Case – Realistic Wind Turbine Blade FE Model for Optical Sensor Development
Insensys
Specialist blade knowledge was blocking independent development
Insensys had strong sensor expertise, but developing reliable optical sensing and condition monitoring systems for wind turbine blades required a deeper understanding of blade structures, composite layups, damage behavior, and simulation methods.
Accessing that knowledge through OEMs could create delays, dependencies, and competing priorities, since blade engineering expertise is closely guarded and not always available for third party development.
Insensys needed an independent way to understand realistic blade behavior, interpret defects correctly, and make sound design decisions without waiting for OEM support.
A practical simulation foundation built for research teams
After reviewing the goals and constraints, we created a plan that allowed Insensys to continue its research and development program independently, supported by our blade engineering specialists.
We deployed a realistic wind turbine blade simulation model and provided the tools and guidance needed to use it effectively. This included a composite layup plan in csv format, a Python script for quickly changing layups, and a method for creating cracks and delaminations in ANSYS SpaceClaim and Mechanical so defects could be included in simulations.
We also supported strain and modal analyses, shared recommendations for further reading on wind turbine blades, and advised on how blade design, damage mechanisms, and defect assessment should influence sensor system development.
Faster progress with less technical risk
The collaboration closed a critical competency gap for Insensys.
Instead of relying on trial and error or waiting for access to OEM expertise, the team gained a realistic blade engineering environment for evaluating optical sensor concepts and condition monitoring strategies.
This reduced the risk of inappropriate sensor placement, incorrect defect interpretation, and development delays. It also helped Insensys create stronger customer value by aligning its sensor technology with how wind turbine blades actually behave in operation. Just as importantly, the delivered models, scripts, methods, and expert guidance built internal know how that enabled Insensys to keep developing independently after the project.
With specialist support from DIS/CREADIS, Insensys could move faster, make better technical decisions, and continue bringing blade monitoring solutions toward market with greater confidence.
Insensys
Insensys has 20 years of experience developing and operating load control sensing systems.
The company wanted to expand into optical sensing and condition monitoring systems for wind turbine blades, an area that requires specialist blade engineering knowledge that is often held inside OEM organizations.
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