Wind and Drivetrain Conference 2012 - SIMPACK · Wind and Drivetrain Conference 2012 ... SIMPACK...
Transcript of Wind and Drivetrain Conference 2012 - SIMPACK · Wind and Drivetrain Conference 2012 ... SIMPACK...
SIMPACK AG 2012, All rights reserved.
General
Steve MulskiDirector Wind Energy Solutions
Wind and Drivetrain Conference 2012Modeling Elements, Database Management, DLC Calculations
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SIMPACK Wind and Drivetrain Conference
SIMPACK Introduction
Agenda
• Modelling in SIMPACK
Aerodynamics
Hydrodynamics
Flexible bodies /Bearings / Gears
Database
Control Interfaces
• Analysis Methods:
Resonance Analysis
Transient Analysis
Order Analysis
Stress and Durability
Load Calculations
• Conclusion
2001
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Aerodynamics
Large forces, non-linear transients, stall, tower shadow, etc.
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Aerodynamics
Blade Element Theory
• Interface to AeroDyn v13, NREL
• Interface to Aero-Module, ECN
Non-linear Lifting Line Vortex Wake Theory
• Interface to Aero-Module, ECN
Reynolds-averaged Navier Stokes
• Co-simulation with CFD codes
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• Load case calculations
(and power performance
predictions): Need of more
accurate prediction of wind
loading in time domain for
further reduction of Cost
of Energy!
• Result of many years of
research and industrial
projects have been
assembled
• Flexible approach is offered
to compromise between
modeling accuracy and
computation time
Standard interface to SIMPACK
ECN Aero-Module
Aerodynamics
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ECN PHATAS formulation as starting point
• ECN Dynamic Inflow model (ECN-C-94-107)
• ECN Yaw/Tilt model (ECN-CX-98-070)
• Many other advanced engineering extensions, continuousimprovement based on wind tunnel results and comparisonto more detailed models (e.g. AWSM)
• Current state of the art, BUT limitations:
- Dynamic effects are approximated (wake not resolved)
- Radial independence assumed
- 2D model: no spanwise flow, planar rotor geometry
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ECN Aero-Module (BEM)
Aerodynamics
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Aero-Module (AWSM)
• Based on non-linear lifting line vortex wake theory
• Input of aerodynamic coefficients still necessary, but..
• Enhanced modeling of
- Dynamic inflow effects (e.g. pitch step)
- Yawed flow
- Tip effect
- Radial dependence included
- Curved blade axis (sweep, winglet)
• Ideal compromise between BEM and CFD
• To be used for more complex load cases and geometries
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ECN Aero-Module (AWSM)
Aerodynamics
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NASA Ames – Dynamic inflow
Visit our stand for more details!!!!!!!!
Aerodynamics
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SIMPACK Wind and Drivetrain Conference
• Simulation of standard loadcases, IEC61400-1, GL2010
• Structural dynamics:
Multi-DOF MBS models (SIMPACK)
• Aerodynamics:
Blade-element-momentum theory - BEM (AeroDyn, NREL; AeroModule, ECN)
Lifting-Line Free Vortex Wake method - AWSM (AeroModule, ECN)
Computational Fluid Dynamics CFD - (FLOWer, DLR)
SWE Task: Advanced Aeroelastic Design Process
[Stuttgart Wind Energy (SWE) ]
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• IEC DLC 1.4 Extreme Coherent Gust with Direction Change (ECD)
• Comparision of BEM and AWSM – Blade tip deflection
• Applying the advanced aerodynamic method offers more accurate
loads and deflections compared to the BEM approach
– In case of IEC DLC 1.4 the blade tip deflection is predicted to besignificantly lower!
SWE Task: Advanced Aeroelastic Design Process – Exemplary Results
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• User Force Element
• HydroDyn (NREL), modified by SWE
for coupling with SIMPACK
• Validated with OC3 Phase IV results
• Validated with FAST HydroDyn
Simulations
• Experimental validation planned
SWE Task: SIMPACK Offshore - Hydrodynamics Force Element
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• Non-linear MBS Mooring Line
• Integrated FOWT system simulation
• Hydrodynamic forces computed with modified
Morison Equation
• Validation against quasi-static model (HydroDyn)
SWE Task: SIMPACK Offshore - MBS Mooring System
[Stuttgart Wind Energy (SWE) ]
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• Application: Tidal Currents Turbines
• Simulation of fluid-structure-interaction based
on MBS and CFD
– Multi-body-Code: SIMPACK
– CFD-Code: Ansys CFX
• Time scheme with full implicit iterations between
SIMPACK and CFX
• Simulation of Aeroelastics rstructure/rfluid > 1000
and Hydroelastics rstructure/rfluid ≈ 1
SWE Task: Fluid-Structure-Interaction on Tidal Current Turbines (In Cooperation with Voith AG)
[Voith AG]
advance in time withsuccessive exchange ofdata in each time step
deformation at discretelocations
CFD (Ansys CFX) Multibody (Simpack)
loads for discrete areas
Examplecase: ‚Turek FSI 3‘-Benchmark:
[Voith AG]
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Tank Container with Sloshing Load
Tank Container with Sloshing Load
• Discrete Element Method (DEM)
• Co-simulation with PASIMODO
• Modeling Elements
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Modeling Elements
• Tower
• Rotorblades
• Shafts
• Detailed FE
Flexible Bodies
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Modeling Elements
• Flexible structures using beam elements
(i.e shafts, towers, rotor blades)
• Non-linear bending (2nd Order)
• Mass and shear centre offset
• Rotorblade Pre-processor
SIMBEAM
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Modeling Elements
Flexible Bodies – Rotorblades
• Rotorblade Generator (SIMBEAM)
• Import from FE
Advanced
Basic
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Modeling Elements
Flexible Bodies – Detailed FE
• Import from FE
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SIMPACK Wind and Drivetrain Conference
Modeling Elements
• Linear and non-linear stiffness and damping
• 6x6 Matrices
• User Routines
• Integrated specialized software
• Complete contact model (not commonly done)
• EHD
LAGER2
Bearings and Bushings
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Modeling Elements, BEARINX
Bearing 3
Bearing 2
Bearing 1
SIMPACKCharacteristic mappreparation
…
Bearingcharacteristic
mapsBearing 1
2
CharacteristicmapDLL
SimulationPreprocessing
• Loads and moments as a result of relative displacements between inner- and outer ring by means ofcharacteristic maps
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Modeling Elements
• Kinematic gear elements:
standard transmission
differential gearbox
planetary gearbox
• Dynamic gear elements
(stiffness, damping, friction)
• Sophisticated tooth wheel element
Extensive Library of Gear Elements
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Modeling Elements
• Torque Converters
• FVA Models
• Detailed SIMPACK Gear Pair
Gear Pairs
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Modeling Elements
• Ladle Crane
• Fault Simulation
Ladle Crane
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Modeling Elements
• Meshing Frequencies
• Misalignments
• Profile and Flank Modification
Gear Pairs
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Modeling Elements
Spline Coupling
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Modeling Elements
Wind Turbine Gearboxes
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Databases
Substructured Model Setup (Wind Turbine Gearbox)
• Different Gearbox Types
• Different level of detail (e.g. parallel shafts, non-parallel shafts)
• Different simulation scenarios
1. Gearbox simulation
2. Windturbine simulation
3. Testrig simulation (back-to-back)
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Modeling Elements
• SIMAT Co-simulation with Simulink
• MatSIM Code Import from Simulink
• Wind Turbine Controller DLL Interface
• FMI – Open Functional Mock-up Interface
Control and Grid
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Interfaces with MATLAB
SIMAT – Linear Model Export
SIMAT – Co-simulation
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Interfaces with MATLAB
MatSIM
S-Function Export
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Modelisar: Multi-Domain by FMI
Chassis,Driveline
• SIMPACK Model Import
• SIMPACK Co-simulation
• Free Definable Interface
Funnctional Mock-up Interface (FMI)
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Resonance Analysis
• Eigenmodes and frequencies
• Campbell plot
• Eigen energies
Norm. Eigen Energy
Bo
die
s
O.51.0
23
3.0
127
RPM
Fre
qu
en
cy
Drivetrain Analysis
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Analysis Methods
Resonance Analysis
• Run-up
• 3D Campbell Plot
Time
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6 DOF
Foundation
Hub Carrier
Sky GEN
Nacelle Interface
1DoF: Gamma(about z)
Pitch-Bearing1
Turbine Carrier
6 DOF
Carrier Interface
Generator Controler
SkyWind Gearbox(Detail Model withGear Pair Elements)
Sky Hub
Pitch-Bearing 2
Gamma(about z)
Rotorblade1
Rotorblade 2
Pitch Controler
6DoF
FE 43:BushingCx, Cy, CzCalpha, Cbeta, Cgamma
Alpha(about x)
1 DOF
Yaw-Bearing
Main Bearing
Tower (Flexible Body) Concrete-Part
0 DoF
Tower (Flexible Body) Steel-Part
0 DOF
Yaw Controler
1DoF
LSSCoupling
Elastomer ElmentsSafety clutch and brakeunit
6DoF
Internal Gear
1 DOF
Pitch Actuator
Pitch Actuator
SIMPACK Model for Design Load Calculation
SIMPACK AG 2012 All rights reserved. Page 35September 2012 Steve Mulski
SIMPACK Wind and Drivetrain Conference
Generator TorqueController
Generator TorqueController
Nacelle YawController
Nacelle YawController
Rotor blade PitchController
Rotor blade PitchController
SIMPACK ControllerSIMPACK Controller
Mita-Teknik Manual
Start Position(Pitch = 90°)
Free Wheeling (Pitch =60°)
Park Position (Pitch= 90°)
Free Wheel -> G1
G1 Grid Connect
Operation
Over SpeedPitch 90°
SIMPACK Model for Design Load Calculation
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FreeWheeling
GrideConnect
Drivetrain Reaction
Co-Simulation “SIMAT”, Generator Controller
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Black Curve: Simple SIMPACK Model
Red Curve: SIMPACK Model with Pitch Actuator and
MATLAB with Simulink Model as Pitch Controller
For more details about Pitch Controller, see SkyWind
presentation, M. Schirru
Fatigue Calculation
Use detail Model for DLC
Define Pitch Actuator for connection between Pitch Controller and Rotor blade
Using details MATLAB with Simulink Model as Pitch/ Yaw Controller
Using details MATLAB with Simulink Model as Generator
Compare Rotor Blade Bending MomentCompare Rotor Blade Bending Moment
Use SIMPACK to decrease the Loads
SIMPACK AG 2012 All rights reserved. Page 38September 2012 Steve Mulski
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Black Curve: Simple SIMPACK Model
Red Curve: SIMPACK Model with Generator as
MATLAB with Simulink Model
For more details about generator model, see
presentation from University of Applied Sciences Kiel,
Prof. Dr. Schümann
Fatigue Calculation
Using details MATLAB with Simulink Model as Generator
Compare Gearbox Input TorqueCompare Gearbox Input Torque
Use SIMPACK to decrease the Loads
SIMPACK AG 2012 All rights reserved. Page 39September 2012 Steve Mulski
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Post ProcessingPost Processing AnalyzingAnalyzingLoad CalculationLoad Calculation
SkyWind SimulationProcess
SkyWind SimulationProcess
SkyWind Simulation Process will controlledby Microsoft Access Tool
Starting SIMPACK Time Integration and configuration ofSimulation Model e.g.:
Choosing Parameter Input File
Changing Wind Profiles
Changing Control Input File
……
Starting SIMPACK Time Integration and configuration ofSimulation Model e.g.:
Choosing Parameter Input File
Changing Wind Profiles
Changing Control Input File
……
Starting SIMPACK Post Processing and choose the ScriptfileStarting SIMPACK Post Processing and choose the Scriptfile
SkyWind DLC Tool
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SIMPACK Wind and Drivetrain Conference
Ultimate loads Calculation
Calculating Damage Equivalent Load (DEL)
Calculating Load Duration Distribution (LDD)
Calculating Markov matrix with Rainflow Counting
Ultimate loads Calculation
Calculating Damage Equivalent Load (DEL)
Calculating Load Duration Distribution (LDD)
Calculating Markov matrix with Rainflow Counting
Ultimate Loads CalculationUltimate Loads Calculation
SkyWind DLC Tool
SIMPACK AG 2012 All rights reserved. Page 41September 2012 Steve Mulski
SIMPACK Wind and Drivetrain Conference
SIMPACK time series input
Output: DEL‘s in anEXCEL file
Output: LDD‘s in anEXCEL file
Output: Markov matrix in anASCII file + plot
Input parameters:
Time series of loads (SIMPACK)
different „Wöhler“-coefficients
Design and simulated lifetime
Distribution of the windspeeds
Input parameters:
Time series of loads (SIMPACK)
different „Wöhler“-coefficients
Design and simulated lifetime
Distribution of the windspeeds
SkyWind DLC Tool
SIMPACK AG 2012 All rights reserved. Page 42September 2012 Steve Mulski
SIMPACK Wind and Drivetrain Conference
Thanks
Thank You for Your Attention