An Integrated Wind Turbine Design ToolAn Integrated...

WMC Knowledge CentreWind turbine Materials and Constructions

FOCUS5An Integrated Wind Turbine Design Tool

FOCUS5An Integrated Wind Turbine Design Tool

N.P. DuineveldN.P. Duineveld

Sandia 2008 Blade WorkshopSandia 2008 Blade Workshop

Tuesday May 13Tuesday May 13thth, 2008, 2008


OutlineOutline

General Introduction Turbine Design Blade Design Future Development


FOCUS, an integrated wind turbine design tool

IntroductionIntroduction

Novem project 224.720.9535: FOCUS version 4Novem project 224.720.9635: Windows-95 interface for FOCUS4

FOCUS 5: Internal development

SenterNovem project: 2020-04-11-10-003: FOCUS 6 (2004-2008)

INNWIND - Innovation in Wind Energy (2006-2011)


Main FeaturesMain Features

Wind turbine design Detailed blade design Load set calculation according to international standards (IEC,

GL, DNV) Design load sets calculated and blade structural analyses

results are accepted for certification Fatigue and strength analysis based on stress/strain time

series World wide used by main players in industry Focus is also applied for many years in both national and

international research projects Open architecture Support of external formats Graphical analysis of results Integrated help system


Focus flow chartFocus flow chart


Aero elastic simulatorAero elastic simulator


Aero Elastic Simulator (Phatas)Aero Elastic Simulator (Phatas)

Simulation of non-linear structural and aerodynamic response of the complete wind turbine in time domain developed by ECN.

The simulation includes full interaction between aerodynamic loads, structural deformations and controller response.

Is suitable for pitch-to-vane controlled variable-speed turbines

Accurate modal response model for tower and blades, including blade torsion

Geometric non-linear model for blade bending

Optional linkage of tower substructure exported from general purpose FEM package is possible


Aero Elastic Simulator (Phatas)Aero Elastic Simulator (Phatas)

Analyses of the aerodynamic rotor characteristics

Power curve calculations

Built-in advanced PD controller, custom PD controllers can be linked

Modeling of operational states of the turbine like starts and stops and emergency conditions

Detailed modeling options of deterministic wind conditions

Option to apply stochastic wave loading


FOCUS GUIPhatas

FOCUS GUIPhatas

(Click image below to start video)


Load Case PreProcessorLoad Case PreProcessor


Load Case PreProcessorLoad Case PreProcessor

The LoadCase PREProcessorLCPREP is provided for automatic generation of load case input files following IEC-2 and GL or IEC-3.


FOCUS GUILoad Case PreProcessor

FOCUS GUILoad Case PreProcessor

Load case definition

smgershTypewritten Text(Click image below to start video)


3D Wind Field Generator 3D Wind Field Generator


Wind Simulator (SWIFT)Wind Simulator (SWIFT)

SWIFT Simulation of Wind Fields in Time

A full field of three-component turbulent wind is generated for variable speed wind turbines

The discrete time history of the wind speed in wind direction are calculated at nodal points on the rotor plane.

SWIFT is compatible with the commonly applied standards for wind turbine design: IEC, GL and DNV.


FOCUS GUI3D wind definition (Swift)

FOCUS GUI3D wind definition (Swift)

(Click image below to start video)


Post-processingTime series turbine simulation

Post-processingTime series turbine simulation

Load case GL 4.2 Normal stop, Extreme Operating Gust (EOG) at Vout

Vhub

Generator shaft power

Rotor speed

Axial force shaft

Pitch angle blade 1

0 10 20 30 40 50 60 70 80 9020

22

24

26

28

30

32

34

time [s]

Sig

nal=

2

Wind speed hub [m/s]

PHATAS IV model:Demo2MW Date: 21-01-2008Load case: 4280 Description: STOP_EOG1_cutout

0 10 20 30 40 50 60 70 80 900E3

1000E3

2000E3

3000E3

4000E3

time [s]

Sig

nal=

5

Generator shaft power [W]

0 10 20 30 40 50 60 70 80 900

5

10

15

20

25

time [s]S

igna

l=12

Rotor speed [rpm]

0 10 20 30 40 50 60 70 80 90

-100000

0

100000

200000

300000

time [s]

Sig

nal=

64Axial (compressive) force on shaft. [N]

0 10 20 30 40 50 60 70 80 900

20

40

60

80

100

time [s]

Sig

nal=

104

Blade 1: Pitch angle. [deg]


Post-processingPower curve

Post-processingPower curve

Pgenerator

Rotor speed

Cpaero

Pitch angle

Axial Force

2 4 6 8 10 12 14 16 18 20 220E3

400E3

800E3

1200E3

1600E3

2000E3

Wind speed [m/s]

P_ge

n[W

]

Demo2MW

PHATAS IV model:Demo2MW Date: 21-01-2008

2 4 6 8 10 12 14 16 18 20 22

10

12

14

16

18

20

Wind speed [m/s]

roto

r spe

ed [r

pm] Demo2MW

2 4 6 8 10 12 14 16 18 20 220.00

0.10

0.20

0.30

0.40

Wind speed [m/s]Cp

_aer

o [-]

Demo2MW

2 4 6 8 10 12 14 16 18 20 220

4

8

12

16

Wind speed [m/s]

Pitc

h_an

gle1

[deg

]

Demo2MW

2 4 6 8 10 12 14 16 18 20 22

40000

80000

120000

160000

200000

Wind speed [m/s]

Axia

l forc

e [N

]

Demo2MW


External linksExternal links

External controller DLL can be linked to Phatas

Native Phatas API

Bladed API


FOCUS5Blade design

FOCUS5Blade design


Blade modellingBlade modelling


FOCUS blade designFOCUS blade design

1. Define the profiles of the blade2. Define position of profiles in the

blade

3. Define lines through the profiles4. Define materials5. From lines and radii + materials:

define sections (sheets of material)

6. Select load cases7. Run


Profile definitionProfile definition

-0.2

-0.15

-0.1

-0.05

0

0.05

0.1

0.15

0.2

0.25

0 0.2 0.4 0.6 0.8 1 1.2

Normalized shape

# of points constant for the whole blade

Closed profiles


FOCUS shape toolFOCUS shape tool(Click image below to start video)


Use of profile files in blade definitionUse of profile files in blade definition


From profiles to blade shapeFrom profiles to blade shape(Click image below to start video)


Lines definitionLines definition

Lines are defined as 2 points : Radius % chord Offset mm //chord Offset along //profile Offset chord


Define material propertiesDefine material properties

Define materials by:

Type

Isotropic

Orthotropic

Core

Partial material factors according to GL

Additional material properties can be set for export to FEM

Material dependent S-N line data (like slope)

For fatigue analysis


Define fatigue formulationDefine fatigue formulation

Goodman & S-N lines defined by user defined equations

GRP Goodman diagram according to GL2003


Define SectionsDefine Sections

Give radii and lines for each sheet of material

Sequence: start from the mold, as in the production

UD

R=750+v

Foam

R=750+v


Blade Eigen frequencies/modesBlade Eigen frequencies/modes

Coupled eigen frequencies/modes calculated by Focus


Blade Structural analysesBlade Structural analyses


Load case selectionLoad case selection


Run Blade design analysisRun Blade design analysis


Blade structural analysesFatigue Results

Blade structural analysesFatigue Results

Fatigue damage (life based) Fatigue reserve factor (strength based) Stress spectra


Blade Buckling/FINSTRIPBlade Buckling/FINSTRIP

Cross section based buckling analyses


Post ProcessingPost Processing


Post-processing featuresPost-processing features

Plot the structural data of the blade

Plot load-time sequences, load spectra andspectral density plots

Plot the PHATAS simulation variables

Plot stress-spectra

View the FAROB model with the 3D-Viewer



FOCUS Load file format is standardized and made public for external program use.

Load files can be exported to ASCII

Load file import from Flex5/6 and Bladed

FOCUS can convert the blade model into FE mesh

MSC.MARC MSC.Nastran ANSYS


Focus generated FE meshFocus generated FE mesh

MSC.MARC, MSC.Nastran and ANSYS

Thick shell elements Geometry Materials Full ply lay-up


Sample Nastran analysesSample Nastran analyses

Nastran modal analyses with Focus generated FE mesh

First flap mode Second flap mode

(Click image below to start video) (Click image below to start video)


FOCUS GUI Help systemFOCUS GUI Help system


New developmentsFOCUS6/INNWINDNew developmentsFOCUS6/INNWIND

Turbine definition

Bladestructure

Towerstructure

ExternalConditions

Stoch./det.Wave

simulator

Stoch./det.Wind

simulator

Waves WindField

FAROBPre

Aero-elasticsimulator

Turbine database

Airfoilcoordinates

Airfoilcoefficients

ATG

Structuralloads

FAROBStructuralanalyses

SILANTCapitalCosts

functions

StructuralReserve factors

NoiseEmission

CapitalCosts

Perfor-mance

Design check

DesignOK?

AdaptDesign

Optimizeddesign

New optimization cycle

yn

Newmodule

DataStorage

Enhanced existingmodule

Newmodule

DataStorage

Enhanced existingmodule

2004-2011: SenterNovem projects New user interface with a database back-end

Linear and non-linear wave generator for offshore

Aerodynamics table generator

Internal finite element solver for rotor blade calculations

Generic cost module for capital turbine costs

Turbine optimization tool

SILANT, turbine noise emission tool

Structural analyses support structures (offshore applications)

Improvement of the PHATAS tower modelPHATAS

Option to perform load set calculations on a grid of computers to reduce turnaround time significantly.


Thanks!Thanks!

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