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DOE OSTI2023

Effect of the integral length scales of turbulent inflows on wind turbine loads

As wind turbines become larger, the fluctuations in the inflow become increasingly influential in the turbine structural loading. These fluctuations are characterized by the integral length scale, which represents the average size of the largest energy-containing turbulent eddies. Current design standards neglect the varying integral length scales that characterize inflows of wind turbines in operation. Using large-eddy simulations, we generate turbulent inflows of varying integral length scales and quantify the loads of the IEA 15-MW reference wind turbine. Results illustrate that the impact of turbulence on rotor and tower loads is up to 10 times greater than the impact of the mean shear profile. Increasing integral length scales from 0.3x to 0.5x the rotor diameter reduces blade root flapwise moments and rotor and tower loads. Increasing integral length scales from 0.5x to 1.7x the rotor diameter increases the rotor aerodynamic thrust force and the blade root flapwise shear loads and decreases the tower base torsional moment and the tilting and yawing rotor aerodynamic moments. Additionally, turbulence intensity has a greater impact on wind turbine loads than integral length scales. In conclusion, findings indicate that design standards should consider varying integral length scales for accurate wind turbine loading characterization in turbulent inflow conditions.

17 WIND ENERGY↗

DOE OSTI2025

Unsteady aerodynamics of large-scale floating offshore wind turbines in surge motion

Unsteady aerodynamic loads significantly influence the design and wake flow field of floating offshore wind turbines, especially due to wave- or vibration-induced tower top motions triggering various unsteady phenomena. Recent studies show that increasing turbine sizes amplify unsteady aerodynamic effects, as their impact typically grows with rotor diameter. This work combines recent findings from experiments and simulations on model-scale FOWT aerodynamics with new numerical analyses of large-scale rotors, providing a comprehensive understanding of unsteady phenomena occurrence and impact. Numerical analyses of the IEA 15-MW and 22-MW rotors undergoing surge motions characterise the combined influence of motion-induced unsteady phenomena on rotor thrust. Results indicate that unsteady effects can reduce thrust force variations by up to 40% at realistic surge periods. These findings contrast with prior model-scale rotor investigations, attributed to the specialised design of the model rotors. Comparisons between numerical methods - the dynamic blade element momentum method in OpenFAST and free vortex wake modules in panMARE and OpenFAST - reveal persistent differences in thrust predictions under both idealised and realistic conditions. This highlights that classical blade element momentum approaches require enhancement to accurately capture unsteady loads on large-scale floating offshore wind turbines at low wind speeds.

16 TIDAL AND WAVE POWER↗

DOE OSTI2024

Aerodynamic and production comparison of wind farms with downwind versus conventional upwind turbines

Ever-increasing turbine scales and their associated logistical challenges have reignited questions about the performance of downwind rotor configurations. A particular potential benefit of downwind rotor configurations is the farm-scale power increase that may be conferred by tilt-driven downward wake entrainment and associated wake recovery. In this work, a comprehensive aerodynamic analysis is carried out to understand the mechanisms for wake entrainment and recovery across a spectrum of velocity and inflow alignment conditions on a small, structured farm in order to understand the impact of downwind rotors on farm production. The results show that the benefits demonstrated previously in the literature for downwind-rotor farms in aligned flows are fragile, and, outside of strong farm/flow alignment conditions, power production benefits for small farms with downwind rotor configurations are significantly if not completely mitigated by misalignment effects. The work indicates that farm-scale benefits for downwind rotors must be realized either from large-scale entrainment benefits, with more exotic farm arrangements that can take advantage of the aerodynamic effects, or from beneficial fatigue impacts from entrainment of less turbulent outer boundary layer flows.

17 WIND ENERGY↗

DOE OSTI2024

Delamination and Buckling Analysis of a Laminated Component in a High-speed Permanent Magnet Motor

High-speed permanent magnet (PM) machines are widely used because of their high-power density and high efficiency. The high rotation speed also inevitably subjects the PMs to high centrifugal load, which might damage them due to their inherent mechanical vulnerability, such as a much lower tensile strength than the compressive strength. To robustly transfer the torque from the magnet to the shaft, the outer diameter of the laminated rotor core is larger than the inner diameter of the rotor frame to ensure tight contact while working at 20,000 rpm. Motor manufacturing requires the shrink-fit method to assemble the rotor frame and rotor core. However, after the shrink-fit assembly, unexpected local delamination and buckling are observed on the rotor core part. Utilizing finite element simulation, we study the internal stress of assembling these two parts at the provided interference. Simulation results indicate the reasons for the delamination and buckling of the rotor core part and provide suggestions for improving the assembly.

Lin, Lianshan↗

DOE OSTI2024

Nonsteady Load Responses of Wind Turbines to Atmospheric and Mountain-Generated Turbulence Eddies, With Impacts on the Main Bearing: A Validation Study

Previous computational and field experiments identify three characteristic time scales in the aerodynamic responses of utility-scale wind turbine loads to atmospheric boundary layer (ABL) turbulence: a 30-90 second time scale for the passage of high/low speed "streaks" through the rotor plane, the blade and rotor rotation time scales (approximately 1 to 5 seconds), and a sub-second time scale created by blade rotation through gradients within eddy coherent structure. In the current study we compare aerodynamic load responses from daytime ABL turbulence quantified with large-eddy simulation and a actuator line model of the NREL 5 MW wind turbine with analysis of field data from the NREL/GE 1.5 MW wind turbine 5 kilometers east of the Rocky Mountain Front Range in Colorado. In addition, we contrast the responses to the passage of the mountain-generated eddies embedded within the westerly winds with the ABL eddies embedded within northerly/southerly winds. These analyses are in context with the nonsteady forcing of the main bearing by the aerodynamic generation of nontorque bending moments on the main shaft. Potentially relevant to main bearing failure mechanisms, both computational and field data show that the magnitudes of turbulence-generated nontorque bending moments, that we show generate nonsteady force on the main bearing, are of order, and often larger than, torque (which underlies power). However, the temporal variations in these two responses are uncorrelated, implying that the aerodynamic mechanisms that drive power and main bearing response are fundamentally different. We find this to be the case in the field with both mountain-generated eddies (westerly winds) and ABL-generated eddies (northerly/southerly winds). Whereas the time and length scales are comparable, the mountain eddies were somewhat more energetic than the northerly/southerly ABL eddies. Interestingly, however, the fluctuations in nontorque bending moment that force the main bearing were found to be stronger when forced by the ABL eddies than the mountain eddies. The field studies validate the key results from the computational study and show even stronger response in the nontorque bending moment than in the computer simulations. In all cases, the torque and nontorque bending moments are temporally uncorrelated, torque and power are driven by time variations in rotor-averaged horizontal wind velocity and nontorque bending moments are driven by time changes in the degree of nonuniformity in the distribution of velocity over the rotor plane. Thus the results generalize the mechanisms underlying nonsteady aerodynamic forcing to classes of turbulence eddy types with strength of order or stronger than ABL eddies with transverse scale of order the wind turbine rotor. These include atmospheric turbulence eddies, topography-generated turbulence eddies and, by extension, impacts of turbine-wake-scale turbulence eddies on downstream wind turbine rotors.

17 WIND ENERGY↗

DOE OSTI2026

Thermal Management for a Novel Non-Heavy Rare-Earth Interior Permanent Magnet Machine

The work presents a thermal management solution for a novel non-heavy rare-earth permanent magnet machine being developed at Oak Ridge National Laboratory. The motor has been designed to minimize losses while maximizing performance for a range of speeds and power ratings. The novel motor design reduces rare-earth magnet usage, thereby avoiding supply chain issues. The motor component heat losses are established for operating windows and desired performance. These heat losses, along with windage losses, are being used to develop cooling solutions for different components of this machine. A novel thermal management solution for stators and rotors has been developed, and progress is presented in this paper. The stator cooling is achieved with the help of water-ethylene glycol flowing over the finned aluminum stator jacket, and rotor cooling with automatic transmission fluid passing through novel channels designed in the rotor laminations. The attempt is to establish effective cooling of the stator winding, laminations, and rotor magnets. A 3D conjugate heat transfer model has been developed for overall thermal analysis to establish a down- selected thermal management solution for the machine. The model, in addition to estimated component heat losses, includes windage losses and its impact on rotor and stator cooling. Overall, the work presents a workable thermal solution for the interior permanent magnet machine with potential for further improvements. Future work will involve establishing end winding and refinement of other end parts of the machine with the aim of establishing a robust thermal management solution. The work will also focus on different shapes (e.g., round, non-round, presence of wedges) of rotor-stator gaps and investigate windage losses and their impact on thermal management for higher rotational speeds for the machine.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

Land-based wind turbines with flexible rail-transportable blades – Part 1: Conceptual design and aeroservoelastic performance

This work investigates the conceptual design and the aeroservoelastic performance of land-based wind turbines whose blades can be transported on rail via controlled bending. The turbines have a nameplate power of 5 MW and a rotor diameter of 206 m, and they aim to represent the next generation of land-based machines. Three upwind designs and two downwind designs are presented, combining different design goals together with conventional glass and pultruded carbon fiber laminates in the spar caps. One of the five blade designs is segmented and serves as a benchmark to the state of the art in industry. The results show that controlled flexing requires a reduction in the flapwise stiffness of the blades, but it represents a promising pathway for increasing the size of land-based wind turbine rotors. Given the required stiffness, the rotor can be designed either downwind with standard rotor preconing and nacelle uptilt angles or upwind with higher-than-usual angles. A downwind-specific controller is also presented, featuring a cut-out wind speed reduced to 19 m s –1 and a pitch-to-stall shutdown strategy to minimize blade tip deflections toward the tower. The flexible upwind and downwind rotor designs equipped with pultruded carbon fiber spar caps are found to generate the lowest levelized cost of energy, 2.9 % and 1.3 %, respectively, less than the segmented design. The paper concludes with several recommendations for future work in the area of large flexible wind turbine rotors.

17 WIND ENERGY↗

DOE OSTI2024

Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades: Preprint

In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their tidal turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three rotors were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. Instead, it was infused with a novel, infusible thermoplastic resin system. Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermos-mechanical characterization, and evaluation of material performance in marine environments, to understand the key differences between the fiberglass reinforced epoxy and Elium composites used for the respective rotors. Matrix burnoff tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period, however, it was determined that the Elium laminates had higher diffusion coefficients, so initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while taking periodic mass measurements. The datasets were extrapolated out to assume a full 20 year operational life span and it was determined that the blades would not reach full saturation during that time span.

composite manufacturing↗

DOE OSTI2021

Performance and cost of fuel cells for urban air mobility

Several companies are developing enabling elements of urban air mobility (UAM) for air taxis, including prototypes of electric vertical take-off and landing (eVTOL) vehicles. These prototypes incorporate electric and hybrid powertrains for multi-rotor and tilt-rotor crafts. Many eVTOLS are using batteries for propulsion and charging them rapidly between the flights or swapping them for slow charging overnight. Rapid charging degrades the battery cycle life while swapping requires multiple batteries and charging stations. This study has conducted a technoeconomic evaluation of the eVTOL air taxis with alternate powertrains using hydrogen fuel cell systems being developed for light-duty and heavy-duty vehicles. We consider performance metrics such as fuel cell engine power, weight, and durability; hydrogen consumption and weight of storage system; and maximum take-off weight. The metrics for economic evaluation are capital cost, operating and maintenance cost, fuel cost, and the total cost of ownership (TCO). In this work, we compare the performance and TCO of battery, fuel cell and fuel cell – battery hybrid powertrains for multi-rotor and tilt-rotor crafts. We show that fuel cells are the only viable concept for powering multi-rotor eVTOLs on an urban scenario that requires 60-mile range, and hybrid fuel cells are superior to batteries as powertrains for tiltrotor eVTOLs

08 HYDROGEN↗

DOE OSTI2022

Dynamical exponent of a quantum critical itinerant ferromagnet: A Monte Carlo study

Here we consider the effect of the coupling between two-dimensional (2D) quantum rotors near an XY ferromagnetic quantum critical point and spins of itinerant fermions. We analyze how this coupling affects the dynamics of rotors and the self-energy of fermions. A common belief is that near a q = 0 ferromagnetic transition, fermions induce an Ω/q Landau damping of rotors (i.e., the dynamical critical exponent is z = 3) and Landau overdamped rotors give rise to non-Fermi liquid fermionic self-energy Σ∝ω 2/3 . This behavior has been confirmed in previous quantum Monte Carlo (QMC) studies. Here we show that for the XY case the behavior is different. We report the results of large-scale quantum Monte Carlo simulations, which show that at small frequencies z = 2 and Σ∝ω 1/2 . We argue that the new behavior is associated with the fact that a fermionic spin is by itself not a conserved quantity due to spin-spin coupling to rotors, and a combination of self-energy and vertex corrections replaces 1/q in the Landau damping by a constant. We discuss the implication of these results to experiments.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Shape evolution of neutron-rich 106,108,110 Mo isotopes in the triaxial degree of freedom

Background: Neutron-rich nuclei with mass number between 100 and 110 attract much attention, since several kinds of shapes, such as spherical, prolate, oblate, and triaxial shapes, are predicted. In particular, for neutron-rich Mo isotopes, different models predict different magnitudes and rigidity of triaxial deformation. Previous interpretations of experimental results based solely on low-lying $2^+_2$ states are insufficient to distinguish between the rigid triaxial shape, $\gamma$ vibration, or $\gamma$-soft rotor. Purpose: The shape evolution of 106 Mo, 108 Mo, and 110 Mo is investigated through their $2^+_1$-state lifetimes, decay-branching ratios of the $2^+_2$ state, and energies of the low-lying collective excited states with $K^π = 0^+, 2^+$, and $4^+$. Method: $\beta$-delayed $\gamma$-ray spectroscopy was employed for neutron-rich Nb and Zr isotopes produced at the RIKEN RI Beam Factory to populate excited states in 106 Mo, 108 Mo, and 110 Mo. The EUroball-RIKEN Cluster Array was used for high-resolution $\gamma$-ray detection and lifetimes of the $2^+_1$ states were determined using the UK fast-timing array of LaBr 3 (Ce) detectors. Results: New $\gamma$-ray transitions and levels are reported, including newly assigned $0^+_2$ states in 108,110 Mo. Quadrupole deformations were obtained for 106,108,110 Mo from their $2^+_1$ energies and lifetimes. The $\beta$-delayed neutron-emission probabilities of 108 Nb and 110 Nb were determined by examining the $\gamma$ rays of their respective daughter decays. Conclusions: In this work, the even-odd energy staggering in the $2^+_2$ band was compared with typical patterns of the $\gamma$-vibrational band, rigid triaxial rotor, and $\gamma$-soft rotor. The very small even-odd staggering of 106 Mo, 108 Mo, and 110 Mo favors a $\gamma$-vibrational band assignment. The kinematic moment of inertia for the $2^+_2$ band showed a trend similar to the ground-state band, which is as expected for the $\gamma$-vibrational band. Beyond-mean-field calculations employing the constrained Hartree-Fock-Bogoliubov and local quasiparticle-random-phase approximation method using the SLy5 + T interaction reproduced the ground and $2^+_2$ bands in 106 Mo and 108 Mo. The collective wave functions are consistent with the interpretation of the $2^+_2$ band as the $\gamma$-vibrational band of the prolate shape. However, the staggering pattern observed in 110 Mo differs from the one suggested in the calculations which predict a $\gamma$-soft rotor. There was no experimental indication of the oblate shape or the $\gamma$-soft rotor predicted in these Mo isotopes.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Analysis of the Aeroelastic Dynamics of Lightweight Flexible Variations of the SNL-NRT Turbine

Current trends show that wind turbines are growing in size to meet a rising demand for renewable energy generation, and their upscaled rotors have inherently become more flexible to maintain a proportionally lighter design. This is because larger rotors must be less massive relative to their diameter to minimize the levelized cost of energy (LCOE), which means that blades that are notably less stiff are produced as a result. These structural changes to blades are often reflected in their compromised aeroelastic stability and amplified deformation during operation, which has the potential to decrease the blade’s expected lifetime and the performance of the machine overall. Variations in blade flexibility are also known to influence vortex-wake structures downstream of the turbine, causing patterns of velocity deficit to evolve in ways that affect the performance of other turbines in the farm. This research explores how the increased flexibility of modern utility-scale wind turbine blades influences rotor aeroelastic behavior and interactions with farm flow. High-fidelity simulations of Sandia National Laboratories’ (SNL) National Rotor Testbed (NRT) wind turbine are presented. Flexible variations of the NRT baseline blade are simulated in a variety of realistic operational conditions typically expected at the SNL’s SWiFT facility in Lubbock, Texas. Solutions are then compared to investigate how specific changes to the structural properties of the NRT baseline blade’s design and construction can influence its aeroelastic response at the rotor and the evolution of the turbine’s wake.

Farrell, Alayna (ORCID:000000023555720X)↗

DOE OSTI2020

Pulsed start-up system for electrostatic generators

A new rotor start-up system is provided for application to rotating systems such as stationary or vehicular electromechanical battery systems. An embodiment of the system consists of a “locator” that includes a stationary permanent-magnet pole above which is a circular ferromagnetic (e.g., iron) strip embedded in the lower, inner edge of the flywheel rotor. The lower edge of this strip is wave-like so that the magnet can pull the rotor around to a position where the position relative to the minimum capacity between the rotor and stator electrodes is such as to launch the rotor in a chosen direction, i.e., either clock-wise or counter-clockwise. Startup from rest is then accomplished by applying a short high-voltage ac or dc pulse to the EMB capacitor.

42 ENGINEERING↗

DOE OSTI2023

Machines utilizing heavy rare earth free permanent magnets

Various examples are provided related to machines utilizing heavy rare earth (HRE) free permanent magnets. In one example, a rotor assembly including a rotor core having a plurality of rotor slots and magnets positioned within the plurality of rotor slots. At least a portion of the magnets are free of heavy rare earth (HRE) elements. The magnets can include a combination HRE segments and HRE-free segments or can be free of HRE elements. The rotor assembly can be included in an electric machine such as, e.g., a permanent magnet (PM) machine.

Islam, Md. Sariful↗

DOE OSTI2021

Design of a 3.4-MW wind turbine with integrated plasma actuator-based load control

Historically, cost reduction in wind energy has been accomplished by increasing hub heights and rotor diameters to capture more energy per turbine. The growth in rotor and turbine costs with increasing turbine sizes is also driven by the additional structure that must be added to withstand unsteady aerodynamic loads caused by turbulence, gusts, wind shear, misaligned yaw, upwind wakes, and the tower shadow. In this paper, we present a holistic design solution to integrate active load control using a controllable Gurney flap based on plasma actuators. We illustrate the design solution for a land-based 3.4-MW wind turbine rotor. Comparisons to a baseline reference 3.4-MW wind turbine show significant load reduction (15–18% DEL reduction for flap-wise blade root moments), rotor mass reduction (5–8%), and LCOE reduction (1.16–3.11%). To achieve these results, a comprehensive sequential-iterative design procedure is introduced to integrate the controllable Gurney flap into the turbine design and to drive the design solution toward the best LCOE reduction solution. Results are presented for mapping fatigue load reductions into cost reductions. In addition, an evaluation of active load control extended from Region-III to also include Region-II showed a further 34% reduction in DEL.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Upwind vs. downwind: loads and acoustics of a 1.5 MW wind turbine

This paper discusses the motivation, preparation, risk mitigation, execution, and results of a full-scale experiment where the conventional upwind rotor of a 1.5 MW wind turbine was operated in a downwind configuration. The experiment took place at the National Renewable Energy Laboratory Flatirons Campus in Colorado, USA, and involved the collection of loads and power together with acoustic measurements from an array of four microphones. To validate the numerical predictions of the aeroelastic solver OpenFAST in terms of loads and performance, 410 min of downwind operation and 960 min of conventional upwind operations were used. In the wind speed range from 4.5 to 12.5 m s−1, the downwind rotor generates higher damage equivalent loads for the blade root flapwise moment, blade root edgewise moment, and tower-base fore-aft moment compared to the upwind rotor. For these metrics of fatigue loads, numerical predictions match the experimental observations well. OpenFAST is, however, also seen underpredicting a power gain in the downwind rotor. In terms of acoustics, the overall sound pressure levels recorded in the field are similar between the upwind and downwind cases, but downwind operation worsens the metrics describing amplitude modulation.

17 WIND ENERGY↗

DOE OSTI2023

New insights on wind turbine wakes from large‐eddy simulation: Wake contraction, dual nature, and temperature effects

Abstract Large‐eddy simulation (LES) has been adopted to study wind turbine wakes because it can capture fine‐scale details of turbulent wind flows and interactions with wind turbines. Here, we use the LES version of the Weather Research and Forecasting (WRF) model with an actuator disk model to gain insights on several wake effects that have been traditionally difficult to measure. The first finding is that the wake has a “dual nature,” meaning that the wind speed deficit behaves differently from the added turbulent kinetic energy (TKE) and the two are not co‐located in space. For example, the wind speed deficit peaks at hub height and reaches the ground within 8D (D is the rotor diameter), but added TKE peaks near the rotor tip and generally remains aloft. Second, temperature changes near the ground are driven by the added TKE in the rotor area and by atmospheric stability. The combination of these two factors determines the sign and intensity of the vertical heat flux divergence below the rotor, with convergence and warming associated with stable conditions and weak divergence and modest cooling with unstable conditions. Third, wakes do not expand indefinitely, as suggested by similarity theory applied to the wind speed deficit, but eventually stop expanding and actually contract, at different rates depending on atmospheric stability. The implication of these findings is that, in order to study wakes, it is not sufficient to focus on wind speed deficit alone, because TKE is also important and yet behaves differently from the wind speed deficit.

17 WIND ENERGY↗

DOE OSTI2020

Deflection Shape Balancing: An Alternative to Modal Balancing

Rotor balancing is the final step in the rotor manufacturing process and may be necessary during rotor refurbishment. The process can be time consuming and costly, especially for supercritical monolithic rotors, impacting schedule and increasing costs. Modal balancing is a commonly used practice and is effective but requires multiple runs and at least one high-speed run. Deflection shape balancing is introduced as an alternative that may offer a more efficient method of balancing making the process faster with potentially fewer balancing runs. This paper explores the performance of the deflection shape fit balancing technique by utilizing MATLAB code simulations.

Morrell, William Jason↗