Research centre Risø of DTU Copenhagen relies on ZEISS measurement technology

Wind power is a focal point of renewable energy as countries shift away from fossil fuels. The Wind & Energy Systems Institute at the Technical University of Denmark (DTU) aims to enhance wind turbine efficiency.

Understanding load and damage behavior
A key aspect of this research is the design, manufacture, and testing of rotor blades, with a central focus on investigating their load and damage behavior, which is crucial for determining service life. The department utilizes extensive test facilities to analyze rotor blades, focusing on how they perform under extreme loads and identifying factors that contribute to damage. The results are essential not only for optimizing design and production but also for understanding the structural changes that occur over time.

At DTU Risø campus, newly developed rotor blades undergo thorough testing in extensive and advanced facilities.

A significant aspect of this research is the creation of digital twins – virtual replicas of rotor blades that reflect their condition throughout their lifespan. This approach allows researchers to monitor the blades’ integrity and performance continuously. To facilitate accurate assessment, DTU employs advanced optical measurement systems. These technologies enable rapid and precise analyses of large prototypes, enhancing the research process.

More on quality assurance for the wind sector

Flexible and mobile use of the TRITOP 3D coordinate measuring machine

3D measurement of large structures
ZEISS TRITOP is an optical 3D photogrammetry system that captures rotor blade geometry. It consists of a handheld digital camera and calibration objects. By applying coded and uncoded measuring points to the rotor blade, researchers can take images from various angles, generating a detailed 3D point cloud. This system is effective for both non-deformed and deformed rotor blades, allowing an easy evaluation of 3D coordinates using the inspection software ZEISS INSPECT.

Kim Branner, Head of Section Structural Design & Testing, Technical University of Denmark (DTU), Wind & Energy Systems

“ZEISS equipment and software help us to measure the deviations between the models we work with and the real-world testing of the respective structures. In that way we can improve our models significantly.”

Kim Branner
Head of Section Structural Design & Testing, Technical University of Denmark, Wind & Energy Systems

High-precision ZEISS 3D scanning system ARAMIS 1 featuring dual cameras and an array of blue LED lights.

3D testing of deformations and motions

ZEISS ARAMIS 1 is the entry key for beginners to the world of optical 3D measurements of deformation and motion. The system provides measurement data from images and videos offering a precise, flexible, and efficient method for measuring strain, displacement, vibration, and acceleration. It can be used in many different applications in academic materials research and industrial R&D departments. The non-contact measurement method of the ZEISS ARAMIS 1 allows for the many measurement points to be captured simultaneously without any difficulties.

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Attaching the measuring points to the rotor blade.

High-resolution deformation analysis of rotor blades
After recording reference points with the photogrammetry system, ZEISS ARAMIS comes into play. The high-resolution optical 3D measuring system for performing full-field and point-based measurements uses these reference points to automatically transform individual measurements, including coordinates, displacements, and surface strain. To consistently recognize deformations on large objects, multiple systems are linked and synchronized. This comprehensive data collection is vital for assessing rotor blade integrity and performance.

Paving the way for wind energy technology

The research at DTU significantly deepens the understanding of rotor blade dynamics and is critical to the advancement of wind energy technology. By using innovative measurement technologies, DTU effectively optimizes the design and production of wind turbines.

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