SOWE2013_Bouwman

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Copyright ESI Group, 2013. All rights reserved.


Design of Wind turbines using OpenFOAM

as part of the CAE chainOverview

Dr. Ries Bouwman

Dipl.-Ing. Manfred R. Mller

@riesbouwman

20 March 2013

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ESI Group

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Headquarters in Paris,France

Offices in more than 30countries

Average Headcount:+1000 people

Over 200 Scientists

WW Revenue 2012:130 M$

Paris, France Eschborn, Germany Pilsen, Czech Republic Farmington Hills, MI Beijing, China Tokyo, Japan

Licenses Services

EMEA

AsiaPacific

Americas


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ESI Trade Solutions and Vision

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VirtualManufacturing

Virtual Performance

Virtual Environment

Enabled by

a common

Platform

Full Concurrent End to EndVirtual Prototyping

Conceived in the

Real World.

Experienced,Built and Tested

in the Virtual World


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OpenFOAMis a free, open source CFD software toolbox

OpenCFD Ltd contributes software, integrates modules and generatesdocumentation to the OpenFOAMsoftware

OpenFOAM Foundation is a non-profit organization which wasestablished for the purpose of ensuring the sustainable distribution ofOpenFOAM

11 September 2012Acquisition of OpenCFD Ltd., The leader in Open Source software inComputational Fluid Dynamics

ESI becomes owner of OpenFOAMtrademarkESI becomes producer of OpenFOAMsoftware

ESI will continue to manage the development, production andmaintenance of the OpenFOAMSoftware, for distribution through theOpenFOAM Foundation

OpenCFD Ltd. Acquisition

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Contribute

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7/26Copyright ESI Group, 2013. All rights reserved.

Management

IT

Engineering

Open source is the unique software feature

The competitive advantage comes from control to

modifythe software freely

assesscode quality

knowwhat the software is doing

deployOpenFOAM however they wish, e.g. own hardware,

cloud, etc.

influencedevelopment priorities

manage costs, i.e. choose when and how to get something fortheir money

OpenFOAM users benefit from this control

Unique Competitive Advantage

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EnterpriseSubscription

MigrationService

Training: public scheduled and on-site

Engineering Services: pilot projects, consultancy

Process Integration: OpenFOAM into a work-flow

Process Interface: OpenSIM, application specific

Development: OpenFOAM development projects

Advanced Support: hour-based supportPlatform Support: hardware tuning, benchmarking

Code Integration: third-party code into OpenFOAM

Strategic Collaboration: roadmap reviews, planning

ESI OpenFOAM Services

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ESI application based GUI

OpenSIM

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Example: Wind Turbine

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Vibrations/Fatigue:

VPS/Implicit

Acoustic:

VA-ONE

Composites:

PAM-RTM/FORM

Manufacturing:

SYSWELDProCAST

PAM-STAMP

Electromagnetism/

EMC/Lightn./Radar:

PAM-CEM

SYSMAGNA

Gear Box, drive:PAM-MEDYSA

CFD:ACE+PAM-FLOWOpenFOAM

Impact & shocks:

VPS/PAM-CRASH


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Windmill in Natural Wind

Proof of Feasibility

POWER QUALITYnumerical generation

coupled PAM-FLOW / VPS model



Process development requirement

Large parts

Complex and new materials/processes

High performances required

Cost of trials (in time and money)

Production rate increase required

Recyclability

Composites

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Strategy 2Strategy 1

Infusions SimulationComplex Injection Strategy


15/26Copyright ESI Group, 2013. All rights reserved. 15

Explicit-based solutions

PAM-CRASH Linear and non-linear materials,large displacements

PAM-SAFE Restraint systems

PAM-MEDYSA Non-linear DynamicsPAM-SHOCK High velocity impact

Implicit-based solutions

PAM-STATICS Linear and non-linear materials,

large displacementsPAM-NVH Eigen-mode Extraction, Harmonic

and Transient Analyses

PAM-ACOUSTICS Interior acoustics,Porous Elastic Materials

One

Executable



Kinematics

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Time Step Run End Machine Calculation Time

0.8 10e-6 0.85 s 8 proc 4 days


17/26Copyright ESI Group, 2013. All rights reserved.Copyright ESI Group, 2010. All rights reserved.

Oil Management

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Oil Flow

estimation

on each

critical parts

(Bearing,

gears, etc)

Estimation of

the oil

dynamic

unbalance

Estimation of

the impact of

the oil

viscosity.



Velocities for barge close to floating wind turbine in waves

(demo case)

Floating wind turbine in waves



Virtual Performance:

Vibro-Acoustics

SEABEM - FEM

Respons

e

Frequency Log

-Transmission path:

Translational structure born noise

Torsional structure born noise

-Noise emission: Airborn noise (high frequency)

(directed/undirected)



Casting

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The Benefits

For a foundry:

Suppression/reduction of physical trials

Reduction of recovering and rejecting

causes

Enhanced understanding of processcapability

Casting/process optimization

Better fit with customer requirements

For the customer:

Effective and early design for manufacturing

The ChallengeMeet the customersquality standard by accurately

predicting and optimizing microstructure,

mechanical properties and porosity formation in

large cast iron wind power turbine castings.



EMC & Electromagnetismus

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Interference for Weather-Radar: 320 km/hRotationspeed is like a Thunderstorm for Radar (RAM:

Radar absorbing Material)

Interference for Aeronautical-Radar

Thunderlightning

Electrical Grounding & Lightning Strike Protection (LSP)

Materials for Composite Wind Turbines

WindturbineFire in 130 m

(Foto: dpa)



ICIDO belongs to ESI

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ICIDO is the leadingvendor of virtual-

reality based

collaborativedecision-makingsolutions.We allowour customers to

workcollaborativelywith

colleagues, suppliersand customers in a

virtual environment

either at one location

or in a distributed

environment.
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11-14 March 2013, Melbourne, Australia

25-28 March 2013, Barcelona, Spain

15-18 April 2013, Paris, France

29-02 April/May 2013, Boston, MA, USA20-23 May 2013, Munich, Germany

24-27 June 2013, San Francisco, CA, USA

01-04 July 2013, Paris, France

Public OpenFOAM Training

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OpenFOAM Webinars

Start April 2013

OpenFOAM Users Conference 201324-26 April 2013, Frankfurt, Germany

NAFEMS World Congress 2013

9-11 June 2013, Salzburg, Austria

Upcoming Events

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Many Thanks!


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SOWE2013_Bouwman

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