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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 OSTI2024

Acoustic-based monitoring and machine learning of component status for microreactor applications

This report provides a description and assessment of recent efforts to couple acoustic-based experimental measurements and characterization with machine learning models in order to enhance structural health monitoring capabilities for nuclear microreactors. With resilient embedded sensors in development by others supported by programs funded by the US Department of Energy’s Office of Nuclear Energy, the work described herein builds upon ongoing efforts to improve non-destructive testing technology that relates measured acoustic signatures to component stresses and/or structural defects, using a combination of new experimental measurements and machine learning architectures. The experimental procedure remained similar to that developed for the previous year’s demonstration of damage detection by the authors, with the same damaged sample tested under similar applied stress conditions. Notably, a new mounting fixture was designed and implemented to improve measurement consistency and a more sophisticated laser Doppler vibrometer was employed to make high-fidelity vibration measurements. Two nominally identical sets of training data were collected for each experimental setup to better understand the repeatability of the experiment and to better test the generality of trained neural network models. Additionally, we obtained new high-quality 3D mode shapes of the damaged test article at various stress and excitation levels, providing greater insights into the physical response of the sample during testing. Previously, we demonstrated that a machine learning model based on a convolutional neural network can predict structural details of an artificially introduced interface (intact, rough cut, smooth cut), and the applied torque level. In this study, we have transitioned to graph-based neural network architectures to better develop and test a flexible framework that is more suitable to being transferred away from controlled benchtop experiments and into more applied settings where less-structured data inputs may be expected. In general, performance testing of a graph neural network on frequency-domain representations of the data indicates strong and consistent identification of test conditions for datasets recorded on damaged components. With goals of predicting damage location and other changing experimental conditions using limited datasets, predictive models using a graph neural network architecture correctly predicted the applied torque level with an accuracy of 85% using only a single measurement point and predicted within one torque level in 95% of test windows. Predictions of damage location had limited success due to the symmetry and minimal number of the damage scenarios presented during model training. Results were ambiguous as to whether the model could detect the location of the artificial damage, or if it was instead learning the location of a given measurement point on the part and subsequently detecting which points were closest to the location of the damage. This finding will be factored into upcoming planned work on damaged graphite components, where new experimental tests with a larger number and variety of damage scenarios are expected to provide improved validation of recent developments in monitoring methodology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Main Shaft Bending Moment Analysis for a Gamesa G97 2-MW Wind Turbine

In a collaborative project between Siemens Gamesa Renewable Energy and the National Renewable Energy Laboratory (NREL), a cost-effective method to measure dynamic main shaft torque and the influence of non-torque loads was applied to the gearbox of the Gamesa G97 2-megawatt (MW) wind turbine at the NREL Flatirons Campus and verified through a field test campaign that took place in 2023. The method involved the installation of fiber-optic sensors on the ring gear of the gearbox. Additionally, traditional strain gauges and a rotary encoder were installed on the main shaft to measure mechanical torque and orthogonal bending moments. We compare the measured total main shaft bending moments from the field test campaign to those predicted by an updated OpenFAST model of the G97 wind turbine for similar environmental conditions. We also assessed the sensitivity of the predicted bending moment to varying levels of turbulence intensity, shear exponent, and yaw error.

17 WIND ENERGY↗

DOE OSTI2022

Verification and Validation of Model-Scale Turbine Performance and Control Strategies for the IEA Wind 15 MW Reference Wind Turbine

To enable the fast growth of the floating offshore wind industry, simulation models must be validated with experimental data. Floating wind model-scale experiments in wind–wave facilities have been performed over the last two decades with varying levels of fidelity and limitations. However, the turbine controls in these experiments have considered only limited control strategies and implementations. To allow for control co-design, this research focuses on implementing and experimentally validating more advanced turbine control actions and strategies in a wind–wave basin for a 1:70-scale model of the International Energy Agency’s wind 15 MW reference wind turbine. The control strategies analyzed include torque control, collective pitch control, and transition region control (setpoint smoothing). Our experimental and numerical results include the effects of varying rotor speeds, blade pitches, and wind environments on the turbine thrust and torque. Numerical models from three different software tools are presented and compared to the experimental results. Their ability to effectively represent the aero-dynamic response of the wind turbine to the control actions is successfully validated. Finally, turbine controller tuning parameters based on the derivatives of thrust and torque are derived to allow for improved offshore wind turbine dynamics and to validate the ability of modeling tools to model the dynamics of floating offshore wind turbines with control co-design.

17 WIND ENERGY↗

DOE OSTI2024

The Dynamics of Debris Disk Creation in Neutron Star Mergers

Abstract The detection of GW170817/AT2017gfo inaugurated an era of multimessenger astrophysics, in which gravitational-wave and multiwavelength photon observations complement one another to provide unique insight into astrophysical systems. A broad theoretical consensus exists, in which the photon phenomenology of neutron star mergers largely rests upon the evolution of the small amount of matter left on bound orbits around the black hole or massive neutron star remaining after the merger. Because this accretion disk is far from inflow equilibrium, its subsequent evolution depends very strongly on its initial state, yet very little is known about how this state is determined. Using both snapshot and tracer particle data from a numerical relativity/MHD simulation of an equal-mass neutron star merger that collapses to a black hole, we show how gravitational forces arising in a nonaxisymmetric, dynamical spacetime supplement hydrodynamical effects in shaping the initial structure of the bound debris disk. The work done by hydrodynamical forces is ∼10 times greater than that due to time-dependent gravity. Although gravitational torques prior to remnant relaxation are an order of magnitude larger than hydrodynamical torques, their intrinsic sign symmetry leads to strong cancellation; as a result, hydrodynamical and gravitational torques have a comparable effect. We also show that the debris disk’s initial specific angular momentum distribution is sharply peaked at roughly the specific angular momentum of the merged neutron star’s outer layers, a fewr g c, and identify the regulating mechanism.

Astronomy & Astrophysics↗

NASA NTRS1970

Mechanical characteristics of the Bossler coupling

Test results indicate the Bossler coupling has unusual capability for accomodating combined axial motion, misalignment, and torque, suitability for applications requiring long life combined with reliability, lightweight, and minimal maintenance, and the ability to survive shock-torque greatly in excess of ultimate continuous torque.

Bossler, R. B., Jr.↗

NASA NTRS1971

Apollo 14 mission: Inability to disconnect main bus A

During entry, the Apollo 14 spacecraft busses should have de-energized when the main bus-tie motor switches were switched to the off position. One motor switch did not transfer and main bus A remained energized until the battery bus-tie circuit breakers were opened after landing. Analysis revealed that residual catalyst caused the terminal pin seals to revert to a gummy state. Resulting reversion products then migrated to the motor commutator and caused brush degradation, increased and erratic commutator resistance, and reduced motor torque. The motor stalled when available motor torque was reduced below that required to drive through the maximum torque point of the switch.

Source record↗

NASA NTRS1972

The motion and stability of a dual spin satellite during the momentum wheel spin-up maneuver

The stability of a dual-spin satellite system during the momentum wheel spin-up maneuver is treated both analytically and numerically. The dual-spin system consists of: a slowly rotating or despun main-body; a momentum wheel (or rotor) which is accelerated by a torque motor to change its initial angular velocity relative to the main part to some high terminal value; and a nutation damper. A closed form solution for the case of a symmetrical satellite indicates that when the nutation damper is physically constrained for movement (i.e. by use of a mechanical clamp) the magnitude of the vector sum of the transverse angular velocity components remains bounded during the wheel spin-up under the influence of a constant motor torque. The analysis is extended to consider such effects as: the motion of the nutation damper during spin-up; a non-uniform motor torque; and the effect of a non-symmetrical mass distribution in the main spacecraft and the rotor. An approximate analytical solution using perturbation techniques is developed for the case of a slightly asymmetric main spacecraft.

Bainum, P. M.↗

NASA NTRS1973

A study of the dynamic tire properties over a range of tire constructions

The dynamic properties of four model aircraft tires of various construction were evaluated experimentally and compared with available theory. The experimental investigation consisted of measuring the cornering force and the self-aligning torque developed by the tires undergoing sinusoidal steering inputs while operating on a small scale, road-wheel tire testing apparatus. The force and moment data from the different tires are compared with both finite- and point-contact patch string theory predictions. In general, agreement between finite contact patch theory and experimental observation is good. A modified string theory is also presented in which coefficients for cornering force and self-aligning torque are determined separately. This theory improves the correspondence between the experimental and analytical data, particularly on tires with relatively high self-aligning torques.

Nybakken, G. H.↗

NASA NTRS1972

Multivariable control theory applied to hierarchial attitude control for planetary spacecraft

Multivariable control theory is applied to the design of a hierarchial attitude control system for the CARD space vehicle. The system selected uses reaction control jets (RCJ) and control moment gyros (CMG). The RCJ system uses linear signal mixing and a no-fire region similar to that used on the Skylab program; the y-axis and z-axis systems which are coupled use a sum and difference feedback scheme. The CMG system uses the optimum steering law and the same feedback signals as the RCJ system. When both systems are active the design is such that the torques from each system are never in opposition. A state-space analysis was made of the CMG system to determine the general structure of the input matrices (steering law) and feedback matrices that will decouple the axes. It is shown that the optimum steering law and proportional-plus-rate feedback are special cases. A derivation of the disturbing torques on the space vehicle due to the motion of the on-board television camera is presented. A procedure for computing an upper bound on these torques (given the system parameters) is included.

Boland, J. S., III↗

NASA NTRS1973

Experimental investigation of the cornering of a C40 x 14-21 cantilever aircraft tire

An experimental investigation was conducted at the Langley aircraft landing loads and traction facility to define the cornering characteristics of a size C40 x14-21 aircraft tire of cantilever design. These characteristics, which include the cornering-force and drag-force friction coefficients and self-alining torque, were obtained for the tire operating on dry, damp, and flooded runway surfaces over a range of yaw angles from 0 deg to 20 deg and at ground speeds of 5 to 100 knots, both with and without braking. The results of this investigation show that the cornering-force and drag-force friction coefficients and self-alining torque were influenced by the yaw angle, ground speed, brake torque, surface wetness, and the locked-wheel condition.

Dreher, R. C.↗

NASA NTRS1973

Skylab attitude control and angular momentum desaturation with one double-gimbaled control moment gyro

In case two control moment gyros fail, attitude control of Skylab can be maintained with the thruster attitude control system. This results, however, in a severely increased fuel consumption, depleting the fuel in a few days. Therefore, an alternate concept was developed which does not have large fuel consumption under any circumstances. In this concept the attitude reference is commanded to oscillate in the orbital plane with twice the orbital frequency and the remaining control moment gyro controls about orbital north and about the minimum moment-of-inertia axis, while the thruster attitude control system controls rate only about the remaining axis. This rate control in conjunction with the restoring torque due to the gravity gradient will keep bounded the excursion of the minimum moment-of-inertia axis out of the orbital plane. This alternate concept has the additional advantage that it needs no information on the principal moment-of-inertia axes misalignment and is completely insensitive to star tracker failure. Proper phasing of the attitude reference oscillation even allows angular momentum desaturation, which is responsible for the insensitivity of the thruster fuel consumption to unknown disturbances, like vent torques and magnetic torques.

Kennel, H. F.↗

NASA NTRS1971

Improved ITOS attitude control system with Hall generator brushless motor and earth-splitting technique

The ITOS with an improved attitude control system is described. A Hall generator brushless dc torque motor will replace the brush dc torque motor on ITOS-I and ITOS-A (NOAA-1). The four attitude horizon sensors will be replaced with two CO2 sensors for better horizon definition. An earth horizon splitting technique will be used to keep the earth facing side of the satellite toward earth even if the desired circular orbit is not achieved. The external appearance of the pitch control subsystem differs from TIROS-M (ITOS-1) and ITOS-A (NOAA-1) in that two instead of one pitch control electronics (PCE) boxes are used. Two instead of four horizon sensors will be used and one instead of two mirrors will be used for sensor scanning. The brushless motor will eliminate the requirement for brushes, strain gages and the telemetry for the brush wear. A single rotating flywheel, supported by a single bearing provides the gyroscopic stability and the required momentum interchange to keep one side of the satellite facing the earth. Magnetic torquing against the earth's magnetic field eliminates the requirement for expendable propellants which would limit satellite life in orbit.

Peacock, W. M.↗

NASA NTRS1973

In-orbit performance of the ITOS improved attitude control system with Hall generator brushless motor and earth-splitting technique

The National Aeronautics and Space Administration (NASA), launched ITOS-D with an improved attitude control system. A Hall generator brushless dc torque motor replaced the brush dc torque motor on Tiros-M and ITOS-A. Two CO2 attitude horizon sensors and one mirror replaced the four wideband horizon sensors and two mirrors on ITOS-1 and NOAA-1. Redundant pitch-control electronic boxes containing additional electronic circuitry for earth-splitting and brushless motor electronics were used. A method of generating a spacecraft earth-facing side reference for comparison to the time occurrence of the earth-splitting pulse was used to automatically correct pitch-attitude error. A single rotating flywheel, supported by a single bearing, provided gyroscopic stability and the required momentum interchange to keep one side of the satellite facing the earth. Magnetic torquing against the earth's magnetic field eliminated the requirement for expendable propellants which would limit satellite life in orbit.

Peacock, W. M.↗

NASA NTRS1974

Research study on stabilization and control: Modern sampled-data control theory. Continuous and discrete describing function analysis of the LST system

The dynamics of the Large Space Telescope (LST) control system were studied in order to arrive at a simplified model for computer simulation without loss of accuracy. The frictional nonlinearity of the Control Moment Gyroscope (CMG) Control Loop was analyzed in a model to obtain data for the following: (1) a continuous describing function for the gimbal friction nonlinearity; (2) a describing function of the CMG nonlinearity using an analytical torque equation; and (3) the discrete describing function and function plots for CMG functional linearity. Preliminary computer simulations are shown for the simplified LST system, first without, and then with analytical torque expressions. Transfer functions of the sampled-data LST system are also described. A final computer simulation is presented which uses elements of the simplified sampled-data LST system with analytical CMG frictional torque expressions.

Kuo, B. C.↗

NASA NTRS1973

Evaluation of several additional dry lubricants for spacecraft applications

Four transfer-film ball-bearing retainer materials were evaluated for their lubricating ability and wear capability under conditions of 120-gram radial load, 450-gram axial load, 3600-rpm unidirectional rotation, 23 C ambient temperature, and less than .1 microtorr pressure, using R-2 sized unshielded ball bearings. The 'stop-test' criterion was a total of one billion revolutions or a torque buildup greater than 18 gm-cm per bearing pair. A PTFE-fiberglass-MoS2 composite, a PTFE-bronze composite, and a tantalum-molybdenum-MoS2 composite operated for one billion revolutions without reaching the 18-gram torque limit. A p-oxybenzoyl polymer-MoS2 composite operated sixteen million revolutions before reaching the 18-gm cm stop-test torque. The first three materials are considered as suitable lubricants under the test conditions employed.

Vest, C. E.↗

NASA NTRS1975

Dynamic analysis of the long-term zonal earth energy budget experiment (LZEEBE) spacecraft

The motions of the flexible LZEEBE spacecraft after injection into a circular orbit were analyzed. The spacecraft consists of three spherical balloons connected to a central hub by three long flexible booms which lie in a plane such that the angle between any pair of booms is 120 degrees. The major torques acting on the spacecraft are gravity-gradient torques and torques due to solar radiation pressure acting on the balloons which have different reflective properties. A development of the equations of motion is presented. Computer simulations indicate that the spacecraft will have random motion, provided the injection into orbit does not create conditions favorable to gravity-gradient capture.

Meirovitch, L.↗

NASA NTRS1975

Attitude control requirements for an earth-orbital solar electric propulsion stage

Solar Electric Propulsion Stage (SEPS) application in earth orbit requires considerably more maneuvering for thrust vector steering and solar array pointing than planetary missions. Attitude maneuver requirements for geosynchronous and low earth-orbital missions are presented. Situations which result in optimum steering torque requirements exceeding the capability of current SEPS configurations are defined. Sub-optimal steering techniques are defined which reduce the geosynchronous mission torque requirements to acceptable levels with negligible performance penalties. Some low earth-orbital flight regimes with earth shadowing are found to result in much larger torque requirements and impose significant mechanization penalties if serious performance losses are to be avoided. Alternative attitude control mechanization techniques are defined for these cases.

Oglevie, R. E.↗