the Creative Commons Attribution 4.0 License.
the Creative Commons Attribution 4.0 License.
Feasibility of up-tower repair concepts for pultruded carbon spar cap planks in wind turbine blades
Abstract. While modern wind turbine blades utilize pultruded carbon fiber-reinforced polymer (CFRP) planks for structural integrity in spar caps, these materials can sustain damage from operational stresses, leading to potential failures if unaddressed. Traditional down-tower repairs result in significant costs related to dismantling and transportation, especially for offshore installations, emphasizing the need for efficient up-tower repair methods. The research utilizes a finite element model of an 81.6 m rotor blade designed for a 7 MW offshore turbine, subjected to aeroelastic simulations to evaluate load conditions during maintenance. The analysis focuses on a step-wise increased repair zone, assessing susceptibility to buckling, cyclic strains, and permissible wind speeds. Results indicate that while substantial repairs can endanger structural stability, turbulence-induced strain amplitudes are manageable. Recommendations include installing temporary pretensioning and buckling support structures to enhance safety during repairs. Various innovative support designs are proposed for installation from both inside and outside the blade, aimed at improving structural integrity during up-tower repairs.
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CC1: 'Comment on wes-2025-56', Wolfgang Holstein, 22 May 2025
Besten Dank Malo für die Möglichkeit an der Diskussion zur Veröffentlichung teilzunehmen.
Die Erfahrung aus meiner Praxis zeigt, daß Reparaturentscheidungen aufgrund mehrdimensionaler Kriterien erfolgen, die nicht alleine technischer Natur sind. Die Verfügbarkeit von Ersatzteilen, Material und geeignetem Personal, sowie meteorologische Bedingungen spielen hier mit eine Schlüsselrolle.
Gleichwohl zeigt das Verbundprojekt die Leistungsfähigkeit der Simulation und ingeniöse Kreativität durch versteifende Komforten als Exosketett oder Endoprthese die erforderliche Positionierung der Fügepartner herzustellen. Welch ein Aufwand am hängenden Blatt diese Hilfsvorrichtungen ohne Kran aus der Bühne oder dem Seil anzubringen.
Soviel zu dem ersten Eindruck, den ich weiter vertiefen möchte. Ich bin gespannt auf Kommentare, die ich ebenfalls zu sehen bekomme.
Wolfgang Holstein
Disclaimer: this community comment is written by an individual and does not necessarily reflect the opinion of their employer.Citation: https://doi.org/10.5194/wes-2025-56-CC1 -
RC1: 'Comment on wes-2025-56', Anonymous Referee #1, 06 Aug 2025
The comment was uploaded in the form of a supplement: https://wes.copernicus.org/preprints/wes-2025-56/wes-2025-56-RC1-supplement.pdf
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RC2: 'Comment on wes-2025-56', Anonymous Referee #2, 14 Aug 2025
Dear Authors,
Thank you for this interesting submission that already has decent quality.
The submitted manuscript addresses an interesting question with regard to feasibility of up-tower repairs for wind turbine rotor blades. Most of my comments address minor revisions in the manuscript. However, one major problem of the underlying technical challenge has not been addressed.
Please revise according to my comments in the attached *.pdf.
Best regards.
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