Unique worldwide: test stand for rotor blades in Bremerhaven, Germany is set to be climate-neutral by 2045. This has led to the increased installation of wind turbines on land and at sea. The Fraunhofer Institute for Wind Energy Systems (IWES) in Bremerhaven has opened a new test stand for the rotor blades of these turbines. The aim is to test the more powerful blades quickly, so they can be deployed sooner. The success of this testing facility can have a significant impact on the energy transition.
Rotor blade test benches are used to ensure the reliability and functionality of wind turbine systems and their parts. A certification process is put in place, in which the rotor blades are thoroughly examined before being approved. The testers simulate the loads the blades will face throughout their service life, checking if they were built according to plan. The blades are subjected to extreme loads and undergo fatigue testing. The entire testing process can take up to two years. At the end of the test, a blade is deemed defective if it fails to meet the required standards. If a rotor blade type passes the test, it can then be reproduced.
Rotor blade lengths vary, with longer blades leading to increased electricity production. The IWES facility caters to longer blades of over 115 meters, making it unique in the world. In the past, there were limited options for testing longer blades, so the new test stand has been highly praised by industry representatives.
The new test stand in Bremerhaven offers various testing methods for rotor blades, including full-blade tests and tests on individual sub-segments. The modular and convertible structure of the test stand allows for flexibility and the development of intelligent test methods. The material behavior of rotor blades can also be tested, with the ability to divide the blade into segments for optimization and individual testing.
The development of the new wind turbine is seen as a significant step towards achieving expansion targets for wind energy. The Chief Specialist Test and Validation at Vestas Wind Systems A/S, Christian Fenselau, expresses enthusiasm for carrying out the necessary rotor blade test for their prototype V236-15.0 MW, which aims to start series production in 2024. The experience and expertise of IWES in Bremerhaven, with over 40 test campaigns in the past decade, ensures that rotor blades can operate reliably throughout their 20-year service life. The new test bench complements the existing infrastructure and allows for the growing size of wind turbines.
In total, IWES now operates three test facilities for rotor blades along the German coast with open sea access, aiding in transport. The construction of the new test stand is funded by the Federal Ministry of Economics and Climate Protection (BMWK), the Federal Ministry of Education and Research (BMBF), the State of Bremen, and the European Regional Development Fund (ERDF).
