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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Control Co-Design of Wind Turbines

Wind energy is recognized worldwide as cost-effective and environmentally friendly, and it is among the fastest-growing sources of electrical energy. To further decrease the cost of wind energy, wind turbines are being designed at ever-larger scales. To expand the deployment of wind energy, wind turbines are also being designed on floating platforms for placement in deep-water locations offshore. Both larger-scale and floating wind turbines pose challenges because of their greater structural loads and deflections. Complex, large-scale systems such as modern wind turbines increasingly require a control co-design approach, whereby the system design and control design are performed in a more integrated fashion. This article reviews recent developments in control co-design of wind turbines. We provide an overview of wind turbine design objectives and constraints, issues in the design of key wind turbine components, modeling of the wind turbine and environment, and controller coupling issues. Wind turbine control functions and the integration of control design in co-design are detailed with a focus on co-design compatible control approaches.

17 WIND ENERGY↗
DOE OSTI2020

Wind Energy Technologies Office Multi-Year Program Plan Fiscal Years 2021—2025

WETO's Multi-Year Program Plan outlines the Office’s research priorities and plans through the year 2025. With the objectives of reducing the cost of wind energy, enabling the integration of substantial amounts of wind energy into the evolving national energy system, and creating siting and environmental solutions to reduce environmental impacts, the Plan provides insight into DOE’s wind energy research priorities, and will guide planning and execution of future R&D activities. It is organized in six sections: offshore wind, land-based wind, distributed wind, systems integration, modeling and analysis, and crosscutting initiatives.

17 WIND ENERGY↗
DOE OSTI2022

Investigation of Multiple Data Streams for Gearbox Bearing Fault Prediction Through Machine-Learning Models

Operations and maintenance (O&M) cost of wind plant accounts up to 30% of total energy cost, which can be reduced through continuous monitoring and successfully detecting incipient wind turbine failures. To accomplish this, condition monitoring and predictive maintenance systems are being implemented in wind industry to support O&M decision making. A wide range of approaches for condition monitoring and fault prediction have been developed. These approaches generally use historical data of wind turbines collected by Supervisory Control and Data Acquisition (SCADA) system to identify patterns that lead to failure. These SCADA data show the overall condition of a wind turbine and can be leveraged to detect when the turbine's performance is degrading and to identify if a fault is developing. However, it becomes challenging to predict the failure of a specific wind turbine gearbox bearing, because the SCADA data are often not directly linked to the component. To bridge the gap, we have investigated features calculated from SCADA data using physics-based models and the gearbox design over the years. The damaged metric we used in the physics domain is frictional energy. Combining these physics domain variables with SCADA data as inputs to various machine learning models for gearbox bearing fault prediction, we have demonstrated the benefits of leveraging both physics and data domain models. It was an attempt to improve frictional-energy-based damage metric by adding data domain inputs, as we had learned that the frictional-energy-based damage metric alone is not sufficient to single out failed bearings from healthy. As condition monitoring data (either vibration or oil debris data) has become available at more and more wind plants, we would like to evaluate whether by adding the condition monitoring data can help further improve the performance of frictional-energy-based damage metric for gearbox bearing fault prediction. Both cases by modeling through various machine learning algorithms are discussed in this study along with some observations.

fault prediction↗
NASA NTRS1981

An algorithm for minimum-cost set-point ordering in a cryogenic wind tunnel

An algorithm for minimum cost ordering of set points in a cryogenic wind tunnel is developed. The procedure generates a matrix of dynamic state transition costs, which is evaluated by means of a single-volume lumped model of the cryogenic wind tunnel and the use of some idealized minimum-costs, which is evaluated by means of a single-volume lumped model of the cryogenic wind tunnel and the use of some idealized minimum-cost state-transition control strategies. A branch and bound algorithm is employed to determine the least costly sequence of state transitions from the transition-cost matrix. Some numerical results based on data for the National Transonic Facility are presented which show a strong preference for state transitions that consume to coolant. Results also show that the choice of the terminal set point in an open odering can produce a wide variation in total cost.

Tripp, J. S.↗
DOE OSTI2019

Large-Scale Additive Manufacturing for Low Cost Small-Scale Wind Turbine Manufacturing (CRADA NFE-18-07065)

Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility (MDF) worked with XZERES Wind to fabricate small (in comparison to traditional wind energy systems) wind turbine blades using large-scale polymer additive manufacturing (AM) in Phase 1 of this project. The results of Phase 1 showed promise for the use of AM in the production of small wind energy systems. Although, the large-scale polymer AM systems available for this project proved to be too large for this application, ORNL and XZERES Wind were able to prove that AM is a viable opportunity to improve small wind turbine blades. The goal for Phase 2 was for XZERES to design tooling for their existing blade geometry and for ORNL to manufacture the tooling and a blade section using advanced manufacturing techniques. Unfortunately, due to personnel turnover at XZERES, Phase 2 was not completed.

17 WIND ENERGY↗
DOE OSTI2020

Report of the Condition of a General Electric Transportation Systems Gearbox

Wind power plant operations and maintenance (O&M) costs remain an appreciable contributor to the overall cost of wind energy. Premature of wind turbine gearboxes failures are often a result of abrasive wear, micropitting, scuffing, white-etch cracks, and macropitting issues. Micropitting is a fatigue phenomenon that occurs in Hertzian contacts in both gears and rolling-element bearings that operate in mixed or micro elastohydrodynamic lubrication regimes. Micropitting is influenced by and manifests itself in many different ways depending on operating conditions such as load, speed and operating temperature, and on factors such as gear geometry and accuracy, tooth flank roughness, percentage of tooth sliding, and lubricant composition. Despite much research by many investigators, micropitting remains complex, unpredictable, and difficult to control and remains a problem in wind turbine gearboxes. The purpose of this report is to document and describe the micropitting damage observed in a wind turbine gearbox, thereby facilitating further analysis and examination in future reports.

17 WIND ENERGY↗
DOE OSTI2020

Southwest Wind Power R&D Test Site Development at the National Wind Technology Center (CRADA CRD-12-00472 Final Report)

Southwest Windpower, Inc. (SWWP) has been designing and distributing small wind turbines for more than 22 years and is the recognized global leader in the design, manufacturing and distribution of small wind systems (400-3000 watts). The company has been a pioneer in the development of wind technology and has built and shipped more than 170,000 wind turbines to over 120 countries worldwide. Headquartered in Flagstaff AZ, SWWP has sales representatives in over 88 countries. Applications for SWWP systems include residential homes, commercial properties, micro grids, remote cabins, telecom transmitters, offshore platforms, water pumping and sailboats. In addition, U.S. Department of Defense uses SWWP’s products in Forward Operating Bases (FOB’s), USGS uses them for remote monitoring of glacier movements and the CIA uses them to provide power seismic monitoring. Today, SWWP plans development of new technologies to address distributed energy market needs and become even more aggressive in international markets. This strategy includes extensive Research, Development, Demonstration & Deployment (RDD&D) activities to improve existing production line into more simple, reliable, and cost-effective wind turbine systems. Important part of such activities is the field testing of the new systems, which should provide: (i) validation of the reliable operation of hardware and software; (ii) validation of numerical models of the system and its components; (iii) field comparison of various control and optimization strategies; (iv) customized reliability testing; (v) customized monitoring and analysis testing; and (vi) IEC certification testing (vii) filed demonstration of system performance and reliability. Such field testing facility should encompass multiple towers and appropriate data acquisition systems. SWWP is exploring to move part of the engineering department to Colorado, and execute its RDD&D strategies in this new location. Partnership with NREL will provide great insights into SWWP’s RDD&D processes and more efficient commercialization by utilizing NWTC as the field testing site, and working close with NREL personnel. NWTC is ideally suited to strain the design. NREL is very experienced with customized and IEC testing. During this project, Southwest Windpower aims to improve the value proposition of distributed renewable energy, and make it a competitive choice in the energy markets. As of today, more then 170,000 small wind turbines, manufactured in the U.S., are installed in more then 180 countries. With the improved value proposition, Southwest Windpower wants to create and address new market needs, substantially increase its sales domestically and internationally, which should have positive impact on the creation of American jobs, competitiveness of U.S. economy, export or U.S. products, and the use of renewable energy.

17 WIND ENERGY↗
DOE OSTI2019

A Prognostics and Health Management Framework for Wind

Operation and maintenance costs are a major driver for levelized cost of energy of wind power plants and can be reduced through optimized operation and maintenance practices accomplishable by various prognostics and health management (PHM) technologies. In recent years, the wind industry has become more open to adopting PHM solutions, especially those focusing on diagnostics. However, prognostics activities are, in general, still at the research and development stage. On the other hand, the industry has a request to estimate a component's remaining useful life (RUL) when it has faulted, and this is a key output of prognostics. Systematically presenting PHM technologies to the wind industry by highlighting the RUL prediction need potentially helps speed up its acceptance and provides more benefits from PHM to the industry. In this paper, we introduce a PHM for wind framework. It highlights specifics unique to wind turbines and features integration of data and physics domain information and models. The output of the framework focuses on RUL prediction. To demonstrate its application, a data domain method for wind turbine gearbox fault diagnostics is presented. It uses supervisory control and data acquisition system time series data, normalizes gearbox temperature measurements with reference to environmental temperature and turbine power, and leverages big data analytics and machine-learning techniques to make the model scalable and the diagnostics process automatic. Another physics-domain modeling method for RUL prediction of wind turbine gearbox high-speed-stage bearings failed by axial cracks is also discussed. Bearing axial cracking has been shown to be the prevalent wind turbine gearbox failure mode experienced in the field and is different from rolling contact fatigue, which is targeted during the bearing design stage. The method uses probability of failure as a component reliability assessment and RUL prediction metric, which can be expanded to other drivetrain components or failure modes. The presented PHM for wind framework is generic and applicable to both land-based and offshore wind turbines.

17 WIND ENERGY↗
DOE OSTI2021

IACMI Project 4.2: Thermoplastic Composite Development for Wind Turbine Blades

(Section 5.1) Composites made from Arkema’s Elium® thermoplastic resin and Johns Manville fiberglass were researched during this project for applications in wind blade manufacturing. A techno-economic model was developed to model this wind blade manufacturing process using these materials in place of traditional composites made with thermoset resin. This model was based on manufacturing a 61.5-meter wind blade, which showed a 4.7% reduction in wind blade cost as compared traditional thermoset materials. These cost savings were not from the thermoplastic material costing less than traditional thermoset materials, but rather from decreased capital costs, faster cycle times and reduced energy requirements and labor costs. (Section 5.2) An infusion and curing model was developed for thermoplastic composite wind blades using PAM-RTM. The primary goal was to demonstrate the infusion simulation for the Elium® resin system on a 13-meter wind blade. Additionally, the exotherm temperature was predicted and compared to measurements, which showed model results within 10% of actual measurements. (Section 5.3) Composite laminate panels and composite sandwich panels with a balsa core were produced; specimens were cut and characterized. Similar composite specimens were made with Elium® thermoplastic resin and Hexion thermoset epoxy (RIMR135/RIMH1366) to enable comparisons between these resin systems. The static test methods included: tensile, compression, in-plane shear, interlaminar shear, flexural, sandwich core shear flexure, and single cantilever beam tests for sandwich beams. Fatigue testing at room temperature was completed to composite laminate panels at a stress ratio of R=0.1 and R=10. In addition, fatigue testing to laminate panels was completed at -30°C, and at room temperature after conditioning specimens at 70°C and 90% relative humidity. Overall, mechanical test results from Elium® composites are similar to epoxy composites. (Section 5.4) Elium composite panels were produced with intentional defects such as voids and nonwetting of fibers to begin to understand performance sensitivity to defects. A thermal digital image correlation (TDIC) method provides high spatial resolution strain field at elevated temperatures and can be used to identify defective regions within composite panels. Flexural modulus differences of 21% were seen between defect and non-defect panels. Other Elium® composite panels were forced to be defective by boiling the resin after infusion, which created voids throughout the composite laminate. X-ray computed tomography scanning was used to view the internal structure of the defect panels. Defect panels had a significant reduction in fatigue life as compared to baseline panels produced without intentional defects. (Section 5.5) Lap shear specimens were fabricated to compare the lap shear strength of an off-the-shelf adhesive (Plexus MA590) and two new adhesives developed by Arkema (Bostik SAF30 90 and Bostik SAF30 120). ISO standard 4587:2003 was used to standardize the testing method and sample fabrication. Lap shear specimens were made at 1mm, 3mm, and 10mm thicknesses. The Bostik adhesive lap shear test results were similar to Plexus for all thicknesses. (Section 5.6) Fiber-reinforced polymer (FRP) composites are typically used in high-performance applications (e.g., aerospace), and their expansion into high-volume industries (e.g. consumer automotive and wind turbine blade manufacturer or similar) is hindered by their cost and a lack of efficient manufacturing techniques. Monitoring the curing process of these composites during manufacturing can improve the efficiency of the process, and therefore reduce the manufacturing cost. Cure monitoring techniques were developed that use probabilistic estimation methods and surface temperature measurements made using infrared cameras. These techniques enable real-time monitoring of the infusion process to locate manufacturing flaws, and they can, potentially, estimate residual stresses in the part. Their commercialization will help facilitate expansion of FRP composites in high-volume industries. (Section 5.7) A 13-meter composite wind blade was produced with Elium® resin and Johns Manville fiberglass; this blade was made with VARTM processing similar to how megawatt-scale wind blades are currently manufactured, but no post-mold heating was used for this thermoplastic composite blade. The wind blade underwent full-scale validation for static loading (4-different load orientations) and flapwise fatigue loading to simulate 20-years of operational loads. The thermoplastic composite wind blade withstood the loading without any noted issues and performed similar to results from a previous full-scale validation to an equivalent epoxy composite wind blade produced with the same blade molds. (Section 5.8) A study was conducted to determine the feasibility of recycling composite wind turbine blade components fabricated with glass fiber reinforced Elium® thermoplastic resin. Dissolution, which is a process unique to thermoplastic matrices, allows recovery of both the polymer matrix and full-length glass fibers, while maintaining their stiffness and strength throughout the recovery process. The economics of recycling is favorable if 50% of the glass fiber is recovered and resold for a process of $\$$ 0.28/kg, and 90% of the resin is recovered and resold at a price of $\$$ 2.50/kg.(Section 10) Recommendations are outlined for commercializing thermoplastic resin for composite wind blade production, in addition to recommended areas for future research.

17 WIND ENERGY↗
DOE OSTI2020

Scalable Wind Turbine Generator Bearing Fault Prediction Using Machine Learning: A Case Study

Operation and maintenance (O&M) costs for wind turbines pose a risk to competitiveness and asset owners. With machine-learning technologies and digitalization rapidly maturing, the wind industry is actively investigating these new technologies to optimize O&M practices and reduce costs. This paper reviews recent work on machine-learning approaches to generator bearing failure prediction and presents a relevant real-world case study through a collaboration between the National Renewable Energy Laboratory and Envision Digital Corporation. In the case study, we evaluate the performance of representative machine-learning algorithms for predicting wind turbine generator bearing failures. Operational supervisory control and data acquisition data from one wind power plant was used to train and test the machine-learning models. The investigated data channels are chosen based on whether physically they reflect the failed generator bearing conditions and the component historical usage, including both environmental and operational conditions. Benefits and drawbacks of different methods are identified.

generator bearing failures↗
DOE OSTI2021

Estimation of the Ambient Wind Field From Wind Turbine Measurements Using Gaussian Process Regression

In the search for a lower levelized cost of wind energy, one approach is to increase the accuracy of wind turbine measurements such as wind speed and wind direction. The sensors available on wind turbines are susceptible to local turbulence and measurement bias, which can result in suboptimal turbine performance. As an alternative, recent research has considered using the sensor measurements in a coordinated manner. With such a cooperative approach, the local wind conditions can be estimated more accurately and reliably without the need for additional measurement equipment. In this paper, a novel wind field estimation approach is presented that estimates the local wind conditions based on turbine measurements using Gaussian processes. We show that the estimation framework is able to improve the accuracy of the wind direction estimate both in an offline and online manner, as well as identify possible biases in the sensors and reduce unnecessary wind turbine yaw activity.

49 EE - Wind and Water Power Program - Wind (EE-4W↗
NASA NTRS1983

Construction of low-cost, Mod-OA wood composite wind turbine blades

Two sixty-foot, low-cost, wood composite blades for service on 200 kW Mod-OA wind turbines were constructed. The blades were constructed of epoxy resin-bonded Douglas fir veneers for the leading edge sections, and paper honeycombcored, birch plywood faced panels for the afterbody sections. The blades were joined to the wind turbine hub by epoxy resin-bonded steel load take-off studs embedded into the root end of the blades. The blades were installed on the 200 kW Mod-OA wind turbine facility at Kahuku, Hawaii, The blades completed nearly 8,000 hours of operation over an 18 month period at an average power of 150 kW prior to replacement with another set of wood composite blades. The blades were replaced because of a corrosion failure of the steel shank on one stud. Inspections showed that the wood composite structure remained in excellent condition.

Lark, R. F.↗
DOE OSTI2023

IACMI Project 4.7: Pultruded Textile Carbon Fiber for Spar Caps (Final Report)

The primary objective of this project was to demonstrate the potential to significantly reduce the cost of wind turbine blades with carbon fiber reinforced polymer (CFRP) structure. Applicability of textile carbon fibers (TCF) were evaluated for use in pultruded spar cap (SC) elements as a path to cost reduction for utility scale wind turbine blades. In earlier work for the Department of Energy (DOE) Wind Energy Technologies Office (WETO), a collaboration of Sandia National Laboratory (SNL), Oak Ridge National Laboratory (ORNL), and Montana State University has demonstrated potential for pultruded TCF to compete with infused fiberglass and commercially available carbon fiber pultruded sections for spar cap construction. In the design cases evaluated, the TCF sections fared well when compared on cost per unit composite stiffness and cost per unit composite compressive strength for those designs [1]. Both stiffness and compressive strength tend to be key factors in the design of blade composite Spar Cap which carry the bulk of the blade structural loads in bending. Spar Cap design tends to distribute largely symmetric tensile and compressive stresses to opposite sides of the spar structure, but since carbon fiber composite compressive strength is typically 20-50% lower than tensile strength, the compressive loading reaches failure levels well before the tensile loading. Stiffness is critical in containing the large tip deflection in high wind loading situations. However, materials and process development were very limited in the earlier study and the work in this project was expanded to make the comparative information more representative of what will be required in order to make further inroads towards implementation. Similar to that study, this project team confirmed that the primary materials of interest for pultruded spar cap elements should be thermoset (TS) resins reinforced by carbon fibers, utilizing as high a percentage of TCF as practical to benchmark cost and performance against commercial carbon fibers. To make the closest comparison possible and eliminate specific test article size, resin selection, and equipment/operational nuance effects, the team planned to pultrude sections with 100% commercially available carbon fiber (Panex 35 carbon fiber from Zoltek) as well as samples utilizing high fractions of TCF. The resin system chosen was based on formulations recommended by large wind industry supplier Hexion and consisted of Hexion resin RSL-4597, curing agent CCA-138, and internal mold release additive 117, along with common kaolin filler ASP400P from BASF. As commonly deployed in spar cap configurations, the team had a mold built to pultrude a rectangular spar cap element of 100mm width and 3mm thickness. The extremely limited number of samples produced for the earlier study were produced with a “generic” epoxy utilized for a variety of applications by the pultruder contracted to produce test articles for demonstration purposes. More importantly, those samples were produced at a fiber fraction only slightly over 50%. Based on feedback from our industrial advisory team for that project and strongly recommended by this project team, the consensus is that it is highly desirable to obtain fiber fractions of 65-68% for significant penetration in wind blade spar cap. Although this requirement has yet to be exhaustively confirmed in readily available information, this was established as a project goal and informally decided we needed to exceed 60% fiber fraction to gain serious industry consideration. Previous TCF pultrusion trials have been challenged by the lack of robust TCF packages, resulting in non-uniform tension across and between tows, as well as excess labor and waste for removal of interleaved paper. The non-uniform tension and associated intermingling of tows in textile acrylic fiber tows and associated difficulties created from broken filaments in carbon fiber conversion inhibit the ordered packing necessary to enhance fiber fraction elevation. (These “cross-overs” are not considered undesirable for textile applications and there is some sense that they might be advantageous for those applications). In addition to work that is ongoing at the acrylic fiber manufacturers to improve their formats, The Institute of Advanced Composites Manufacturing Innovation (IACMI) Project 6.12 (report PA16-0349-6.12-01) [2] has developed and demonstrated a more robust packaging and creeling approach that at least partially addresses these issues, thus improving control of the TCF feed into the pultrusion unit. It was hoped that these and other improvements currently being implemented would allow us to achieve fiber fractions at least approaching these fiber fraction targets. During this project, sections utilizing 100% commercially available carbon fiber reinforcement were produced as a baseline, as well as sections reinforced with about 94% TCF and the balance being commercially available fiber for comparison. The most important finding was that similar to results reported in the earlier WETO-funded project and results from tests of TCF reported at IACMI meetings, this work demonstrated that sections pultruded with TCF in an epoxy resin frequently utilized in actual spar cap production had stiffness and compressive strengths largely comparable to similar sections pultruded with a commercially available carbon fiber also frequently utilized in the wind industry. Although the amount of that data is limited, some of the tensile strength results were actually closer than would have been expected based on fiber strength results provided by the TCF and commercial fiber producers. The actual test data are reported and discussed in detail in Section 5. The pultruded sections dominated by TCF reinforcement were approximately 8-10% lower in fiber fraction than for the sections produced using commercial fiber alone, making direct comparison difficult. The COVID-19 project has provided significant insight into the current state-of-the-art with various TCF product forms. The data obtained in this project will guide the planned improvements at the precursor level, especially in attaining uniform tensioning and payout to facilitate enhanced fiber fractions and overall processability of the TCF composites. The project team is providing guidance to stakeholders concerning the attributes, needs, and potential demand for TCF in wind blade spar caps. Results achieved in this project are consistent with findings in the related work cited [1] and support this guidance and the high potential for this product type. TCF precursor-producing partners continue to express interest in enhancing their product forms and the team looks forward to working with these improved materials as they become available.

42 ENGINEERING↗
NASA NTRS1987

Visual display and alarm system for wind tunnel static and dynamic loads

A wind tunnel balance monitor and alarm system developed at NASA Ames Research Center will produce several beneficial results. The costs of wind tunnel delays because of inadvertent balance damage and the costs of balance repair or replacement can be greatly reduced or eliminated with better real-time information on the balance static and dynamic loading. The wind tunnel itself will have enhanced utility with the elimination of overly cautious limits on test conditions. The microprocessor-based system features automatic scaling and 16 multicolored LED bargraphs to indicate both static and dynamic components of the signals from eight individual channels. Five individually programmable alarm levels are available with relay closures for internal or external visual and audible warning devices and other functions such as automatic activation of external recording devices, model positioning mechanisms, or tunnel shutdown.

Hanly, Richard D.↗
NASA NTRS1987

Visual display and alarm system for wind tunnel static and dynamic loads

A wind tunnel balance monitor and alarm system developed at NASA Ames Research Center will produce several beneficial results. The costs of wind tunnel delays because of inadvertent balance damage and the costs of balance repair or replacement can be greatly reduced or eliminated with better real-time information on the balance static and dynamic loading. The wind tunnel itself will have enhanced utility with the elimination of overly cautious limits on test conditions. The microprocessor-based system features automatic scaling and 16 multicolored LED bargraphs to indicate both static and dynamic components of the signals from eight individual channels. Five individually programmable alarm levels are available with relay closures for internal or external visual and audible warning devices and other functions such as automatic activation of external recording devices, model positioning mechanism, or tunnel shutdown.

Hanly, Richard D.↗
DOE OSTI2024

Levelized Cost of Energy Comparison of Floating Wind Farms With and Without Shared Anchors

As part of the Innovative Deep-Water Mooring Systems for Floating Wind Farms (DeepFarm) R&D project, led by Principle Power Inc., the National Renewable Energy Laboratory (NREL) performed an LCOE analysis to compare the changes in LCOE between floating wind farms with individual anchors versus shared anchors. This report presents a comparative analysis of the LCOE of two different wind farms with different mooring systems: one with taut mooring lines each connected to individual suction pile anchors, and one with taut mooring lines connected to shared anchors. A brief description of the methodology employed to conduct the LCOE comparison is given, including the underlying assumptions. Then, results are presented with a compilation of key findings.

16 TIDAL AND WAVE POWER↗