Dynamometer Test Rig Drive Train Control with a High Dynamic Performance: Measurements and Experiences

Neshati, Mohsen; Wenske, Jan

doi:10.1016/j.ifacol.2020.12.1846

Cited by 5 publications

(6 citation statements)

References 4 publications

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“…The nominal rotational speed of the shaft is 11 rpm at 8.6 MN m. The drive system without DUT provides an air-gap torque with a control bandwidth of approx. 40 Hz [33]. To replicate realistic operation and load conditions, shear and lateral forces of up to 2 MN as well as bending moments of up to 20 MN m can be applied to the drive train by a so-called parasitic load application system, shown in the picture of the laboratory hall in Fig.…”

Section: ) Mechanical Hardware and Control Setupmentioning

confidence: 99%

Opportunities and Challenges of Advanced Testing Approaches for Multi-Megawatt Wind Turbines

Hans,

Borowski,

Wendt

et al. 2024

IEEE Open J. Power Electron.

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To safely integrate large numbers of wind turbines into the electric power grid, turbines must demonstrate compliance with grid codes and technical guidelines through rigorous testing. Such tests are traditionally performed using prototype turbines on designated measurement sites. So-called field tests offer little flexibility and repeatability, as factors such as wind and grid conditions cannot be adjusted at will. Recently, specialized laboratory test facilities were established to augment or completely replace conventional field tests. These facilities need to constantly grow in size, power, and functionality to keep up with wind turbine trends, while new and increasingly complex grid requirements necessitate more advanced testing methodologies. This paper presents four testing concepts and how they can be further integrated into the development and certification process of wind turbines using the laboratories of Fraunhofer IWES as an example. In particular, turbine, nacelle, subsystem, and component testing are reviewed and their advantages and anticipated challenges for evaluating grid code compliance are highlighted. Experiences gained over the past decade from testing wind turbines and constructing experimental testing facilities are shared, including key data and capabilities of the developed test benches. The authors expect the presented approach to be used for validating simulation models that can be embedded into larger interaction and stability studies of wind farms at a later stage. Such an integrated testing approach may lead to quicker and more flexible design and optimization of new generations of wind turbines, effectively increasing the speed of grid integration and ensuring safe and reliable grid operation.INDEX TERMS Electrical certification, grid compliance, grid simulator, model validation, power hardwarein-the-loop, real-time simulation, test bench, wind turbine testing

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Section: ) Mechanical Hardware and Control Setupmentioning

confidence: 99%

Opportunities and Challenges of Advanced Testing Approaches for Multi-Megawatt Wind Turbines

Hans,

Borowski,

Wendt

et al. 2024

IEEE Open J. Power Electron.

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show abstract

“…On the other hand, the installed torque measurement adapter provides a valuable additional measurement, however, it is not experimentally calibrated in a certified manner as described in section 4. In addition, the test bench including actuators, control, and observer systems demonstrates high performance, but possesses its inherent dynamic characteristics [4]. Finally, the DUT itself (including control), acts as a black box and the HiL setup only reacts to actions taken by the DUT during test events.…”

Section: Objectivementioning

confidence: 99%

“…2) as the device under test (DUT). More information on system operation and capabilities at DyNaLab can be found in previous publications [4]. The DUT considered in this paper is a prototype incorporating geared drive train with a doubly fed induction generator (DFIG), and a partial converter system.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of a Hardware-in-the-loop Test Setup Using Mechanical Measurements with a DFIG Wind Turbine Nacelle

Neshati

Zhang

Thomas

et al. 2022

J. Phys.: Conf. Ser.

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The impact of system test benches on the development and validation of wind energy converters is significantly increasing, and that is due to the higher availability as well as the provided powerful actuator and emulation systems. However, the question remains to be answered about how consistent measurements in the laboratory are. Especially in the case where no field measurements are available for prototypes. The challenge in this regard is the unknown accuracy of simulations and the lack of an experimentally calibrated torque measurement in the hardware-in-the-loop (HiL) setup. The presented paper handles this topic and presents an evaluation method to elaborate measurement consistency independent from field tests. A transparent and comprehensive comparison is provided, taking advantage of the deterministic test environment enabled by the HiL system and the dedicated designed torque measurement adapter. Provided results demonstrate consistent measures obtained from the real-time simulation, HiL control system, and the electrical and mechanical measurements, where a low deviation of up to 2 % is partly observed.

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“…An example of such a test rig for full-scale nacelles in the 2-10 MW range [6] is the Dynamic Nacelle Testing Laboratory (DyNaLab) at Fraunhofer IWES shown in Figure 1. The test bench 2 features a HiL environment, which utilizes advanced control algorithms and real-time simulation models to emulate the missing WEC components [7].…”

Section: Introductionmentioning

confidence: 99%

Framework for Design Validation of Control Algorithms used on Mechanical Hardware-in-the-Loop Nacelle Test Rigs

Feindt,

Siddiqui,

Zuga

et al. 2024

J. Phys.: Conf. Ser.

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Full scale multi-MW Wind Energy Converter (WEC) nacelles including the mechanical and electrical components as well as the main and converter control systems, are tested at the Dynamic Nacelle Testing Laboratory (DyNaLab) at Fraunhofer IWES. A Hardware-in-the-Loop environment emulates the missing rotor and accurately applies torque to the nacelle via a motor and the test rig drivetrain. In a current nacelle test campaign, several structural changes have been made to reduce the necessary adaptor tolerances of the test rig interface and to include the nacelle hub. These changes can potentially impact the system’s dynamic response and controller performance. This paper presents the current research with a focus on improving the control algorithms for accurate application of the rotor torque by implementing a simulative validation framework. The objectives of this framework include addressing the impact of modifications to the test rig drivetrain, variations in the nacelle adaptor, and communication delays between real-time simulation models, the test rig, and the WEC controller prior to performing tests on the real system. The methodology shown therefore involves three steps: controller design using a simplified multi-mass torsional model of all components necessary for testing, validation with a high-fidelity virtual test bench model and testing the resulting controller performance during the commissioning phase for the actual test. Overall, this approach is expected to reduce the commissioning duration, enhance the performance of the test rig, and identify the limitations in achieving stable torque control before the application to the real wind turbine nacelle on the test rig.

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Dynamometer Test Rig Drive Train Control with a High Dynamic Performance: Measurements and Experiences

Cited by 5 publications

References 4 publications

Opportunities and Challenges of Advanced Testing Approaches for Multi-Megawatt Wind Turbines

Opportunities and Challenges of Advanced Testing Approaches for Multi-Megawatt Wind Turbines

Evaluation of a Hardware-in-the-loop Test Setup Using Mechanical Measurements with a DFIG Wind Turbine Nacelle

Framework for Design Validation of Control Algorithms used on Mechanical Hardware-in-the-Loop Nacelle Test Rigs

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