The full-scale static testing of wind turbine blades is an effective means to verify the accuracy and rationality of the blade design, and it is an indispensable part in the blade certification process. In the full-scale static experiments, the strain of the wind turbine blade is related to the applied loads, loading positions, stiffness, deflection, and other factors. At present, researches focus on the analysis of blade failure causes, blade load-bearing capacity, and parameter measurement methods in addition to the correlation analysis between the strain and the applied loads primarily. However, they neglect the loading positions and blade displacements. The correlation among the strain and applied loads, loading positions, displacements, etc. is nonlinear; besides that, the number of design variables is numerous, and thus the calculation and prediction of the blade strain are quite complicated and difficult using traditional numerical methods. Moreover, in full-scale static testing, the number of measuring points and strain gauges are limited, so the test data have insufficient significance to the calibration of the blade design. This paper has performed a study on the new strain prediction method by introducing intelligent algorithms. Back propagation neural network (BPNN) improved by Particle Swarm Optimization (PSO) has significant advantages in dealing with non-linear fitting and multi-input parameters. Models based on BPNN improved by PSO (PSO-BPNN) have better robustness and accuracy. Based on the advantages of the neural network in dealing with complex problems, a strain-predictive PSO-BPNN model for full-scale static experiment of a certain wind turbine blade was established. In addition, the strain values for the unmeasured points were predicted. The accuracy of the PSO-BPNN prediction model was verified by comparing with the BPNN model and the simulation test. Both the applicability and usability of strain-predictive neural network models were verified by comparing the prediction results with simulation outcomes. The comparison results show that PSO-BPNN can be utilized to predict the strain of unmeasured points of wind turbine blades during static testing, and this provides more data for characteristic structural parameters calculation.

This paper proposes a strain prediction method for wind turbine blades using genetic algorithm back propagation neural networks (GA-BPNNs) with applied loads, loading positions, and displacement as inputs, and the study can be used to provide more data for the wind turbine blades’ health assessment and life prediction. Among all parameters to be tested in full-scale static testing of wind turbine blades, strain is very important. The correlation between the blade strain and the applied loads, loading position, displacement, etc., is non-linear, and the number of input variables is too much, thus the calculation and prediction of the blade strain are very complex and difficult. Moreover, the number of measuring points on the blade is limited, so the full-scale blade static test cannot usually provide enough data and information for the improvement of the blade design. As a result of these concerns, this paper studies strain prediction methods for full-scale blade static testing by introducing GA-BPNN. The accuracy and usability of the GA-BPNN prediction model was verified by the comparison with BPNN model and the FEA results. The results show that BPNN can be effectively used to predict the strain of unmeasured points of wind turbine blades.

Carbon fiber-reinforced plastics (CFRP)-packaged fiber Bragg grating (FBG) sensors are widely used in full-scale structural testing of wind turbine blades (WTBs). However, the specific process to make CFRP-packaged FBG sensors, such as packaging, bonding, welding, etc., are mainly manually operated, and no unified standard or rule has been formed yet. Non-standard specific processes, coupled with complex stress distribution, unstable working environments, etc., result in the CFRP-packaged FBG sensors having various failures with time, resulting in inaccurate measurements. Thus, the need to carry out related failure analysis is urgent. This paper therefore performed a reliability analysis for CFRP-packaged FBG sensors using failure mode and effects analysis (FMEA) and fault tree analysis (FTA) techniques. The results provide an important basis towards analyzing performance degradation and functional failures for CFRP-packaged FBG sensors.