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DOE OSTI2022

Active rotor coning for a 25 MW downwind offshore wind turbine

A two-bladed downwind turbine system was upscaled from 13.2 MW to 25 MW by redesigning aerodynamics, structures, and controls. In particular, three 25-MW rotors were developed, and the final version is a fully redesigned model of the original rotor. Despite their radically large sizes, it was found that these 25-MW turbine rotors satisfy this limited set of structural design drivers at the rated condition and that larger blade lengths are possible with conewise load-alignment. In addition, flapwise morphing (varying the cone angle with a wind-speed schedule) was investigated to minimize mean and fluctuating blade root bending loads using steady inflow proxies for the maximum and lifetime damage equivalent load moments. Compared to the fixed coned rotor case, morphing can provide an Annual Energy Production (AEP) increase of 6%, and the maximum blade root flapwise bending moment increases 21% (still under the constraint, i.e., 10% of the ultimate moments) as a trade-off. The resulting series of 25-MW rotors can be a valuable baseline for further development and assessment of ultra-large-scale wind turbines.

17 WIND ENERGY↗

DOE OSTI2025

Characterization of HRRR-simulated rotor layer wind speeds and clouds along the coast of California

Stratocumulus clouds, with their low cloud base and top, affect the atmospheric boundary layer wind and turbulence profile, thereby modulating wind energy resources. GOES satellite data reveal an abundance of stratocumulus clouds in the late spring and summer months off the coast of northern and central California, where there are active plans to deploy floating offshore wind farms at two lease areas (near Morro Bay and Humboldt). Since the fall of 2020, two buoys equipped with multiple instruments, including Doppler lidar, have been deployed for about 1 year in these wind farm lease areas to assess the rotor layer wind conditions in these locations. The objective of this study is to evaluate how well the High-Resolution Rapid Refresh (HRRR) model represents stratocumulus cloud characteristics and turbine-relevant rotor layer winds (surface to 300 m) by comparing HRRR simulations with buoy and satellite observations. We first find that the HRRR model reproduces the seasonal cycle of cloud top height reasonably well in these regions. However, during the warm season – especially at Morro Bay – the HRRR-simulated stratocumulus clouds tend to have lower tops by about 150 m and exhibit weaker diurnal cycles than satellite observations. Our analysis also shows that rotor layer wind speeds and vertical shear are stronger at Humboldt than at Morro Bay, and both are generally stronger under clear-sky conditions. Finally, the HRRR model bias in rotor layer wind speed is small under cloudy conditions but larger and dependent on observed wind speed under clear skies. Specifically, HRRR underestimates wind speeds at Morro Bay and overestimates them at Humboldt under clear-sky conditions.

17 WIND ENERGY↗

DOE OSTI2023

A simple vortex model applied to an idealized rotor in sheared inflow

A simple analytical vortex model is presented and used to study an idealized wind turbine rotor in uniform and sheared inflow, respectively. Our model predicts that 1D momentum theory should be applied locally when modelling a non-uniformly loaded rotor in a sheared inflow. Hence the maximum local power coefficient (expressed with respect to the local, upstream velocity) of an ideal rotor is not affected by the presence of shear. We study the interaction between the wake vorticity generated by the rotor and the wind shear vorticity and find that their mutual interaction results in no net generation of axial vorticity: the wake effects and the shear effects exactly cancel each other out. This means that there are no resulting cross-shear-induced velocities and therefore also no cross-shear deflection of the wake in this model.

17 WIND ENERGY↗

DOE OSTI2021

Flexing the Limits of Land-Based Wind Turbine Rotor Growth

The Big Adaptive Rotor (BAR) project works to design and enable the next generation of land-based wind turbines with rotors that stretch 206 meters (m) in diameter, which will increase capacity factors by 10% or more over a typical land-based turbine. These high-energy-capture turbines have lower specific-power ratings, meaning they have larger rotors relative to the size of their generator, which helps them capture more wind and perform better at lower wind speeds, thereby increasing the turbine capacity factor. High-energy-capture turbines with larger rotors have many advantages, but the length and width of their blades creates transportation challenges that must be overcome to make true on the adage, bigger is better.

wind, big, adaptive, rotor↗

DOE OSTI2020

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

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.

17 WIND ENERGY↗

DOE OSTI2021

Influence of tower shadow on downwind flexible rotors: Field tests and simulations

Abstract As wind turbine rotors become larger, the blades become more flexible, requiring extra stiffness and cost to avoid the risk of tower strike. Wind turbines in a downwind configuration have a reduced risk of tower strike because the rotor thrust acts away from the tower. However, downwind blades pass through the wake of the tower, and the resulting load variation may contribute to blade fatigue. To date, there have been no field tests to quantify this tower shadow effect on unsteady blade moments. The present study reports on the first field testing of a flexible, downwind, coned rotor and compares the experimental data against simulations run in OpenFAST. The tower shadow effect is simulated using the conventional Powles model and a new Eames model (developed herein), which includes the influence of upstream turbulence. Both models reasonably predict the blade root out‐of‐plane bending moment data and the tower shadow dip magnitude when compared to field test data in Region 3. Tower shadow was found to increase the short‐term Damage Equivalent Loads (DELs) by less than 10% compared to other effects (gravity, shear, and turbulence), and the predictions were consistent with experiments. These results indicate that the tower shadow effect can be reasonably modeled with the simpler Powles model and that the tower shadow effect can be small compared to the effect of turbulence. However, long‐term fatigue due to tower shadow should be included in detailed structural analysis and design of the rotor and the tower.

Simpson, Juliet G.↗

DOE OSTI2022

Parked aeroelastic field rotor response for a 20% scaled demonstrator of a 13‐MW downwind turbine

Abstract Aeroelastic parked testing of a unique downwind two‐bladed subscale rotor was completed to characterize the response of an extreme‐scale 13‐MW turbine in high‐wind parked conditions. A 20% geometric scaling was used resulting in scaled 20‐m‐long blades, whose structural and stiffness properties were designed using aeroelastic scaling to replicate the nondimensional structural aeroelastic deflections and dynamics that would occur for a lightweight, downwind 13‐MW rotor. The subscale rotor was mounted and field tested on the two‐bladed Controls Advanced Research Turbine (CART2) at the National Renewable Energy Laboratory's Flatiron Campus (NREL FC). The parked testing of these highly flexible blades included both pitch‐to‐run and pitch‐to‐feather configurations with the blades in the horizontal braked orientation. The collected experimental data includes the unsteady flapwise root bending moments and tip deflections as a function of inflow wind conditions. The bending moments are based on strain gauges located in the root section, whereas the tip deflections are captured by a video camera on the hub of the turbine pointed toward the tip of the blade. The experimental results are compared against computational predictions generated by FAST, a wind turbine simulation software, for the subscale and full‐scale models with consistent unsteady wind fields. FAST reasonably predicted the bending moments and deflections of the experimental data in terms of both the mean and standard deviations. These results demonstrate the efficacy of the first such aeroelastically scaled turbine test and demonstrate that a highly flexible lightweight downwind coned rotor can be designed to withstand extreme loads in parked conditions.

17 WIND ENERGY↗

DOE OSTI2020

Magneto-Structural Combined Dimensional and Topology Optimization of Interior Permanent Magnet Synchronous Machine Rotors

A magneto-structural combined dimensional and topology optimization approach for interior permanent magnet synchronous machine (IPMSM) rotor design is proposed using the Solid Isotropic Material Penalization (SIMP) density-based topology optimization method. This method optimizes the location and dimensions of the permanent magnets (PMs) embedded in the rotor, while simultaneously optimizing the lamination flux barriers using topology optimization.To allow for the location and dimensions of the PMs to change while retaining the same number of mesh elements and connectivity, the mesh must be deformed. Mesh deformation is accomplished using a Laplace smoothing technique. To increase the range of PM displacement and size changes, the non-PM areas of the rotor design domain are divided into sub-regions along whose boundaries the mesh nodes are redistributed also using a Laplace smoothing algorithm. Three examples of IPMSM rotor optimizations are presented to demonstrate the proposed approach.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Combined Dimensional and Topology Optimization of Synchronous Machine Rotors Using a Material Density Interpolation Method

This article presents a magneto-structural combined dimensional and topology optimization technique for interior permanent magnet synchronous machine (IPMSM) and wound field synchronous machine (WFSM) rotors. Dimensional changes to the permanent magnet (PM) and rotor winding location or size are accomplished by interpolating or projecting a smoothed Heaviside rectangular function representing the presence of PM material onto the IPMSM rotor design domain mesh, whereas the presence of copper material for WFSM rotor is interpolated in the same manner. A density based Solid Isotropic Material with Penalization (SIMP) topology optimization approach is then used to vary the presence of electrical steel in mesh elements to form flux barriers around the PM. The proposed method enforces a defined shape for the PM without requiring the mesh in the design domain to be deformed. Four examples are presented to demonstrate the technique: Two flat bar IPMSM, one V-shaped IPMSM, and a WFSM. Here, a comparative study is performed on one of the flat bar IPMSMs using Metamodel of Optimal Prognosis (MOP) based method.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Welding of Haynes 282 to Steels to Enable Modular Rotors for Advanced Ultra Super-Critical Steam Turbines

Steam turbines for an Advanced Ultra Super Critical (AUSC) fossil fired power plant will operate at temperatures well above those of current commercial steam cycles with inlet temperatures more than 760 C , which is beyond the capabilities of alloy steels presently used for steam turbine applications and requires advanced materials. Large components such as steam turbine rotors may be made of nickel based super alloys such as Haynes 282 (H282). However, monolithic forgings of superalloys in the sizes required for large steam turbines rotors can be prohibitively expensive besides many technical challenges. To minimize cost and alleviate the related technical challenges, superalloy use needs to be limited to locations on the steam turbine rotor where strength and temperature requirements cannot be met by conventional steels. This is possible if nickel-based superalloys can be successfully welded to steels and the related technical challenges - machining parts made of dissimilar welded materials, non-destructive examination of such welds for flaw detection; and, material properties of such hybrid components – are sufficiently addressed. In this technology development project, we successfully welded H282 to plates up to ~ 75 mm (~ 3 inches) to a 3.5NiCrMoV steel of similar thickness. Advanced ultrasonic inspection technique called Phased Array Ultrasonic Testing (PAUT) was employed to examine the dissimilar H282-Steel welds, into which flat bottomed side drilled holes (SDH) of various diameters were introduced, to determine the minimum detectable feature sizes; it was shown that with PAUT SDH of dia. down to 0.5 mm could be detected in the base alloys and SDH with dia. down to 2.4 mm could be detected in the weld metal under multiple orientations successfully. An autonomous machining process monitoring system was developed and demonstrated whereby the forces acting on the cutting tool could be actively monitored as the cutting tool transitioned from H282 to Steel across the weld using which the machining parameters can be potentially altered without interruption to extend tool life. This project successfully achieved its objectives of - i. Developing a welding methodology and viable welding geometries, to successfully join H282 to steel 3.5CrMoNiV steel to enable manufacture of modular steam turbine rotors for AUSC applications (conditions of at least 760 °Celsius and 3,100 psia (pounds per square inch absolute pressure) and evaluate the material properties of the welded specimen. ii. Employ the advanced ultrasonic inspection technique to the dissimilar weld metal joint and determine the minimum detectable feature sizes. iii. Develop effective machining techniques to machine such hybrid structures with online tool force monitoring and effect machine state metrics for optimal results.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

50 MW Segmented Ultralight Morphing Rotors for Wind Energy

A multi-institutional team designed a 50 Megawatt (MW) rated wind turbine featuring downwind aeroelastic morphing to reduce blade loads and allow an ultralight segmented rotor (mass reduction of about 25% compared to a conventional upwind rotor). The team used a control co-design approach with state-of-the art simulations including for the rotor and tower design using non-linear fluid-structure interactions and control algorithms, and the team also designed, built, and field-tested an aeroelastically-scaled downwind rotor to demonstrate this novel technology and validate the design tool fidelity. In a follow-on phase, these results were used along with an updated Levelized Cost Of Energy (LCOE) methodology to co-design a more detailed set of 25 MW rated turbine designs (including individual pitch control) based on minimum LCOE with highly flexible blades for an Atlantic Ocean offshore fixed-bottom design targeted towards market technology evaluation. A set of upwind and downwind designs at 25 MW rated scales were found to provide the best LCOE, with strong improvements over all previous offshore reference turbines (NREL 5MW, DTU 10 MW and IEA 15 MW). The optimized design would represent the world’s largest offshore turbine design, which combines several state-of-the-art structural, aerodynamic, and control technologies into a new and optimized system concept.

17 WIND ENERGY↗

DOE OSTI2021

Rotor for an electric machine

A rotor for an electric machine comprises a rotor core that defines a rotor slot having a central portion and an end portion. The end portion has a maximum width that is greater than a maximum width of the central portion immediately adjacent the end portion. A perimeter of the rotor slot at the end portion includes a plurality of segments extending between a first extremity at the maximum width of the end portion and a second extremity at the maximum width of the end portion. The plurality of segments include segments with different radii that decrease in magnitude from the center axis to the first extremity, and from the center axis to the second extremity.

Kim, Jihyun↗

DOE OSTI2023

Additively manufactured radial turbine rotor with cooling manifolds

A turbine rotor includes a base and a plurality of blades. A central nose is radially inward of the blades and defines an axis of rotation. A plurality of cooling manifolds is disposed within the turbine rotor and includes impingement cooling jets extending through a rear surface of the turbine rotor. An internal cooling manifold extends radially inward of the impingement cooling jets and extends between the base and the rear surface of the turbine rotor. A central nose cooling manifold extends into the central nose and is fluidically connected to the internal cooling manifold. A base cooling manifold is fluidically connected to the central nose manifold and extends radially outward from the central nose cooling manifold. A blade cooling manifold is fluidically connected to the base cooling manifold and extends within the blade. Trailing edge jets extend from the blade cooling manifold and through the trailing edge of blades.

Dai, Zhongtao↗

DOE OSTI2024

Additively manufactured radial turbine rotor with cooling manifolds

Dai, Zhongtao↗

DOE OSTI2020

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

A new sub-scale field-prototype design solution is developed to realize the dynamics, structural response, and distributed loads (gravitational, aerodynamic, centrifugal) that are characteristic of a full-scale large, modern wind turbine rotor. Prior work in sub-scale wind turbine testing has focused on matching aerodynamic/aero-elastic characteristics of full-scale rotors at wind tunnel scale. However, large-scale rotor designs must expand beyond this limited set of scaling parameters for cost-effective prototyping and meet strict requirements for structural safety for field testing. Here, the challenge lies in producing a structural design meeting two competing objectives: novel scaling objectives that prescribe the sub-scale blade to have low mass and stiffness; and traditional structural safety objectives that drive the design to have higher stiffness and mass. A 20% gravo-aeroelastically scaled wind turbine blade is developed successfully that satisfies these competing objectives. First, it achieved close agreement for non-dimensional tip deflection and flap-wise blade frequency (both within 2.1%) with a blade mass distribution constrained to produce target gravitational and centrifugal loads. Second, the entire blade structure was optimized to ensure a safe, manufacturable solution meeting strict strength requirements for a testing site that can experience up to 45 m/s wind gusts. The prototype-scale blade was fabricated and successfully proof-load tested.

17 WIND ENERGY↗

DOE OSTI2020

An efficient approach to explore the solution space of a wind turbine rotor design process

This study proposes a novel approach to explore the solution space of a wind turbine rotor design process. The goal is to offer to blade designers the possibility to select an optimal rotor for given market conditions, assessing trade-offs and alternatives in a matter of minutes. The design process consists of sequential aerodynamic-structural optimizations, where the two loops are linked via a blade-loading parameter that can be varied by the user. A design study is performed starting from the IEA Wind Task 37 land-based reference wind turbine. The solution space is characterized for rotor diameters in the range of 130–160 m, rated generator power values in the range of 3.0–6.0 MW, and tip-speed ratios in the range of 7.5–12.5. Results are discussed highlighting optimal design decisions and trade-offs.

17 WIND ENERGY↗

DOE OSTI2024

Robust Disturbance Rejection Rotor Current Control of Doubly-Fed Induction Generators

This article proposes a robust transient disturbance rejection current controller (TDRCC) to improve the transient performance of doubly-fed induction generators (DFIGs) in wind turbines during grid disturbances, such as short circuits. Here, the proposed robust TDRCC replaces the proportional-integral-derivative (PID) current controllers conventionally used in the vector control scheme of the DFIG rotor side converter (RSC). The TDRCC estimates the transient disturbances caused by grid faults or other external disturbances and provides compensation to the DFIG rotor voltage in the current control loops of the RSC to improve the robustness of the controller to disturbance. A sliding-mode current controller (SMCC) is also designed to highlight the transient performance improvement of the DFIG using the TDRCC over the state-of-the-art control methods during grid short circuit faults. Simulation studies are conducted in PSCAD/EMTDC for a 3.6-MW DFIG wind turbine with the proposed TDRCC, the conventional PI controller, and the SMCC, respectively during the most severe balanced three-phase grid short circuit fault specified by the U.S. grid code as well as an unbalance single-phase grid short circuit fault. Hardware experiments are conducted on a 200-W DFIG wind turbine emulator with the three different controllers for the same three-phase short circuit fault. Simulation and hardware experiment results show that the TDRCC reduces the peak rotor current significantly when compared with the PI and SMCC controlled DFIG system and, therefore, would help prolong the lifespan of the DFIG's power electronics and reduce maintenance costs.

42 ENGINEERING↗

DOE OSTI2021

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

Abstract 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.

Chetan, Mayank↗