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At least 829 records · Page 46

Vibration Based Crack Detection in a Rotating Disk: Experimental Results - Part 2

This paper describes the experimental results concerning the detection of a crack in a rotating disk. The goal was to utilize blade tip clearance and shaft vibration measurements to monitor changes in the system's center of mass and/or blade deformation behaviors. The concept of the approach is based on the fact that the development of a disk crack results in a distorted strain field within the component. As a result, a minute deformation in the disk's geometry as well as a change in the system's center of mass occurs. Here, a notch was used to simulate an actual crack. The vibration based experimental results failed to identify the existence of a notch when utilizing the approach described above, even with a rather large, circumferential notch (l.2 in.) located approximately mid-span on the disk (disk radius = 4.63 in. with notch at r = 2.12 in.). This was somewhat expected, since the finite element based results in Part 1 of this study predicted changes in blade tip clearance as well as center of mass shifts due to a notch to be less than 0.001 in. Therefore, the small changes incurred by the notch could not be differentiated from the mechanical and electrical noise of the rotor system. Although the crack detection technique of interest failed to identify the existence ofthe notch, the vibration data produced and captured here will be utilized in upcoming studies that will focus on different data mining techniques concerning damage detection in a disk.

Gyekenyesi, Andrew L.↗

Computational Assessment of a 3-Stage Axial Compressor Which Provides Airflow to the NASA 11- by 11-Foot Transonic Wind Tunnel, Including Design Changes for Increased Performance

A 24 foot diameter 3-stage axial compressor powered by variable-speed induction motors provides the airflow in the closed-return 11- by 11-Foot Transonic Wind Tunnel (11-Foot TWT) Facility at NASA Ames Research Center at Moffett Field, California. The facility is part of the Unitary Plan Wind Tunnel, which was completed in 1955. Since then, upgrades made to the 11-Foot TWT such as flow conditioning devices and instrumentation have increased blockage and pressure loss in the tunnel, somewhat reducing the peak Mach number capability of the test section. Due to erosion effects on the existing aluminum alloy rotor blades, fabrication of new steel rotor blades is planned. This presents an opportunity to increase the Mach number capability of the tunnel by redesigning the compressor for increased pressure ratio. Challenging design constraints exist for any proposed design, demanding the use of the existing driveline, rotor disks, stator vanes, and hub and casing flow paths, so as to minimize cost and installation time. The current effort was undertaken to characterize the performance of the existing compressor design using available design tools and computational fluid dynamics (CFD) codes and subsequently recommend a new compressor design to achieve higher pressure ratio, which directly correlates with increased test section Mach number. The constant cross-sectional area of the compressor leads to highly diffusion factors, which presents a challenge in simulating the existing design. The CFD code APNASA was used to simulate the aerodynamic performance of the existing compressor. The simulations were compared to performance predictions from the HT0300 turbomachinery design and analysis code, and to compressor performance data taken during a 1997 facility test. It was found that the CFD simulations were sensitive to endwall leakages associated with stator buttons, and to a lesser degree, under-stator-platform flow recirculation at the hub. When stator button leakages were modeled, pumping capability increased by over 20 of pressure rise at design point due to a large reduction in aerodynamic blockage at the hub. Incorporating the stator button leakages was crucial to matching test data. Under-stator-platform flow recirculation was thought to be large due to a lack of seals. The effect of this recirculation was assessed with APNASA simulations recirculating 0.5, 1, and 2 of inlet flow about stators 1 and 2, modeled as axisymmetric mass flux boundary conditions on the hub before and after the vanes. The injection of flow ahead of the stators tended to re-energize the boundary layer and reduce hub separations, resulting in about 3 increased stall margin per 1 of inlet flow recirculated. In order to assess the value of the flow recirculation, a mixing plane simulation of the compressor which gridded the under-stator cavities was generated using the ADPAC CFD code. This simulation indicated that about 0.65 of the inlet flow is recirculated around each shrouded stator. This collective information was applied during the redesign of the compressor. A potential design was identified using HT0300 which improved overall pressure ratio by removing pre-swirl into rotor 1, replacing existing NASA 65 series rotors with double circular arc sections, and re-staggering rotors and the existing stators. The performance of the new design predicted by APNASA and HT0300 is compared to the existing design.

Turbomachinery↗

A semi-coupled aero-servo-hydro numerical model for floating vertical axis wind turbines operating on TLPs

Floating vertical axis wind turbines (VAWTs) have many advantages over floating horizontal axis wind turbines (HAWTs) at large scales in deep water; however, there are several key challenges to overcome as well. One of the challenges is accurate prediction of the dynamic motion and loads performance of a floating VAWT. Here, a new semi-coupled aero-servo-hydro method is developed to assess dynamic responses of a floating VAWT by modeling the system as a 7-degree-of-freedom (7-DOF) model: the supporting platform is considered as a 6-DOF rigid body; the rotation of the rotor is considered as the 7th DOF. Aerodynamic, hydrodynamic, and mooring loads and control of the rotor speed are fully considered. This model can predict performance of floating VAWTs with reasonable fidelity according to validation with OrcaFlex through static and dynamic responses of a floating VAWT with Darrieus rotor operating on a new tension-leg platform (TLP). Being a reduced complexity model, the 7-DOF model can be efficiently applied to assess performance of the newly designed floating VAWT. This model is used to examine the relative contributions of aerodynamic and wave loads imparted to the floating system and the benefits of a three-bladed VAWT over a two-bladed VAWT through dynamic and fatigue analysis.

17 WIND ENERGY↗

Grand challenges in the design, manufacture, and operation of future wind turbine systems

Abstract. Wind energy is foundational for achieving 100 % renewable electricity production, and significant innovation is required as the grid expands and accommodates hybrid plant systems, energy-intensive products such as fuels, and a transitioning transportation sector. The sizable investments required for wind power plant development and integration make the financial and operational risks of change very high in all applications but especially offshore. Dependence on a high level of modeling and simulation accuracy to mitigate risk and ensure operational performance is essential. Therefore, the modeling chain from the large-scale inflow down to the material microstructure, and all the steps in between, needs to predict how the wind turbine system will respond and perform to allow innovative solutions to enter commercial application. Critical unknowns in the design, manufacturing, and operability of future turbine and plant systems are articulated, and recommendations for research action are laid out. This article focuses on the many unknowns that affect the ability to push the frontiers in the design of turbine and plant systems. Modern turbine rotors operate through the entire atmospheric boundary layer, outside the bounds of historic design assumptions, which requires reassessing design processes and approaches. Traditional aerodynamics and aeroelastic modeling approaches are pressing against the limits of applicability for the size and flexibility of future architectures and flow physics fundamentals. Offshore wind turbines have additional motion and hydrodynamic load drivers that are formidable modeling challenges. Uncertainty in turbine wakes complicates structural loading and energy production estimates, both around a single plant and for downstream plants, which requires innovation in plant operations and flow control to achieve full energy capture and load alleviation potential. Opportunities in co-design can bring controls upstream into design optimization if captured in design-level models of the physical phenomena. It is a research challenge to integrate improved materials into the manufacture of ever-larger components while maintaining quality and reducing cost. High-performance computing used in high-fidelity, physics-resolving simulations offer opportunities to improve design tools through artificial intelligence and machine learning, but even the high-fidelity tools are yet to be fully validated. Finally, key actions needed to continue the progress of wind energy technology toward even lower cost and greater functionality are recommended.

17 WIND ENERGY↗

Low-Cost, Rugged High-Vacuum System

A need exists for miniaturized, rugged, low-cost high-vacuum systems. Recent advances in sensor technology have led to the development of very small mass spectrometer detectors as well as other analytical instruments such as scanning electron microscopes. However, the vacuum systems to support these sensors remain large, heavy, and power-hungry. To meet this need, a miniaturized vacuum system was developed based on a very small, rugged, and inexpensive-to-manufacture molecular drag pump (MDP). The MDP is enabled by a miniature, very-high-speed (200,000 rpm), rugged, low-power, brushless DC motor optimized for wide temperature operation and long life. The key advantages of the pump are reduced cost and improved ruggedness compared to other mechanical hig-hvacuum pumps. The machining of the rotor and stators is very simple compared to that necessary to fabricate rotor and stator blades for other pump designs. Also, the symmetry of the rotor is such that dynamic balancing of the rotor will likely not be necessary. Finally, the number of parts in the unit is cut by nearly a factor of three over competing designs. The new pump forms the heart of a complete vacuum system optimized to support analytical instruments in terrestrial applications and on spacecraft and planetary landers. The MDP achieves high vacuum coupled to a ruggedized diaphragm rough pump. Instead of the relatively complicated rotor and stator blades used in turbomolecular pumps, the rotor in the MDP consists of a simple, smooth cylinder of aluminum. This will turn at approximately 200,000 rpm inside an outer stator housing. The pump stator comprises a cylindrical aluminum housing with one or more specially designed grooves that serve as flow channels. To minimize the length of the pump, the gas is forced down the flow channels of the outer stator to the base of the pump. The gas is then turned and pulled toward the top through a second set of channels cut into an inner stator housing that surrounds the motor. The compressed gas then flows down channels in the motor housing to the exhaust port of the pump. The exhaust port of the pump is connected to a commercially available diaphragm or scroll pump.

Sorensen, Paul↗

Second-Generation Large Civil Tiltrotor 7- by 10-Foot Wind Tunnel Test Data Report

An approximately 6-percent scale model of the NASA Second-Generation Large Civil Tiltrotor (LCTR2) Aircraft was tested in the U.S. Army 7- by 10-Foot Wind Tunnel at NASA Ames Research Center January 4 to April 19, 2012, and September 18 to November 1, 2013. The full model was tested, along with modified versions in order to determine the effects of the wing tip extensions and nacelles; the wing was also tested separately in the various configurations. In both cases, the wing and nacelles used were adopted from the U.S. Army High Efficiency Tilt Rotor (HETR) aircraft, in order to limit the cost of the experiment. The full airframe was tested in high-speed cruise and low-speed hover flight conditions, while the wing was tested only in cruise conditions, with Reynolds numbers ranging from 0 to 1.4 million. In all cases, the external scale system of the wind tunnel was used to collect data. Both models were mounted to the scale using two support struts attached underneath the wing; the full airframe model also used a third strut attached at the tail. The collected data provides insight into the performance of the preliminary design of the LCTR2 and will be used for computational fluid dynamics (CFD) validation and the development of flight dynamics simulation models.

Theodore, Colin R.↗

Single-particle and collective excitations in Zn 66

Single-particle and collective excitations in 66 Zn have been investigated via the multinucleon transfer reaction, 26 Mg( 48 Ca, α4nγ) using the Gammasphere multidetector array and the Fragment Mass Analyzer. In addition to confirming and complementing the previously known low-spin structure, a new quasi-rotational band comprising several stretched E2 transitions has been established to high spins. However, due to fragmentary nature of its decay, it was not possible to link this sequence to the low-lying states and, thus, determine the absolute excitation energies, spins, and parities unambiguously. Large-scale shell-model calculations employing the JUN45 and jj44b effective interactions are able to successfully describe the low-spin structure and herewith confirm that it is dominated by single-particle excitations. Furthermore, the newly established rotational cascade is compared with known superdeformed bands in the A ≈ 60–70 mass region, and with results of calculations performed within the frameworks of the cranked shell model and the adiabatic and configuration-fixed constrained covariant density functional theory and the quantum particle-rotor model.

59 ≤ A ≤ 89↗

Simulated Altitude Performance of Combustors for the 24C Turbojet Engine. III - Performance of Rectangular-Slot Baskets: Performance of Rectangular-Slot Baskets - 3

The performance of an annular combustion chamber from a 24C turbojet engine was investigated over a range of simulated altitudes from 20,000 to 55,000 feet and corrected engine rotor speeds from 6000 to 13,000 rpm at a simulated ram-pressure ratio of 1.04. The purpose of the investigation was to determine the effects on the altitude operational limits, combustor-outlet gas temperature distribution, combustion efficiencies, and combustor inlet-to-outlet total-pressure drops of two changes in the 24C-4B basket air-passage arrangements that were designed to improve combustor-outlet temperature distribution. These changes were: (a) replacement of the downstream secondary air holes with large rectangular slots further upstream (rectangular-slot basket), and (b) enlargement of anticoking holes in the rectangular-slot basket (modified rectangular-slot basket). The results indicate that improved outlet-gas temperature distribution of each succeeding combustor basket investigated was attained at a sacrifice in the altitude limit of operation. The altitude limits of operation of the combustor with the original basket ranged from 34,000 feet at a corrected engine speed of 6000 rpm to a maximum of 52,000 feet at 12 ' 500 rpm. The altitude limits of the rectangular-slot basket were about 2000 feet lower throughout the engine speed range than those of the original basket. The altitude limits of the combustor with the modified rectangular-slot basket were about equivalent to those of the other baskets in the corrected-engine-speed range from 12,000 to 12,500 rpm but were about 10,000 feet lower than those of the original basket in the corrected-engine-speed range from 6000 to 9000 rpm. For the same inlet-air conditions, the combustion efficiencies were highest for the original basket and progressively lower for each of the other two baskets. The combustor inlet-to-outlet pressure drops of all three combustor baskets at the same operating conditions were within +/- 10 percent of the pressure drop of the original basket.

Tischler, Adelbert O.↗

Design and operating experience on the U.S. Department of Energy Experimental Mod-O 100 kW Wind Turbine

The Mod-O 100 kW Experimental Wind Turbine was designed and fabricated by NASA, as part of the Federal Wind Energy Program, to assess technology requirements and engineering problems of large wind turbines. The machine became operational in October 1975 and has demonstrated successful operation in all of its design modes. During the course of its operations the machine has generated a wealth of experimental data and has served as a prototype developmental test bed for the Mod-OA operational wind turbines which are currently used on utility networks. This paper describes the mechanical and control systems as they evolved in operational tests and describes some of the experience with various systems in the downwind rotor configuration.

Glasgow, J. C.↗

Fan noise caused by the ingestion of anisotropic turbulence - A model based on axisymmetric turbulence theory

An analytical model of fan noise caused by inflow turbulence, a generalization of earlier work by Mani, is presented. Axisymmetric turbulence theory is used to develop a statistical representation of the inflow turbulence valid for a wide range of turbulence properties. Both the dipole source due to rotor blade unsteady forces and the quadrupole source resulting from the interaction of the turbulence with the rotor potential field are considered. The effects of variations in turbulence properties and fan operating conditions are evaluated. For turbulence axial integral length scales much larger than the blade spacing, the spectrum is shown to consist of sharp peaks at the blade passing frequency and its harmonics, with negligible broadband content. The analysis can then be simplified considerably and the total sound power contained within each spectrum peak becomes independent of axial length scale, while the width of the peak is inversely proportional to this parameter. Large axial length scales are characteristic of static fan test facilities, where the transverse contraction of the inlet flow produces highly anisotropic turbulence. In this situation, the rotor/turbulence interaction noise is mainly caused by the transverse component of turbulent velocity.

Kerschen, E. J.↗

Experimental investigation of turbine disk cavity aerodynamics and heat transfer

An experimental investigation of turbine disk cavity aerodynamics and heat transfer was conducted to provide an experimental data base that can guide the aerodynamic and thermal design of turbine disks and blade attachments for flow conditions and geometries simulating those of the space shuttle main engine (SSME) turbopump drive turbines. Experiments were conducted to define the nature of the aerodynamics and heat transfer of the flow within the disk cavities and blade attachments of a large scale model simulating the SSME turbopump drive turbines. These experiments include flow between the main gas path and the disk cavities, flow within the disk cavities, and leakage flows through the blade attachments and labyrinth seals. Air was used to simulate the combustion products in the gas path. Air and carbon dioxide were used to simulate the coolants injected at three locations in the disk cavities. Trace amounts of carbon dioxide were used to determine the source of the gas at selected locations on the rotors, the cavity walls, and the interstage seal. The measurements on the rotor and stationary walls in the forward and aft cavities showed that the coolant effectiveness was 90 percent or greater when the coolant flow rate was greater than the local free disk entrainment flow rate and when room temperature air was used as both coolant and gas path fluid. When a coolant-to-gas-path density ratio of 1.51 was used in the aft cavity, the coolant effectiveness on the rotor was also 90 percent or greater at the aforementioned condition. However, the coolant concentration on the stationary wall was 60 to 80 percent at the aforementioned condition indicating a more rapid mixing of the coolant and flow through the rotor shank passages. This increased mixing rate was attributed to the destabilizing effects of the adverse density gradients.

Daniels, W. A.↗

Heat-flux measurements for the rotor of a full-stage turbine. II - Description of analysis technique and typical time-resolved measurements

An analytical technique for obtaining the time-resolved heat flux of a turbine blade is applied to the case of a TFE 731-2 hp full-stage rotating turbine. In order to obtain the heat flux values from the thin film gage temperature histories, a finite difference procedure is used to solve the heat equation with variable thermal properties. After setting out the data acquisition and analysis procedures, their application is illustrated for three midspan locations on the blade and operation at the design flow function. Results demonstrate that the magnitude of the heat flux fluctuation due to vane-balde interaction is large by comparison to the time-averaged heat flux at all investigated locations; FFT of a portion of the heat flux record illustrates that the dominant frequencies occur at the wake-cutting frequency and its harmonics.

Dunn, M. G.↗

Signal Analysis of Helicopter Blade-Vortex-Interaction Acoustic Noise Data

Blade-Vortex-Interaction (BVI) produces annoying high-intensity impulsive noise. NASA Ames collected several sets of BVI noise data during in-flight and wind tunnel tests. The goal of this work is to extract the essential features of the BVI signals from the in-flight data and examine the feasibility of extracting those features from BVI noise recorded inside a large wind tunnel. BVI noise generating mechanisms and BVI radiation patterns an are considered and a simple mathematical-physical model is presented. It allows the construction of simple synthetic BVI events that are comparable to free flight data. The boundary effects of the wind tunnel floor and ceiling are identified and more complex synthetic BVI events are constructed to account for features observed in the wind tunnel data. It is demonstrated that improved recording of BVI events can be attained by changing the geometry of the rotor hub, floor, ceiling and microphone. The Euclidean distance measure is used to align BVI events from each blade and improved BVI signals are obtained by time-domain averaging the aligned data. The differences between BVI events for individual blades are then apparent. Removal of wind tunnel background noise by optimal Wiener-filtering is shown to be effective provided representative noise-only data have been recorded. Elimination of wind tunnel reflections by cepstral and optimal filtering deconvolution is examined. It is seen that the cepstral method is not applicable but that a pragmatic optimal filtering approach gives encouraging results. Recommendations for further work include: altering measurement geometry, real-time data observation and evaluation, examining reflection signals (particularly those from the ceiling) and performing further analysis of expected BVI signals for flight conditions of interest so that microphone placement can be optimized for each condition.

Rogers, James C.↗

On the interaction of a wind turbine wake with a conventionally neutral atmospheric boundary layer

In this work, we investigate the dynamics of wind turbine tip-vortex breakdown in a conventionally neutral atmospheric boundary layer (ABL). To this end, high-resolution data are collected from large-eddy simulations of a wind turbine operating within a neutral ABL and studied by means of proper orthogonal decomposition (POD) and Fourier analysis. The high resolution of the generated data in both space and time allows us to gain insight into the tip-vortex breakdown mechanisms by (i) capturing the energy modes of the coherent structures, (ii) studying their contribution to the tip-vortex breakdown through their power spectra functions and mean kinetic energy (MKE) flux, and (iii) analysing the growth rate of each contributing perturbation frequency along tip vortices. Our analysis shows that under a fully turbulent scenario, the growth rate of perturbations along the tip vortices is largest for low wave numbers, i.e. long-wave perturbations. Additionally, the MKE flux reaches its highest value at two diameters downstream of the rotor plane, a behaviour that can be attributed to the coexistence of multiple interacting POD modes, with the streamwise vortex roller mode being the primary contributor to the total MKE flux budget, contributing approximately . Finally, comparisons with a laminar, uniform flow scenario subject to a single-frequency perturbation highlight the differences between the two ambient flow conditions. In the non-turbulent, uniform flow scenario, the growth rate attains its maximum value at a wave number corresponding to the out-of-phase mutual-inductance mechanism, whereas the MKE flux exhibits local minima and maxima along the wake and at different downstream locations depending on the perturbation frequency. Our analyses suggest that the breakdown of the wind turbine tip vortices under a fully turbulent neutral ABL inflow is due to complex interactions across a range of excitation frequencies, in which the mutual-inductance instability may not be the dominant one.

17 WIND ENERGY↗

The passage of an infinite swept airfoil through an oblique gust

An approximate solution is reported for the unsteady aerodynamic response of an infinite swept wing encountering a vertical oblique gust in a compressible stream. The approximate expressions are of closed form and do not require excessive computer storage or computation time, and further, they are in good agreement with the results of exact theory. This analysis is used to predict the unsteady aerodynamic response of a helicopter rotor blade encountering the trailing vortex from a previous blade. Significant effects of three dimensionality and compressibility are evident in the results obtained. In addition, an approximate solution for the unsteady aerodynamic forces associated with the pitching or plunging motion of a two dimensional airfoil in a subsonic stream is presented. The mathematical form of this solution approaches the incompressible solution as the Mach number vanishes, the linear transonic solution as the Mach number approaches one, and the solution predicted by piston theory as the reduced frequency becomes large.

Adamczyk, J. L.↗

Dynamics and Control of Attitude, Power, and Momentum for a Spacecraft Using Flywheels and Control Moment Gyroscopes

Several laws are designed for simultaneous control of the orientation of an Earth-pointing spacecraft, the energy stored by counter-rotating flywheels, and the angular momentum of the flywheels and control moment gyroscopes used together as an integrated set of actuators for attitude control. General, nonlinear equations of motion are presented in vector-dyadic form, and used to obtain approximate expressions which are then linearized in preparation for design of control laws that include feedback of flywheel kinetic energy error as a means of compensating for damping exerted by rotor bearings. Two flywheel steering laws are developed such that torque commanded by an attitude control law is achieved while energy is stored or discharged at the required rate. Using the International Space Station as an example, numerical simulations are performed to demonstrate control about a torque equilibrium attitude, and illustrate the benefits of kinetic energy error feedback. Control laws for attitude hold are also developed, and used to show the amount of propellant that can be saved when flywheels assist the CMGs. Nonlinear control laws for large-angle slew maneuvers perform well, but excessive momentum is required to reorient a vehicle like the International Space Station.

Roithmayr, Carlos M.↗

Design and analysis of a segmented blade for a 50 MW wind turbine rotor

Extreme-size wind turbines face logistical challenges due to their sheer size. A solution, segmentation, is examined for an extreme-scale 50 MW wind turbine with 250 m blades using a systematic approach. Segmentation poses challenges regarding minimizing joint mass, transferring loads between segments and logistics. We investigate the feasibility of segmenting a 250 m blade by developing design methods and analyzing the impact of segmentation on the blade mass and blade frequencies. This investigation considers various variables such as joint types (bolted and bonded), adhesive materials, joint locations, number of joints and taper ratios (ply dropping). Segmentation increases blade mass by 4.1%–62% with bolted joints and by 0.4%–3.6% with bonded joints for taper ratios up to 1:10. Cases with large mass growth significantly reduce blade frequencies potentially challenging the control design. We show that segmentation of an extreme-scale blade is possible but mass reduction is necessary to improve its feasibility.

Escalera Mendoza, Alejandra S.↗

Aero‐servo‐elastic co‐optimization of large wind turbine blades with distributed aerodynamic control devices

Abstract This work introduces automated wind turbine optimization techniques based on full aero‐servo‐elastic models and investigates the potential of trailing edge flaps to reduce the levelized cost of energy (LCOE) of wind turbines. The Wind Energy with Integrated Servo‐control (WEIS) framework is improved to conduct the presented research. Novel methods for the generic implementation and tuning of trailing edge flap devices and their controller are also introduced. Primary flap and controller parameters are optimized to demonstrate potential maximum blade tip deflection reductions of 21 % . Concurrent design optimization (i.e., co‐design) of a novel segmented wind turbine blade with trailing edge flaps and its controller is then conducted to demonstrate blade cost savings of 5 % . Additionally, rotor diameter co‐design optimization is demonstrated to reduce the LCOE by 1.3 % without significant load increases to the tower. These results demonstrate the efficacy of control co‐design optimization using trailing edge flaps, and the entirety of this work provides a foundation for numerous control co‐design‐oriented studies for distributed aerodynamic control devices.

17 WIND ENERGY↗