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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Assessment of ProgPy - An Open-Source Condition Monitoring and Diagnostics Tool

Traditional maintenance programs, such as corrective and preventive strategies, may lead to high costs and operational inefficiencies. Condition Monitoring and Diagnostics (CM&D) aims to improve these maintenance strategies by enabling timely insights into equipment health and performance. However, implementation of CM&D can be challenging without a robust framework that manages data efficiently, supports interoperability and simplifies integration. To address these challenges ProgPy, an open-source Python-based prognostics tool developed by NASA Ames Research Center, offers a structured solution for broader Prognostics and Health Management (PHM) applications. Ongoing research is assessing the feasibility of implementing ProgPy as a Condition Monitoring and Diagnostics (CM&D) solution by comparing its framework to the guidelines for open CM&D systems recommended in the ISO 13374-2 standard. This evaluation aims to highlight ProgPy’s strengths and identify opportunities for improvement, thereby, contributing to its advancement as an effective tool for Prognostics and Health Management (PHM). This paper presents the results of an initial assessment of the ProgPy toolbox through a gearbox case study using open-source datasets.

Condition-Monitoring, Diagnostics, Failure, Gearbo↗
DOE OSTI2015

Design Evaluation of Wind Turbine Spline Couplings Using an Analytical Model: Preprint

Articulated splines are commonly used in the planetary stage of wind turbine gearboxes for transmitting the driving torque and improving load sharing. Direct measurement of spline loads and performance is extremely challenging because of limited accessibility. This paper presents an analytical model for the analysis of articulated spline coupling designs. For a given torque and shaft misalignment, this analytical model quickly yields insights into relationships between the spline design parameters and resulting loads; bending, contact, and shear stresses; and safety factors considering various heat treatment methods. Comparisons of this analytical model against previously published computational approaches are also presented.

17 WIND ENERGY↗
DOE OSTI2015

Next Generation Drivetrain Development and Test Program

This presentation was given at the Wind Energy IQ conference in Bremen, Germany, November 30 through December 2, 2105. It focused on the next-generation drivetrain architecture and drivetrain technology development and testing (including gearbox and inverter software and medium-voltage inverter modules.

17 WIND ENERGY↗
DOE OSTI2022

Drivetrain Reliability Collaborative Update

Pitch bearings, main bearings, and gearboxes in conventional wind turbine drivetrains often do not meet their 20-year minimum specified lifetime, resulting in turbine downtime as well as expensive, time-consuming repairs or replacements. The dominant failure modes of the drivetrain components and the conditions that lead to their failure are not fully accounted for during product design or routinely modeled for life management. Drivetrain reliability improvements and O&M cost reductions remain top priorities for both land-based and offshore wind turbines, especially as wind turbines continue to be deployed in increasingly remote and offshore locations, continue to increase in size, and are becoming expected to be in service beyond their original design life, all of which correspond to an increase in the impact of any reliability issues on O&M costs. This presentation summarizes the most recent activities by NREL and ANL on drivetrain reliability.

bearing↗
DOE OSTI2021

A proposed criteria to identify wind turbine drivetrain bearing loads that induce roller slip based white-etching cracks

In this article, the type of roller slip behavior that may result in the formation of white-etching cracks (WECs) in wind turbine gearbox bearings is identified. A new hypothesis based on the inner raceway normal contact load magnitude at the time of roller slip is proposed as the probable cause of WECs. For this purpose, the maximum normal contact loads are identified when roller slip occurs in high-speed shaft bearings at different mean wind speeds. Subsequently, the annual probability of occurrence of the maximum normal loads are obtained. The probability of maximum load under slip exceeding a limit probability is hypothesized as a probable cause for WEC. In order to apply the proposed hypothesis, two different wind turbines high-speed shaft bearings are used: the cylindrical roller bearing of the General Electric 1.5 SLE turbine and the tapered roller bearing of Vestas V52 turbine. Both the chosen bearings are on the generator side of the high-speed shaft. For both turbines, measurement data together with analytical models are used for identifying the slip and the maximum normal contact loads. We propose forecasting the probability of exceedance of a threshold maximum normal contact load level during slip to identify the possibility for inducing WECs.

17 WIND ENERGY↗
DOE OSTI2018

The Effect of Lubricant Composition on White Etching Crack Failures

White etching cracks (WECs) are the dominant mode of failure for wind turbine gearbox bearings. These failures are characterized by subsurface initiation and local region of microstructural alterations adjacent to the crack faces. The definitive cause of WECs within the field is unknown, because of this laboratory replication has proved difficult. At a benchtop scale, specific lubricant formulations referred to as bad reference oils (BROs) are often employed to aid in the formation of WECs; however, exactly how these lubricants induce WECs is unknown. The present work intends to elucidate how these lubricants facilitate the formation of WECs by systematically varying the additives which are found in BROs and studying the effect that these additive combinations have on time until failure, as well as tribofilm development. It was found that the lubricant containing Zinc dialkyldithiophosphate alone led to the formation of WECs sooner than any lubricant studied. It was also documented that a lubricants frictional characteristics play a more dominant role than the tribofilm characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Competition Between Growth and Removal in Zirconia Nanocrystal-Derived Tribofilms: The Role of Co-additives

Antiwear additives permit energy-efficient lubrication of gearboxes, bearings, and other tribological interfaces. We study zirconia (ZrO 2 ) nanocrystal additives, which readily form protective tribofilms in tribological contacts. Our prior work demonstrated cooperative antiwear performance between ZrO 2 and the S- and P-based co-additives in fully formulated hydrocarbon gear oils. Here, we extend that work by examining the growth kinetics of the ZrO 2 tribofilms, including the influence of the co-additives. In the boundary lubrication regime for mixed rolling-sliding contacts, the initial phase of ZrO 2 tribofilm growth is soon overtaken by removal processes, phenomena whose importance has gone unnoticed in prior work. Tribofilm removal affects the steady-state thickness and morphology of the tribofilm as well as its growth kinetics. The S- and P-based co-additives are incorporated into the ZrO 2 tribofilm, and alter the competition between the growth and removal processes, increasing initial net growth rates per contact cycle and contributing to a more polished final interface. This work highlights the significance of removal processes in determining tribofilm antiwear performance, and suggests several routes for improving tribofilm growth kinetics using co-additives.

Coadditives↗
DOE OSTI2022

An algorithmic approach to predicting mechanical draft cooling tower fan speeds from infrasound signals

Mechanical draft cooling towers (MDCTs) serve a critical heat management role in a variety of industries. For nuclear reactors in particular, the consistent, predictable operation of MDCTs is required to avoid damage to infrastructure and reduce the potential for catastrophic failure. Accurate, reliable measurement of MDCT fan speed is therefore an important maintenance and safety requirement. To that end, we have developed an algorithm for automatically predicting the rotational speeds of multiple, simultaneously operating fan rotors using contactless, infrasound measurements. The algorithm is based on identifying the blade passing frequencies (BPFs), their harmonics, as well as the motor frequencies (MFs) for each fan in operation. Using the algorithm, these frequencies can be automatically identified in the acoustic waveform’s short-time Fourier transform spectrogram. Attribution is aided by a set of filters that rely on the unique spectral and temporal characteristics of fan operation, as well as the intrinsic frequency ratios of the BPF harmonics and the BPF/MF signals. The algorithm was tested against infrasound data acquired from infrasound sensors deployed at two research reactors: the Advanced Test Reactor (ATR) located at Idaho National Laboratory (INL) and the High Flux Isotope Reactor (HFIR) located at Oak Ridge National Laboratory (ORNL). After manually identifying the MDCT gearbox ratio, the algorithm was able to quickly yield fan speeds at both reactors in good agreement with ground truth. Ultimately, this work demonstrates the ease by which MDCT fans may be monitored in order to optimize operational conditions and avoid infrastructure damage.

42 ENGINEERING↗
DOE OSTI2017

An analysis of premature cracking associated with microstructural alterations in an AISI 52100 failed wind turbine bearing using X-ray tomography

Crack surrounded by local areas of microstructural alteration deemed "White etching cracks" (WECs) lead to unpredictable and premature failures within a multitude of applications including wind turbine gearbox bearings. While the exact cause of these failures remains unknown, a large number of hypotheses exist as to how and why these cracks form. The aim of the current work is to elucidate some of these hypotheses by mapping WEC networks within failed wind turbine bearings using high energy X-ray tomography, in an attempt to determine the location of WEC initiation, and the role of defects within the steel, such as inclusions or carbide clusters. Four completely subsurface WECs were found throughout the presented analysis, thereby confirming subsurface initiation as method of WEC formation. Additionally, a multitude of small butterfly like cracks were found around inclusions in the steel, however further analysis is needed to verify if these inclusions are initiation sites for WECs. (C) 2017 Elsevier Ltd. All rights reserved.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Fleetwide data-enabled reliability improvement of wind turbines

Wind farms are an indispensable driver toward renewable and nonpolluting energy resources. However, as ideal sites are limited, placement in remote and challenging locations results in higher logistics costs and lower average wind speeds. Therefore, it is critical to increase the reliability of the turbines to reduce maintenance costs. Robust implementation requires a thorough understanding of the loads subject to the turbine's control. Yet, such dynamically changing multidimensional loads are uncommon with other machinery, and generally underresearched. Therefore, a multitiered approach is proposed to investigate the load spectrum occurring in wind farms. Our approach relies on both fundamental research using controllable test rigs, as well as analyses of real-world loading conditions in high-frequency supervisory control and data acquisition data. A method is introduced to detect operational zones in wind farm data and link them with load distributions. Additionally, while focused research further investigates the load spectrum, a method is proposed that continuously optimizes the farm's control protocols without the need to fully understand the loads that occur. A case of gearbox failure is investigated based on a vast body of past experiments and suspect loads are identified. Starting from this evidence on the cause and effects of dynamic loads, the potential of our methods is shown by analyzing real-world farm loading conditions on a steady-state case of wake and developing a preventive row-based control protocol for a case of cascading emergency brakes induced by a storm.

17 WIND ENERGY↗
DOE OSTI2019

Figure the impact of steel microstructure and heat treatment on the formation of white etching cracks

White etching crack (WECs) associated macro-pitting is a dominant mode of damage within wind turbine gearbox bearings. This damage is characterized by broadly branching crack networks surrounded by local regions of microstructural alterations. The definitive cause of WECs in the field is unknown; therefore, the implementation of effective mitigation techniques has proven difficult. The current work utilized an accelerated benchtop testing technique in order to quantify differences in performance between through-hardened AISI 52100 steel and carburized AISI 3310 steel. It was found that the carburized AISI 3310 steel demonstrated a more than twofold increase in the time elapsed until WEC macro-pitting damage occurred compared to the through-hardened AISI 52100 steel samples.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Validation of Combined Analytical Methods to Predict Slip in Cylindrical Roller Bearings

This paper presents a combination of models that together calculate the cage and roller speeds of a cylindrical roller bearing. The models consider elastohydrodynamic lubrication and contact elasticity between the roller and raceway, roller centrifugal forces, hydrodynamic lubrication at the cage pocket, and frictional forces. Using these models, the predicted cage and roller speeds and the extent of slip are compared to measurements acquired on cylindrical roller bearings in a commercial gearbox in steady-state and transient operating conditions of a wind turbine. In steady-state conditions at low wind speeds and low lubricant temperatures, cage and roller slip up to 60% occur in the loaded zone of the bearing. In the unloaded zone, up to 80% roller slip occurs. Cage and roller slip then decrease as the lubricant temperature and wind speed increases. In general, the analytical model results match experimental measurements within 10% for lubricant temperatures above 40 degrees C and wind speeds over 10 meters per second. The analytical model is further evaluated during a transient start-up event and highly dynamic emergency stop event and also used to examine changes in the bearing design or lubricant properties. Furthermore, roller and cage slip in cylindrical bearings is a combined effect of the bearing design, applied load, shaft speed, and lubricant properties and temperature, and can be quickly evaluated with the combined analytical models.

17 WIND ENERGY↗
DOE OSTI2025

Marine Toxicity, Biodegradability, and Rolling-Sliding Tribological Performance of Ionic Liquid-Enhanced Environmentally-Acceptable Lubricants for Tidal Turbomachinery

Environmentally acceptable lubricants (EALs) are increasingly being recognized in many fields including waterpower, hydraulics, water transport, agricultural machinery, offshore wind turbines, etc. Specifically, high-performance EALs are demanded for tidal turbomachinery to ensure high efficiency and reliability and avoid the significant risk of direct contamination of the marine ecosystem upon leaks. Here we report a new development of ionic liquid (IL)-enhanced EALs for tidal energy. One short-chain phosphonium phosphate and one short-chain ammonium phosphate ILs were used as the candidate additives and the IL-containing EALs demonstrated significantly improved lubricating performance, much lower toxicity, and increased biodegradability compared with commercial baselines. Specifically, in a rolling-sliding test simulating the operation of a model tidal turbine gearbox bearing, an EAL containing the ILs at a 0.5 wt % concentration demonstrated 40% lower friction, 45% less wear loss, substantially reduced rolling contact fatigue-induced surface damage, and one order of magnitude lower vibration noise compared with a commercial gear oil. In an EPA standard toxicity test, 90 and 70% survival of marine biota was observed when exposed to an EAL containing 5 wt % of the short-chain phosphonium phosphate and ammonium phosphate ILs, respectively, while the selected commercial gear oil and bioderived additive killed all marine biota. In a standard biodegradability test, 2 wt % addition of the phosphonium phosphate IL not only retained the EAL’s ready biodegradability but further boosted the oil decomposition from a range of 60–80% to a higher level of 80–95%. Conversely, adding the commercial bioderived additive downgraded the EAL from readily to inherently biodegradable. Furthermore, this work offers scientific insights for development of ILs as potential EAL additives for marine energy and broader applications.

additives↗
DOE OSTI2019

Hardware-in-the-Loop Simulation for the Proposed Slider-Crank Wave Energy Conversion Device

In this work, a novel model of a wave energy converter that utilizes a slider crank power take-off system (PTOS) is simulated in a hardware-in-the-loop framework. The simulated parts in this framework include a buoy, slider crank linkage, and a gearbox. The slider crank linkage acting as the linear to rotary converter is represented by a DC motor coupled with a physical generator. With a regular sinusoidal wave excitation force in simulation, the hydrodynamic forces are converted into a torque, emulated by a physical motor that is directly coupled with another identical physical DC machine as the generator. By utilizing the dSPACE Control Desk software and the associated dSPACE hardware, the control algorithm in the device uses a power electronics board to drive the machines. The results show that the control system applied to the hardware-in-the-loop framework can successfully extract energy for a scaled down version of the proposed WEC device.

16 TIDAL AND WAVE POWER↗
DOE OSTI2020

Magnetic Field Optimization of an In-Vacuum Undulator at NSLS-II Transactions on Applied Superconductivity

A 3.0 m long In-Vacuum Undulator (IVU) is employed at the National Synchrotron Light Source II (NSLS-II) for the Hard X-ray Nanoprobe (HXN) beamline providing structural and X-ray fluorescence imaging with world-leading spatial resolution. On July 1 st 2018 a gearbox shaft in the gap drive train assembly sheared due to corrosion fatigue caused by stress due to mechanical misalignment. Furthermore, the device was extracted from the storage ring and measured. The magnetic field measurements detected a degradation of the magnetic performance as well as a localized demagnetization of the magnetic modules of the first 3 upstream periods. We describe here the mechanical repairs and the magnetic phase shimming optimization implemented to restore the spectral performance of the device.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Dynamic Characteristics and Test Results of a Wave Power Take-off System with Mechanical Motion Rectification and Transmission

An innovative ocean wave power takeoff (PTO) system is presented here to enhance electrical energy generation from oscillating wave motions. This PTO system, mainly consisting of dual ball screws, gearbox with mechanical motion rectification (MMR) and a permanent magnet synchronous generator (PMSG), can convert bidirectional irregular motions from a floating wave buoy into unidirectional regular generator rotations. Systematical operating principles, design and prototyping details of the PTO system are presented and analyzed. A hydrodynamics-mechanical-electrical model of the system is established by reasonably representing power switches attached to the PMSG as an equivalent external resistance. The overall dynamics of the system are then analyzed in the frequency-domain. Three power control strategies are proposed to maximize the wave power absorption by changing the equivalent external resistance. The effectiveness and relatively high energy conversion efficiency of the PTO system have been demonstrated based on lab bench test results. The levelized cost of energy of a full scale wave energy converter system is also calculated based on the proposed PTO system.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Analyzing Gas Turbine-Generator Performance of the Hybrid Power System

We report kinetic energy available from the turbomachinery may boost short-term ramp rates during load shifting between generator and fuel cell that may be exploited to optimize the performance of turbine-fuel cell hybrid systems during load following. The paper starts with modeling a gas turbine, gearbox, and generator sitting on the rigid shafts as a two-mass model primarily for estimating the rotational inertia available from the turbogenerator. The gas turbine and its environment impose constraints of available space allowances, measurements from high-speed rotating parts, lack of accessibility to the shaft of measure, making replacements and/or required installation adjustments of the torque transducer difficult. It is demonstrated that in the absence of torque measurement, the data containing only a slow excursion of the rotor motion in response to a slight load change is sufficient to determine inertia and damping coefficients from the model. Furthermore, the generator’s reactive power capability was investigated because it serves as an asset in integrated hybrid systems to meet dynamic reactive power demands, reducing the burden on the fuel cell’s power electronics control in generating reactive power.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2019

DESIGN AND DYNAMICS OF HYBRID WAVE AND CURRENT ENERGY CONVERTER

The ocean has been identified as one of the most promising energy sources and it can be comprehended as the “unlimited” energy source as well. Therefore, a reasonable exploitation and development on ocean energy recovery are applicable in this energy shortage era. This paper investigates the design and dynamic analysis of the Hybrid Wave and Current Energy Converter (HWCEC), which uses current and wave to recover energy from the ocean. In general, the HWCEC system contains the oscillating buoy and rotating turbine, while the ocean wave and current pass through the system. The energy harvested from the ocean flows through the Mechanical Motion Rectifier (MMR) gearbox [1], and the oscillating motion is converted to a unidirectional rotational motion, which will drive the generator and produce electricity. The dynamic of the HWCEC is developed by combing the dynamics of a heaving buoy, a horizontal axis hydro-turbine and the working status of an MMR-based Power Take-off system (PTO). A 1:10 scaled down prototype has been manufactured and assembled. Further tests will be conducted in the cooperating facilities. Simulation is conducted based on hydrodynamic coefficients obtained from WAMIT and the blade element momentum theory for the scaled-down prototype. Considering a regular wave with 0.08 meters of wave height with 1 second of wave period together with 0.3m/s constant current velocity, Results show that the HWCEC has an improvement in the energy extraction ratio compared to a traditional Wave Energy Converter (WEC) by 53%. The simulation indicates the fact that harvesting energy from both wave and current is simply more efficient than the traditional types of ocean energy harvester, which consists of only harvesting energy from a single source.

Chen, Shuo↗