A gravo-aeroelastically scaled wind turbine rotor at field-prototype scale with strict structural requirements

Yao, Shulong; Griffith, D. Todd; Chetan, Mayank; Bay, Christopher J.; Damiani, Rick; Kaminski, Meghan; Loth, Eric

doi:10.1016/j.renene.2020.03.157

Cited by 23 publications

(41 citation statements)

References 12 publications

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“…Based on IEC and GL standards, by considering all partial safety factors for loads and composite materials, the safety factor for ultimate strength analysis under normal load was determined to be 2.977, the safety factor for fatigue calculations was 1.634 and the buckling analysis was 2.042, as in Table 1, which were consistent with studies by Griffith and Ashwill (2011) and Yao et al (2019, 2020).…”

Section: Sumr13 Series Structural Designsupporting

confidence: 80%

“…The structural advantages for two-bladed downwind turbine have been described in the introduction section and Yao et al (2019, 2020), however, the higher requirements of two-bladed rotor in rated rotor speed and loads experienced by the blade to maintain the rated power introduce a significant challenge into the design process, especially for large rotors. In this section, we present the structure design process for SUMR13i/A, a slender and longer design (SUMR13B), and the longest design in the series (SUMR13C).…”

Section: Sumr13 Series Structural Designmentioning

confidence: 99%

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Structural design and optimization of a series of 13.2 MW downwind rotors

2021

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The quest for reduced LCOE has driven significant growth in wind turbine size. A key question to enable larger rotor designs is how to configure and optimize structural designs to constrain blade mass and cost while satisfying a growing set of challenging structural design requirements. In this paper, we investigate the performance of a series of three two-bladed downwind rotors with different blade lengths (104.3-m, 122.9-m, and 143.4-m) all rated at 13.2 MW. The primary goals are to achieve 25% rotor mass and 25% LCOE reduction. A comparative analysis of the structural performance and economics of this family rotors is presented. To further explore optimization opportunities for large rotors, we present new results in a root and spar cap design optimization. In summary, we present structural design solutions that achieve 25% rotor mass reduction in a SUMR13i design (104.3-m) and 25% LCOE reduction in a SUMR13C design (143.4-m).

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Section: Sumr13 Series Structural Designsupporting

confidence: 80%

Section: Sumr13 Series Structural Designmentioning

confidence: 99%

Structural design and optimization of a series of 13.2 MW downwind rotors

2021

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“…As mentioned, the rotor summarized in Table 3, Column 2, represents the ideal GAS scaled system; however, as previously noted, environmental and manufacturing constraints also required that the fabricated SUMR‐D parameters differ from the ideal. Yao et al 19 provides a detailed summary of the blade structural design for the manufactured rotor. The blade mass of the as‐built model (summarized in Table 3, Column 3) is three times the ideal blade mass with the extra mass concentrated near the blade root; however, the blade mass remains less than half the weight of the conventional blades typically mounted on the CART2 turbine 20,21 due to both scaling and the lower power rating as summarized in Table 3, Column 4.…”

Section: Resultsmentioning

confidence: 99%

“…Ground testing and numerical simulation of operational conditions are used to investigate the blade scaling methodology 17,18 . The scaled rotor is denoted the SUMR‐Demonstrator (SUMR‐D) 19 and was designed for operational field testing on a research turbine and employs the GAS method previously employed for a 1% model 13 but with modifications due to safety constraints for operational testing at the National Wind Technology Center (NWTC) at the Flatirons Campus on the two‐bladed Controls Advanced Research Turbine (CART2) 20,21 . To retain the desired scaled aeroelastic dynamics with the nonideal blade mass and stiffness, controller set points are altered to achieve an aeroelastically scaled blade.…”

Section: Introductionmentioning

confidence: 99%

Gravo‐aeroelastic scaling of a 13‐MW downwind rotor for 20% scale blades

et al. 2020

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A 105‐m, 13‐MW two‐bladed downwind Segmented Ultralight Morphing Rotor (SUMR‐13) blade was gravo‐aeroelastically scaled by 20% to a 20.87‐m‐long demonstrator blade and confirmed through structural ground testing. The subscale model was achieved through geometric scaling and by aeroelastic scaling principles based on operational flapwise deflections combined with rotational and structural frequencies while retaining the turbine tip‐speed ratio. In particular, the subscale demonstrator was designed to replicate, as closely as possible, the nondimensional geometry, the ratio of centrifugal to gravitational moments, the tip‐speed ratio, and the nondimensional rotation rate. The intent for this demonstrator was to achieve the same nondimensional flapwise blade deflections and dynamics of the full‐scale 13‐MW rotor. The manufactured SUMR‐D blade resulted in less than half of the mass of the conventional two‐bladed Controls Advanced Research Turbine (CART2) rotor blade based on scaling and a lower power rating, though with some differences in mass and stiffness from the ideal scaled‐down design to meet safety requirements at the test site. To achieve proper scaling, operational pitch control set points were altered to account for the differences by evaluating simulated operation of both the SUMR‐13 and SUMR‐D rotors. Structural testing of the SUMR‐D blade investigated the response to well‐defined flapwise loads and indicated that the subscale blade had the appropriate elastic properties needed for both scaling and for safe operational field testing.

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“…However, the design of the blades that are examined in this paper was published as a part of previous research by the authors. 10,11 This resulted in the current work being able to start the calibration process with detailed design specifications as well as knowledge of the blade manufacturing process. The current paper aims to add to this knowledge base by developing a multi-fidelity digital twin structural model with a detailed high-fidelity model that is updated at the composite laminate level and multiple finite element (FE) models derived from the high-fidelity model that can be used for aeroelastic simulations.…”

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confidence: 99%

Multi‐fidelity digital twin structural model for a sub‐scale downwind wind turbine rotor blade

2021

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This paper presents the development of a multi-fidelity digital twin structural model (virtual model) of an as-built wind turbine blade. The goal is to develop and demonstrate an approach to produce an accurate and detailed model of the as-built blade for use in verifying the performance of the operating two-bladed, downwind rotor.The digital twin model development methodology, presented herein, involves a novel calibration process to integrate a wide range of information including design specifications, manufacturing information, and structural testing data (modal and static) to produce a multi-fidelity digital twin structural model: a detailed high-fidelity model (i.e., 3D finite element analysis [FEA]) and consistent beam-type models for aeroelastic simulation. A key element is that the multi-fidelity structural digital twin method follows the rotor from the stages of design, to manufacturing, then to the ground testing and field operation. The result of this comprehensive approach is an accurate multi-fidelity digital twin structural model for the geometric, structural, and structural dynamic properties of the as-built blade within a 1% match in mass properties, 3.2% in blade frequencies, and 6% in deflection. The different stages of processing this information within the methodology are discussed. The rotor examined is the SUMR-Demonstrator (SUMR-D), which was installed on the Controls Advanced Research Testbed (CART-2) wind turbine at the National Wind Technology Center. The digital twin model developed here was utilized to design controllers to safely operate SUMR-D in field tests, which are providing additional data for further evaluation and development of the multi-fidelity digital twin structural model.digital twin, downwind, extreme-scale wind turbine, field-testing, multi-fidelity model | INTRODUCTIONA numerical model that represents a physical system (i.e., "Digital Twin" as it's commonly known) has a wide variety of uses specifically to understand the behavior of a system under varying environmental or operating conditions without the cost of experimental operation time. Digital twins can aid in troubleshooting and remediation of performance issues, assist in prediction of failure of a real-world system, and help understand systems in extreme conditions that are difficult or risky to replicate physically. Digital twins can also provide estimates of system response (i.e., sensing) that are difficult or costly to measure. The low cost of digital twin models provides an abundance of opportunities for industry and

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A gravo-aeroelastically scaled wind turbine rotor at field-prototype scale with strict structural requirements

Cited by 23 publications

References 12 publications

Structural design and optimization of a series of 13.2 MW downwind rotors

Structural design and optimization of a series of 13.2 MW downwind rotors

Gravo‐aeroelastic scaling of a 13‐MW downwind rotor for 20% scale blades

Multi‐fidelity digital twin structural model for a sub‐scale downwind wind turbine rotor blade

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