infrastructure. Our main facilities and services are described in brief here. More detailed information and the names of contact persons can be found at Competence Center Rotor Blades Offshore test locations Static and fatigue tests on full-scale rotor blades make it possible in a few months to predict the performance of a rotor blade, according to certification standards, over its 20 year life-span. Loads of up to 50 MNm are applied to rotor blades at various load points on a unique 70 m test stand. The application of the loads using hydraulic cylinders permits precise control of the loading. Fatigue testing is accomplished through cyclic loading at an eigenfrequency of the rotor blade, which provides an ideal load distribution along the blade. This is a fast testing method, with low energy consumption. Through measurement and frequency analyses, the rotor blade eigenfrequencies can be determined. Up to 250 strain gauges along with load cells, cable sensors, angle sensors and acceleration/temperature/humidity sensors provide a wealth of meaningful data. In addition to the testing of full-scale rotor blades, the laboratory infrastructure consists of facilities for coupon and component testing, providing characteristic values for the evaluation and development of rotor blade substructures. For standard material characterization, uniaxial coupon test machines, 3-4 point bending jigs, antibuckling devices and a climate chamber are available. For structural characterization, an adaptable test bench of 12 m x 3 m with versatile loading capabilities, i.e. hydraulic cylinders up 100 kn and an excenter with 20 kn at 2 Hz, is utilized, e.g. for beam testing. º º Dr. Arno van Wingerde, arno.van.wingerde@iwes.fraunhofer.de The cumulative loads at an offshore test site differ considerably from the loads on materials in laboratory tests. Materials are subjected to extreme conditions offshore: temperature fluctuations, increased UV radiation, exposure to seawater, biologically induced corrosion and mechanical loads. At four test locations Wilhelmshaven, Sylt, Helgoland and at the mouth of the River Weser materials and components are being tested under offshore conditions in order to acquire new knowledge about the long-term stability of sensor systems. As the environmental conditions at the locations differ, so do the damage profiles. Accordingly, customized strategies for protection are being developed. Sensors are being increasingly used in offshore wind turbines for recording material fatigue data. They can detect very small changes in the material structure and report these to the system. The results are used for validation and improvement of current laboratory test methods. Laboratory material tests designed to mimic and increase the real loads are able to give meaningful statements in a short space of time. In turn, these results are used for developing general standard tests for offshore materials and components. New methods for material testing are also developed for specific tasks. º º Dr. Holger Huhn, holger.huhn@iwes.fraunhofer.de º º Dr. Hanno Schnars, hanno.schnars@iwes.fraunhofer.de 20

21 1 2 Climate chamber for simultaneous simulation of mechanical and environmental influences Laboratory for control systems for large wind turbines Fraunhofer IWES has developed a special offshore test chamber; which for the first time simultaneously simulates the mechanical and environmental loads that offshore wind turbines are subjected to. This allows realistic simulation of the actual loads under offshore conditions and gives feedback about the reliability of the systems under test and their service life. This test facility is a valuable addition to the offshore test locations as the information being acquired there about the mechanisms of material failure are used to design near-reality tests under laboratory conditions. Laboratory tests that give reliable statements about material behavior are beneficial for customers, due to the accelerated testing and the reproducibility of the results. This allows accurate conclusions to be drawn about service life and effective protection strategies to be developed. º º Dr. Holger Huhn, holger.huhn@iwes.fraunhofer.de º º Leena Kruse, leena.kruse@iwes.fraunhofer.de A development platform for pitch control systems for rotor blades for large wind turbines is available in order to develop load-reducing control systems. The test stand permits realistic testing of three interacting, controlled pitch drives for individual blade pitch control. Near-real counter-moments are produced via real-time simulation of large wind turbines using synthesized inhomogeneous and turbulent wind fields. There is also a test stand for testing antagonistically controlled pitch drives which permits very low-load blade pitch control. º º Martin Shan, martin.shan@iwes.fraunhofer.de Wind measuring network and 200 meter measuring mast Fraunhofer IWES has since 1990 operated a Germany-wide network of measuring masts. The network currently comprises 30 masts. All the measuring stations are close to wind farms and are fitted with MEASNET calibrated anemometers. Besides the standard 30 m masts (for wind measurement at 10 m and 30 m heights), four 50 m masts have also been erected. These allow not only wind conditions but also other meteorological data to be recorded. The measurement data are recorded at a sampling rate of 1 Hz and are transferred hourly in 5 minute data sets to the data center in Kassel. In addition, Fraunhofer IWES operates three mobile LIDAR measuring units and these will be complemented this year by a 200 m high measuring mast. º º Reinhard Mackensen, reinhard.mackensen@iwes.fraunhofer.de º º Paul Kühn, paul.kuehn@iwes.fraunhofer.de 1 Testing in the climate chamber 2 Tests on whole rotor blades allow possible damage to be detected in a short time 21

22 1 2 Experimental Center for Bioenergy System Technology IWES SysTec: Test Center for Smart Grids and Electromobility In collaboration with the Eichhof Agricultural Training and Research Center, Fraunhofer IWES operates an experimental center for bioenergy system technology in Bad Hersfeld (Hesse). This covers the whole process chain from biomass production through to grid integration. A biogas test plant with a raw gas capacity of up to 50 m 3 /h is available for demonstration purposes and pilot plant trials. Up to 6 containers with test equipment can be provided. Experiments on biomass preparation, residue treatment, thermal biogas utilization, and gas upgrading and feeding are possible. Laboratories are also available for investigating specific biological, chemical, and physical parameters. º º Dr. Bernd Krautkremer, bernd.krautkremer@iwes.fraunhofer.de In Rothwesten near Kassel, Fraunhofer IWES is developing and testing new equipment for smart low voltage and medium voltage grids. On the 80,000 m² site, along with the outdoor test field for photovoltaic systems and small wind turbines, two new halls have been built. In one hall are test stands for low voltage and medium voltage converters and for electrical machines. The other hall houses experimental equipment for the grid integration of electrical vehicles and electricity storage systems. System services will also be tested in the future at IWES-SysTec. Mobile test containers are being constructed for this, so allowing the fault ride through tests of wind turbines and photovoltaic systems or other electricity generators of up to 6 MVA nominal power. º º Dr. Thomas Degner, thomas.degner@iwes.fraunhofer.de DeMoTec: Design-Centre for Modular Supply Technology Accredited test laboratories for converters and EMC The DeMoTec Center is jointly operated with the University of Kassel. Decentralized electricity generators, storage systems, loads, and novel energy managementsystems are developed and tested here. The network integration of converters and the design of hybrid systems and island grids have special roles. The control technology for decentralized grid services can be tested here on a real scale in combination with decentralized generators. In particular, systems for electrification in rural areas remote from the grid and on islands are optimized here and are used for training purposes. A reproducible hardware simulation of a 90 kva grid connection and an adjustable direct current source allow accredited testing of grid converters and the evaluation of photovoltaic converters for example with regard to MPP tracking behavior. º º Markus Landau, markus.landau@iwes.fraunhofer.de Fraunhofer IWES in Kassel carries out accredited tests in its laboratories in accordance with DIN EN ISO/IEC These are tests on the electromagnetic compatibility of electrical equipment, on the grid properties of converters for decentralized electricity generators (e.g. according to BDEW and FGW TR3), and on the efficiency of photovoltaic converters and systems. º º Dr. Norbert Henze, norbert.henze@iwes.fraunhofer.de 22

23 3 4 Development laboratories for converters IWES- TPE: Test Center for Electromobility Fraunhofer IWES develops converters for wind turbines, battery systems and other decentralized electricity generators. Several laboratories are available for the development of electronic circuits. In the laboratory for microprocessor and decive-oriented software technology, control circuits for converters can be developed using the hardware-in-the-loop and rapid-prototyping methods. The reliability of equipment can be tested in climate chambers and thermographically. º º Dr. Norbert Henze, norbert.henze@iwes.fraunhofer.de Outdoor test fields for photovoltaic systems Several Fraunhofer IWES departments have brought together their know-how to create virtual development platforms for lithium ion batteries, charging units, and grid simulators in the new Test Center for Electromobility IWES-TPE. Based on an existing collaborative agreement with the University of Kassel, the collaborative work is being expanded via the Research Alliance for Vehicle System Technology. The focus of Fraunhofer IWES here is grid integration and the supply of renewable energies. The University of Kassel is focusing on the vehicle system technology. º º Dr. Philipp Strauß, philipp.strauss@iwes.fraunhofer.de In outdoor test fields for photovoltaic systems individual modules and complete systems are measured over a long period in accordance with European guidelines for different manufacturers. Kassel is a key reference site for standardized tests offered by DERlab e.v. Europe-wide. º º Peter Funtan, peter.funtan@iwes.fraunhofer.de Battery laboratories The infrastructure for testing electrochemical systems comprises automated charging and discharging equipment, climate chambers, and the necessary measuring technology and safety technology. There is also a laboratory for testing fuel cell systems. These facilities are complemented by a development platform for virtual and multi-virtual electrochemical systems such as starter batteries and virtual lithium ion cells. º º Matthias Puchta, matthias.puchta@iwes.fraunhofer.de DERlab Network of Excellence (NoE) of DER Laboratories and Pre- Standardization Leading research institutes from eleven European countries have formed the DERlab Network of Excellence which is coordinated by Fraunhofer IWES. The aim is to jointly develop criteria for the operation of decentralized electricity generators in the grid and to hence support the development of test methods and standards. The laboratory infrastructure is being expanded in a co-ordinated manner so that the facilities are complementary. The Association of European Distributed Energy Resources Laboratories was founded at the end of 2008 and is based at Fraunhofer IWES in Kassel. º º Dr. Philipp Strauß, philipp.strauss@iwes.fraunhofer.de 1 DeMoTec test center 2 Experimental Center for Bioenergy System Technology 3 Test Center for Electromobility 4 SysTec test center 23

24 RESEARCH DEPARTMENTS COMPETENCE CENTER ROTOR BLADE In order to evaluate the reliability of rotor blades it is vital to know the loading conditions where a rotor blade shows signs of fatigue, and where material flaws become critical. Experimental tests include confirmation of the initial static strength and stiffness, cyclic dynamic fatigue durability, and the residual strength and stiffness after fatigue loading. Accompanying numerical simulation of the static strength and structural durability improve the validity of the residual service life calculation. In addition to fullscale rotor blade tests, material tests and numerical simulation studies are necessary for determining the structural durability of a blade design. There is an increasing interest of component testing in order to bridge the gap between full- scale testing and material testing. The unique loads to which materials are exposed in the wind energy sector put special requirements on those materials, for example favorable fatigue behavior, high resistance to wear, and production-related thermal and rheological properties. The determination of the specific properties of individual materials is vital. The materials are firstly subjected to various mechanical tests to determine, for example, the service life under a variety of load conditions, and also to environmental tests which provide important results on practical usage. For the determination of mechanical parameters specified in current standards and norms, coupon testing is an appropriate way for this. These can be tailored to the individual wishes of customers by adapting the test equipment. Our experimental services cover the range of uniaxial tests for isotropic materials, cyclic-multiaxial tests for anisotropic material and the physical characterization of materials. For compression tests, a combined loading device that prevents buckling of the test specimen can be used. In most cases, these results are closer to reality than data acquired with standard methods. This device is also used for fatigue tests in order to determine meaningful Wöhler curves for compression-compression loading. For aging studies, mechanical tests can be used in conjunction with a versatile climate chamber. The shear properties of adhesives and fiber composite materials can be determined on torsion test specimens. Besides testing standard coupon specimens, structures such as adhesive-laminate specimen can be tested. The development of material models, simulation of materials, and specific advanced development of materials is another option. Evaluation of combinations of materials Due to the increasing importance of lightweight construction, the development and evaluation of a wide range of combinations of materials plays a major role. This includes the manufacture of fiber composite materials. Besides the development of materials for structure-supporting elements, such as spar caps or shear webs, fillers and coating materials are also tested for their suitability for use on wind turbines. Component testing and production Rotor blades of wind turbines are complex, large-area, highly stressed structures. They are usually made of fiber composite materials due to the requirement for lightweight design. In this regard, the anisotropic properties of materials are being increasingly utilized for the customized design of components and materials. As fiber composite materials are produced during the production of components and their processing determines the material properties, knowledge of realistic material parameters is a key advantage. Therefore, component-specific specimen production and test methods are used. 24

25 1 2 The behavior of a material during production depends on the conditions to which the component is exposed. From a mechanical viewpoint, production-related tests on small components are necessary even prior to construction of the first prototypes. In addition, modifications to the as-received specimens and test set-ups are often unavoidable for mechanical tests. Steering committee Precondition for quality assurance The development and construction of command structures is accompanied by tests on materials. This is a vital part of the quality assurance process. Due to the size of rotor blades and the component-related behavior of materials, manufacturers are also increasingly carrying out tests on specimen beams and components. Components are nowadays being increasingly tested for their structural durability, in order to avoid distortion of the calculated structural durability due to factors such as normal and shear stresses, force deflections, material combinations, and production methods. In particular, these new test methods are highly advanced for bonded seams and ply drops, and can provide important information for rotor blade manufacturers. At Fraunhofer IWES there are three test platforms with a maximum size of 12 x 3 meters and relevant mounting structures for testing a variety of components and subcomponents. The test specimens can be stressed with powerful hydraulics (maximum 100 kn) or with an excenter (e.g. 20 kn at 2 Hz) for example for determining Wöhler curves at a high number of load cycles. Smaller loads can also be applied for other purposes. The effect of environmental conditions can also be simulated using a climate chamber in which the temperature, humidity, UV light, and salt content can be regulated as wished. Computer simulations can accompany the experimental testing. The simulation programs ANSYS and ABAQUS are available for this. These software solutions are also suitable for processing very complex, non-linear tasks. 1 For dynamic tests loads are applied via a hydraulic cylinder 2 Preparing a rotor blade for mounting in the test block 25

26 1 2 SUPPORT STRUCTURES The ever increasing power and size of wind turbines in particular those offshore is putting extreme demands on their foundations and support structures. The new dimensions of components and the higher load level require accompanying theoretical and experimental studies to be carried out on the support structures. Investigations are concentrating on fatigue strength of multi-axial loaded structural members and soil-structure interactions. This is why the Support Structures project group was formed at Fraunhofer IWES in Near- reality testing in the planned large test laboratory at Leibniz University in Hanover Marienwerder should provide ideal conditions for this work. Fraunhofer IWES is systematically expanding its expertise in support structures for wind turbines. For the Hanover facility the collaboration with the universities in the ForWind alliance and the planned large test laboratory also exemplify this. The focus is on the optimization and new development of support structures for repowering measures for onshore turbines and on the optimization/development of support structures for offshore wind turbines. Innovative concepts for support structures are being developed using optimized design processes and improved simulation models and tools, supported by accompanying experimental testing. Other topics of research include new combinations of materials, corrosion protection, and building process engineering. Experimental tests under multi-axial loads Lattice support structures for water depths of between 25 m and 70 m are exposed to multi-axial stress at sea due to wind, waves, and operating loads, in particular in the region of the structural nodes. In contrast to existing test facilities, the planned experimental rigs will allow Fraunhofer IWES to undertake innovative structural tests under multi-axial dynamic loads. Seabed-support structure interactions The dynamic properties of the support structure depend significantly on the soil conditions. When developing the fatigue design it is essential to consider ground/seabed conditions that change during the course of the operating life of a wind turbine due to the dynamic loads. There is an enormous need for research to be able to more precisely predict the behavior of foundation elements under cyclic loads. A novel test concept for support structures with foundation elements under real offshore seabed conditions and on a large scale should validate and improve the design basis for the whole structure and for the foundation elements. Optimization and innovation Optimized, lighter support structures increase the economic via bility of wind energy due to material and cost savings and also protect the environment. Tests on a large scale on complete structures and tests on a 1:1 scale on critical components under near-realistic, multi-axial load scenarios provide a first class basis for this. The following tests should be possible: Validation tests Accelerated service life tests for structures made of steel, steel composites, and fiber composite materials Tests on foundation elements under cyclic loads and mimicked offshore seabed conditions Testing of the dynamic behavior of the complete structure with near-realistic simulation of soil-support structure interactions Quick deriving of fatigue strength by high-frequency tests of material specimen Optimization and testing of construction technologies 1 Slim jacket support structure in the alpha ventus offshore test field 2 Bending test on grouted joints at Leibniz University, Hanover 26

27 1 2 TECHNICAL RELIABILITY The development of sensor methods, and processes for data analysis and evaluation for wind turbines enhances their technical reliability. The aim is to gain precise knowledge of critical points of a wind turbine and of potential failure mechanisms. By these means, improved availability and productivity as well as a better overall profitability can be assured. This can qualitatively and quantitatively be determined. As part of a total evaluation, reliability-related indicators and parameters are identified and made available in order to quantitatively describe the effects of technical modifications, design and operating strategies over the service lifetime. For next generation and existing wind turbines For planning, construction and operation of offshore wind turbines and wind farms, the reliability of the machinery is a critical success-determining factor. It describes how effectively a product fulfills its function over a defined period of time. In order to increase profitability, this department highlights improvements for the development of next generation wind turbines as well as opportunities for fitting out and retrofitting existing turbines. Due to the large distance from shore and hence the poor accessibility of offshore wind farms, there is an increasing need for reliable measurement technology and sensor systems for the remote monitoring of structures and turbines. In addition, loads on materials are considerably higher offshore than on land and accelerate the material's aging process. Biologically induced degradation is an extra burden for materials and components. For example, some microorganisms are able to metabolize substances from protective layers and/or anti-corrosion coatings which can cause considerable damage to the structure. Offshore degradation testing As part of a total evaluation, the functioning of sensor systems under offshore conditions is currently being studied at three sites. In addition, component tests under maritime conditions can be simulated in a climate chamber. This work provides information about the conditions, loads and time frames under which sensor applications fail, and the time frames involved. It shows precisely in which way the transition from a reliable application to an unusable application takes place. Strategies for material protection The data being acquired enables strategies to be developed for protecting offshore materials, components, and structures. Including measurement data from total sensor systems in the operational management of wind turbines helps to reduce peak cumulative loads. Hence, harmful operating conditions are avoided. Structural health monitoring (SHM) systems based on neural networks provide new information for describing the condition of wind turbines and their residual service life at any moment in time. In the future, non-destructive test (NDT) methods could also provide important information about the structural health of wind turbines. Services Monitoring wind turbines Evaluation and processing of measurement data, including the validation of simulation data Determination of cumulative loads and stresses Development and application of methods for estimating aging / residual service life / residual bearing capacity Offshore and near-shore exposure and testing of materials and sensor systems Development and testing of sensor systems and sensor applications 1 Improved technical reliability improves the economics of wind energy 2 Intelligent logistics and maintenance concepts increase the availability of wind turbines 27

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