Exploring additive manufacturing of wind tunnel models for a hypersonic wind tunnel
Presentation for supersonic tunnel association international.
Bhakta, Rajkumar Bipin [Sandia National Laboratori↗
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Wind Tunnel Model of the Turner-Fairbank Highway Research Center Aerodynamics Laboratory [TFHRC Project Report]
The computational fluid dynamics (CFD) and computational structural mechanics (CSM) focus areas at Argonne’s Transportation Research and Analysis Computing Center (TRACC) initiated a project to support and compliment the experimental programs at the Turner-Fairbank Highway Research Center (TFHRC) with high performance computing based analysis capabilities in August 2010. The project was established with a new interagency agreement between the Department of Energy and the Department of Transportation to provide collaborative research, development, and benchmarking of advanced three-dimensional computational mechanics analysis methods to the aerodynamics and hydraulics laboratories at TFHRC for a period of five years, beginning in October 2010. The analysis methods employ well benchmarked and supported commercial computational mechanics software. Computational mechanics encompasses the areas of Computational Fluid Dynamics (CFD), Computational Wind Engineering (CWE), Computational Structural Mechanics (CSM), and Computational Multiphysics Mechanics (CMM) applied in Fluid-Structure Interaction (FSI) problems. This report documents one of the tasks in this project. In this task, a detailed CFD model of the wind tunnel laboratory at TFHRC was built and tested to provide a means to assess the air flow uniformity provided by the tunnel to the test zone and assess room geometry effects. Considerable effort went into the construction and testing of the model and various submodels, such as the screens in the wind tunnel. The model is available for use in further studies.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Focus enhancement in long schlieren imaging systems using corrector lenses
Long schlieren imaging systems, where the parallel light test section is longer than the focal length of the focusing schlieren optics, have a limited region in the test section in which any occluding object, such as a wind tunnel model, is in focus in the schlieren image. Corrector lenses are introduced here to alter the location in the test section where image focus is achieved. Corrector lenses with focal lengths varying from −1000 to −100mm were studied. Lens-type inline and z -type mirror schlieren systems were experimentally tested with multiple collecting optic focal lengths to characterize the changes in focal position. An automated image processing method was used to determine the plane of best focus from image sequences. The introduction of the corrector lens was observed to move the location of best focus within the schlieren system test section while also causing a decrease in the focal sharpness of the images and altering the magnification. The thin lens equation was found to provide a good estimate of the focal location change in the schlieren imaging systems with the addition of the corrector lens.
Torres, Sivana M.↗
Thermal Modeling of Hypersonic Wind Tunnel Heater Using Low-Fidelity Fluid Model.
Abstract not provided.
Snyder, Alexander↗
Thermal Modeling of Hypersonic Wind Tunnel Heater Using Low-Fidelity Fluid Model.
Abstract not provided.
Gilkey, Lindsay↗
Air Flow Modeling in the Wind Tunnel of the FHWA Aerodynamics Laboratory at Turner-Fairbank Highway Research Center
Computational fluid dynamics (CFD) modeling is widely used in industry for design and in the research community to support, compliment, and extend the scope of experimental studies. Analysis of transportation infrastructure using high performance cluster computing with CFD and structural mechanics software is done at the Transportation Research and Analysis Computing Center (TRACC) at Argonne National Laboratory. These resources, available at TRACC, were used to perform advanced three-dimensional computational simulations of the wind tunnel laboratory at the Turner-Fairbank Highway Research Center (TFHRC). The goals were to verify the CFD model of the laboratory wind tunnel and then to use versions of the model to provide the capability to (1) perform larger parametric series of tests than can be easily done in the laboratory with available budget and time, (2) to extend testing to wind speeds that cannot be achieved in the laboratory, and (3) to run types of tests that are very difficult or impossible to run in the laboratory. Modern CFD software has many physics models and domain meshing options. Models, including the choice of turbulence and other physics models and settings, the computational mesh, and the solver settings, need to be validated against measurements to verify that the results are sufficiently accurate for use in engineering applications. The wind tunnel model was built and tested, by comparing to experimental measurements, to provide a valuable tool to perform these types of studies in the future as a complement and extension to TFHRC’s experimental capabilities. Wind tunnel testing at TFHRC is conducted in a subsonic open-jet wind tunnel with a 1.83 m (6 foot) by 1.83 m (6 foot) cross section. A three component dual force-balance system is used to measure forces acting on tested models, and a three degree of freedom suspension system is used for dynamic response tests. Pictures of the room are shown in Figure 1-1 to Figure 1-4. A detailed CAD geometry and CFD model of the wind tunnel laboratory at TFHRC was built and tested. Results were compared against experimental wind velocity measurements at a large number of locations around the room. This testing included an assessment of the air flow uniformity provided by the tunnel to the test zone and assessment of room geometry effects, such as influence of the proximity the room walls, the non-symmetrical position of the tunnel in the room, and the influence of the room setup on the air flow in the room. This information is useful both for simplifying the computational model and in deciding whether or not moving, or removing, some of the furniture or other movable objects in the room will change the flow in the test zone.
97 MATHEMATICS AND COMPUTING↗
Computational examination of utility scale wind turbine wake interactions
We performed numerical simulations of small, utility scale wind turbine groupings to determine how wakes generated by upstream turbines affect the performance of the small turbine group as a whole. Specifically, various wind turbine arrangements were simulated to better understand how turbine location influences small group wake interactions. The minimization of power losses due to wake interactions certainly plays a significant role in the optimization of wind farms. Since wind turbines extract kinetic energy from the wind, the air passing through a wind turbine decreases in velocity, and turbines downstream of the initial turbine experience flows of lower energy, resulting in reduced power output. Our study proposes two arrangements of turbines that could generate more power by exploiting the momentum of the wind to increase velocity at downstream turbines, while maintaining low wake interactions at the same time. Furthermore, simulations using Computational Fluid Dynamics are used to obtain results much more quickly than methods requiring wind tunnel models or a large scale experimental test.
17 WIND ENERGY↗
3D Volumetric Analysis of Wind Turbine Wake Properties in the Atmosphere Using High-Resolution Doppler Lidar
Wind turbine wakes in the atmosphere are three-dimensional (3D) and time dependent. An important question is how best to measure atmospheric wake properties, both for characterizing these properties observationally and for verification of numerical, conceptual, and physical (e.g., wind tunnel) models of wakes. Here a scanning, pulsed, coherent Doppler lidar is used to sample a turbine wake using 3D volume scan patterns that envelop the wake and simultaneously measure the inflow profile. The volume data are analyzed for quantities of interest, such as peak velocity deficit, downwind variability of the deficit, and downwind extent of the wake, in a manner that preserves the measured data. For the case study presented here, in which the wake was well defined in the lidar data, peak deficits of up to 80% were measured 0.6-2 rotor diameters (D) downwind of the turbine, and the wakes extended more than 11D downwind. Temporal wake variability over periods of minutes and the effects of atmospheric gusts and lulls in the inflow are demonstrated in the analysis. Lidar scanning trade-offs important to ensuring that the wake quantities of interest are adequately sampled by the scan pattern, including scan coverage, number of scans per volume, data resolution, and scan-cycle repeat interval, are discussed.
17 WIND ENERGY↗
Simulating Wind Around Isolated Buildings with the System for Atmospheric Modeling
A method to represent the flow around obstacles such as buildings is implemented in the System for Atmospheric Modeling (SAM). The method, which we call a Quasi-Solid Box Method (QSBM), introduces a simple modification to the anelastic equations that forces the flow to stagnate within the obstacle's boundaries. The performance of the modified SAM is evaluated using CEDVAL (Compilation of Experimental Data for Validation of Microscale Dispersion Models) wind tunnel measurements of the wind and tracer dispersion around a single rectangular building. All major observed features of the flow are quite well reproduced. The dispersion of the tracer released at the building base is also simulated. The results of simulation of a flow around a cubic building rotated by 45 degrees relative to the flow, and around a building in the form of a cylinder of aspect ratio of one, are also presented.
54 ENVIRONMENTAL SCIENCES↗
PV High Wind User Test Facility
The creation of a PV high wind test facility at the NREL Flatirons Campus that will enable private and public research efforts aimed at storm hardening PV systems. The facility will be instrumented to monitor effects of high wind conditions on modules and other array components. These in-field tests will coordinate with flow models, wind tunnel testing, validation of PV aeroelastic design codes, and post-testing module and system component analysis.
14 SOLAR ENERGY↗
Coastal Ohio Wind Project
The Coastal Ohio Wind Project intends to address problems that impede deployment of wind turbines in the coastal and offshore regions of Northern Ohio. The project evaluates different wind turbine designs and the potential impact of offshore turbines on migratory and resident birds by developing multidisciplinary research, which involves wildlife biology, electrical and mechanical engineering, and geospatial science. Firstly, the project conducts cost and performance studies of two- and three-blade wind turbines using a turbine design suited for the Great Lakes. The numerical studies comprised an analysis and evaluation of the annual energy production of two- and three-blade wind turbines to determine the levelized cost of energy. This task also involved wind tunnel studies of model wind turbines to quantify the wake flow field of upwind and downwind wind turbine-tower arrangements. The experimental work included a study of a scaled model of an offshore wind turbine platform in a water tunnel. The levelized cost of energy work consisted of the development and application of a cost model to predict the cost of energy produced by a wind turbine system placed offshore. The analysis found that a floating two-blade wind turbine presents the most cost effective alternative for the Great Lakes. The load effects studies showed that the two-blade wind turbine model experiences less torque under all IEC Standard design load cases considered. Other load effects did not show this trend and depending on the design load cases, the two-bladed wind turbine showed higher or lower load effects. The experimental studies of the wake were conducted using smoke flow visualization and hot wire anemometry. Flow visualization studies showed that in the downwind turbine configuration the wake flow was insensitive to the presence of the blade and was very similar to that of the tower alone. On the other hand, in the upwind turbine configuration, increasing the rotor blade angle of attack reduced the wake size and enhanced the vortices in the flow downstream of the turbine-tower compared with the tower alone case. Mean and rms velocity distributions from hot wire anemometer data confirmed that in a downwind configuration, the wake of the tower dominates the flow, thus the flow fields of a tower alone and tower-turbine combinations are nearly the same. For the upwind configuration, the mean velocity shows a narrowing of the wake compared with the tower alone case. The downwind configuration wake persisted longer than that of an upwind configuration; however, it was not possible to quantify this difference because of the size limitation of the wind tunnel downstream of the test section. The water tunnel studies demonstrated that the scale model studies could be used to adequately produce accurate motions to model the motions of a wind turbine platform subject to large waves. It was found that the important factors that affect the platform is whether the platform is submerged or surface piercing. In the former, the loads on the platform will be relatively reduced whereas in the latter case, the structure pierces the wave free surface and gains stiffness and stability. The other important element that affects the movement of the platform is depth of the sea in which the wind turbine will be installed. Furthermore, the wildlife biology component evaluated migratory patterns by different monitoring systems consisting of marine radar, thermal IR camera and acoustic recorders. The types of radar used in the project are weather surveillance radar and marine radar. The weather surveillance radar (1988 Doppler), also known as Next Generation Radar (NEXRAD), provides a network of weather stations in the US. Data generated from this network were used to understand general migratory patterns, migratory stopover habitats, and other patterns caused by the effects of weather conditions. At a local scale our marine radar was used to complement the datasets from NEXRAD and to collect additional monitoring parameters such as passage rates, flight paths, flight directions, and flight altitudes of nocturnal migrating species. Our work focused on the design and development of custom built marine radar that used t-bar and parabolic dish antennas. The marine radar used in the project was Furuno (XANK250) which was coupled with a XIR3000B digitizing card from Russell Technologies for collection of the radar data. The radar data was processed by open source radR processing software using different computational techniques and methods. Additional data from thermal IR imaging cameras were collected to detect heat emitted from objects and provide information on movements of birds and bats, data which we used for different animal flight behavior analysis. Lastly, the data from the acoustic recorders were used to provide the number of bird calls for assessing patterns and peak passage rates during migration. The development of the geospatial database included collection of different data sources that are used to support offshore wind turbine development. Many different data sets were collected and organized using initial version of web-based repository software tools that can accommodate distribution of rectified pertinent data sets such as the lake depth, lake bottom engineering parameters, extent of ice, navigation pathways, wind speed, important bird habitats, fish efforts and other layers that are relevant for supporting robust offshore wind turbine developments. Additional geospatial products developed during the project included few different prototypes for offshore wind farm suitability which can involve different stakeholders and participants for solving complex planning problems and building consensus. Some of the prototypes include spatial decision support system (SDSS) for collaborative decision making, a web-based Participatory Geographic Information System (PGIS) framework for evaluating importance of different decision alternatives using different evaluation criteria, and an Android application for collection of field data using mobile and tablet devices . In summary, the simulations of two- and three-blade wind turbines suggested that two-bladed machines could produce comparable annual energy as the three-blade wind turbines but have a lighter tower top weight, which leads to lower cost of energy. In addition, the two-blade rotor configuration potentially costs 20% less than a three blade configuration that produces the same power at the same site. The cost model analysis predicted a potential cost savings of approximately 15% for offshore two-blade wind turbines. The foundation design for a wind turbine in Lake Erie is likely to be driven by ice loads based on the currently available ice data and ice mechanics models. Hence, for Lake Eire, the cost savings will be somewhat smaller than the other lakes in the Great Lakes. Considering the size of cranes and vessels currently available in the Great Lakes, the cost optimal wind turbine size should be 3 MW, not larger. The surveillance data from different monitoring systems suggested that bird and bat passage rates per hour were comparable during heavy migrations in both spring and fall seasons while passage rates were significantly correlated to wind directions and wind speeds. The altitude of migration was higher during heavy migrations and higher over water relative to over land. Notable portions of migration on some spring nights occurred parallel the shoreline, often moving perpendicular to southern winds. The birds approaching the Western basin have a higher propensity to cross than birds approaching the Central basin of Lake Erie and as such offshore turbine development might be a better option further east towards Cleveland than in the Western basin. The high stopover density was more strongly associated with migration volume the following night rather than the preceding night. The processed mean scalar wind speeds with temporal resolutions as fine as 10-minute intervals near turbine height showed that August is the month with the weakest winds while December is the month, which typically has the strongest winds. The ice data suggests that shallow western basin of Lake Erie has higher ice cover duration many times exceeding 90 days during some winters.
17 WIND ENERGY↗
Analyzing the Energy Performance, Wind Loading, and Costs of Photovoltaic Slat Modules on Commercial Rooftops
NREL studied a new type of photovoltaic (PV) module configuration wherein multiple narrow, tilted slats are mounted in a single frame. Each slat of the PV slat module contains a single row of cells and is made using ordinary crystalline silicon PV module materials and processes, including a glass front sheet and weatherproof polymer encapsulation. Compared to a conventional ballasted system, a system using slat modules offer higher energy production and lower weight at lower LCOE. The key benefits of slat modules are reduced wind loading, improved capacity factor and reduced installation cost. First, the individual slats allow air to flow through, which reduce wind loading. Using PV performance modeling software, we compared the performance of an optimized installation of slats modules to a typical installation of conventional modules in a ballasted rack mounting system. Based on the results of the performance modeling two different row tilt and spacing were tested in a wind tunnel. Scaled models of the PV Slat modules were wind tunnel tested to quantify the wind loading of a slat module system on a commercial rooftop, comparing the results to conventional ballasted rack mounted PV modules. Some commercial roofs do not have sufficient reserve dead load capacity to accommodate a ballasted system. A reduced ballast system design could make PV system installation on these roofs feasible for the first time without accepting the disadvantages of penetrating mounts. Finally, technoeconomic analysis was conducted to enable an economic comparison between a conventional commercial rooftop system and a reduced-ballast slat module installation.
14 SOLAR ENERGY↗
Aerodynamic Characterization of 3D Scanned Wind Turbine Blades Using Experimental and Computational Methods
This study presents an aerodynamic characterization of 3D scanned wind turbine blades using both experimental and computational methods. The research was conducted by Gulf Wind Technology and Sandia National Laboratories. The primary objective was to investigate the aerodynamic impacts of leading-edge manufacturing defects on wind turbine blades. The study utilized the Stratasys NEO 800 3D Printer for high-precision manufacturing and the GWT Accelerator Wind Tunnel for experimental testing. Computational simulations were performed using COMSOL Multiphysics to model the wind tunnel and analyze flow characteristics and OpenFOAM to study the aerodynamic impacts of leading-edge defects. OpenFAST was used to estimate how these defects can lead to revenue losses for wind farm operators as high as 6%. The results demonstrated significant aerodynamic performance variations due to defects, with detailed analysis provided through wind tunnel and CFD data. The findings contribute to the understanding of defect impacts on wind turbine blade performance and offer insights for future design improvements.
17 WIND ENERGY↗
Investigation of Dynamic Aerodynamics and Control of Wind Turbine Sections Under Relevant Inflow/Blade Attitude Conditions
The growth of wind turbines has led to highly variable loading on the blades. Coupled with the relative reduced stiffness of longer blades, the need to control loading on the blades has become important. One method of controlling loads and maximizing energy extraction is local control of the flow on the wind turbine blades. The goal of the present work was to better understand the sources of the unsteady loading and then to control them. This is accomplished through an experimental effort to characterize the unsteadiness and the effect of a Gurney flap on the flow, as well as an analytical effort to develop control approaches. It was planned to combine these two efforts to demonstrate control of a wind tunnel test model, but that final piece still remains to be accomplished.
17 WIND ENERGY↗
Summary of UMI Chemical Work
Our initial work for the Urban Modeling Integration (UMI) project was to validate the QUIC model dense gas dispersion of chlorine advection up a ramp. The validation task was to use QUIC to model an experiment done in a wind tunnel. Naturally the QUIC model uses a slumping cylindrical model where inside the cylinder the gas is treated as dense but outside ideal. In trying to validate using the wind tunnel experiment, due to the scale of the wind tunnel experiment and ramp, The model formed a very clear, discrete, concentration barrier at the edge of the cylinder that likely doesn’t line up well with the real dense gas advection/diffusion. This effect is much less noticeable at a larger scale such as an instantaneous release of a 25 ton tank.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Observations of airflow around a supertall curved building and its impact on temperature and humidity in Houston's urban center
Characterization of realistically shaped skyscrapers embedded in non-uniform neighbourhoods experiencing intricate weather patterns remains inadequately investigated. Aiming to close this gap, the Center for Multiscale Applied Sensing team deployed its mobile observatory in the street canyons around the curved Wells Fargo Plaza skyscraper in downtown Houston, TX. Three deployments allowed airflow observations under different inflow wind and thermodynamic stability conditions. Doppler lidar measurements reveal that when inflow hits the curved wall of the skyscraper, perpendicular canyons experience similar vortex configurations creating two windward and two leeward circulations. Windsond measurements support that buoyancy within the deep street canyons can generate thermal updrafts as strong as 2 m s -1 which is sufficient to overturn the mechanical downwash under gentle wind conditions. Canyons experiencing venting during the daytime were observed to be more thermodynamically stable at night while thermodynamically stable canyons during the day were observed to be more thermodynamically unstable at night owing to the accumulation of heat near street-level. Fourier decomposition of the vertical velocity measurements shows that in all cases flow exhibited high Reynolds numbers and was composed of turbulent eddies of predominantly 6 and 15 min periods. Here, this observational dataset provides insights to assess wind load, pedestrian comfort, urban air mobility, and natural ventilation and may be used as a benchmark for numerical model and wind tunnel studies attempting to represent realistically complex urban conditions.
54 ENVIRONMENTAL SCIENCES↗
Toward flow control: An assessment of the curled wake model in the FLORIS framework
In this work, a new controls-oriented wake model is modified and compared to an analytical Gaussian wake model, high-fidelity simulation data, and experimental wind tunnel campaign. This model, called the curled wake model, captures a wake phenomenon that occurs behind yawed turbines, modeled as a collection of vortices shed from the rotor plane. Through turbine simulations, these vortices are shown to have a significant impact on the prediction of the wake steering's performance. Overall, the results support the concept of secondary steering, or a yawed turbine's ability to deflect the wake of a downstream turbine, and suggest that future turbine wake studies and yaw optimizations should include the curled wake phenomenon.
17 WIND ENERGY↗
Using system identification in modeling the yaw response of tail fins for small wind turbines with bearing friction
Here, we describe three main developments of our previous study of the nonlinear yaw dynamics of the tail fins for small wind turbines [Khedr et al., J. Renewable Sustainable Energy 16, 053305 (2024)]. First, the model constants derived from archived computational and experimental studies are adjusted by employing system identification (SI) to maximize the model's agreement with wind tunnel tests. This adjustment was done for high wind speeds, where yaw bearing friction can be ignored. When starting a turbine at low wind speed, however, friction can become important. Our second development is to implement a model for the frictional resistive torque and use SI to maximize its accuracy. These developments used wind tunnel experiments on generic delta, elliptical, and rectangular planforms that were described by Khedr et al. [J. Renewable Sustainable Energy 16, 053305 (2024)]. Since the aerodynamic and friction models employ a large number of constants, we describe ways to constrain the values using linearized solutions of the response equations for small and large yaw angles. Third, we test the generality of the aerodynamic and friction modeling using the complex planform from a commercial small turbine, for which limited theoretical and computational guidance is available in selecting the model constants. The model implemented with SI is shown to provide an accurate description of the yaw response of the complex planform. Guidelines are given for the use of wind tunnel tests to determine the model constants for tail fins of any planform.
17 WIND ENERGY↗