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  • SIMPACK AG 2012, All rights reserved.

    General

    Steve MulskiDirector Wind Energy Solutions

    Wind and Drivetrain Conference 2012Modeling Elements, Database Management, DLC Calculations

  • SIMPACK AG 2012 All rights reserved. Page 2September 2012 Steve Mulski

    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

  • SIMPACK AG 2012 All rights reserved. Page 3September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    Aerodynamics

    Large forces, non-linear transients, stall, tower shadow, etc.

  • SIMPACK AG 2012 All rights reserved. Page 4September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    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

  • SIMPACK AG 2012 All rights reserved. Page 5September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    5

    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 ofresearch and industrial

    projects have been

    assembled

    Flexible approach is offeredto compromise between

    modeling accuracy and

    computation time

    Standard interface to SIMPACK

    ECN Aero-Module

    Aerodynamics

  • SIMPACK AG 2012 All rights reserved. Page 6September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    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

    6

    ECN Aero-Module (BEM)

    Aerodynamics

  • SIMPACK AG 2012 All rights reserved. Page 7September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    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

    7

    ECN Aero-Module (AWSM)

    Aerodynamics

  • SIMPACK AG 2012 All rights reserved. Page 8September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    8

    NASA Ames Dynamic inflow

    Visit our stand for more details!!!!!!!!

    Aerodynamics

  • SIMPACK AG 2012 All rights reserved. Page 9September 2012 Steve Mulski

    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) ]

  • SIMPACK AG 2012 All rights reserved. Page 10September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    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

  • SIMPACK AG 2012 All rights reserved. Page 11September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    User Force Element

    HydroDyn (NREL), modified by SWEfor coupling with SIMPACK

    Validated with OC3 Phase IV results

    Validated with FAST HydroDynSimulations

    Experimental validation planned

    SWE Task: SIMPACK Offshore - Hydrodynamics Force Element

  • SIMPACK AG 2012 All rights reserved. Page 12September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    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) ]

  • SIMPACK AG 2012 All rights reserved. Page 13September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    Application: Tidal Currents Turbines

    Simulation of fluid-structure-interaction basedon MBS and CFD

    Multi-body-Code: SIMPACK

    CFD-Code: Ansys CFX

    Time scheme with full implicit iterations betweenSIMPACK 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]

  • SIMPACK AG 2012 All rights reserved. Page 14September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    Tank Container with Sloshing Load

    Tank Container with Sloshing Load

    Discrete Element Method (DEM)

    Co-simulation with PASIMODO

    Modeling Elements

  • SIMPACK AG 2012 All rights reserved. Page 15September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    Modeling Elements

    Tower

    Rotorblades

    Shafts

    Detailed FE

    Flexible Bodies

  • SIMPACK AG 2012 All rights reserved. Page 16September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    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

  • SIMPACK AG 2012 All rights reserved. Page 17September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    Modeling Elements

    Flexible Bodies Rotorblades

    Rotorblade Generator (SIMBEAM)

    Import from FE

    Advanced

    Basic

  • SIMPACK AG 2012 All rights reserved. Page 18September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    Modeling Elements

    Flexible Bodies Detailed FE

    Import from FE

  • SIMPACK AG 2012 All rights reserved. Page 19September 2012 Steve Mulski

    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

  • SIMPACK AG 2012 All rights reserved. Page 20September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    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

  • SIMPACK AG 2012 All rights reserved. Page 21September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    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

  • SIMPACK AG 2012 All rights reserved. Page 22September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    Modeling Elements

    Torque Converters

    FVA Models

    Detailed SIMPACK Gear Pair

    Gear Pairs

  • SIMPACK AG 2012 All rights reserved. Page 23September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    Modeling Elements

    Ladle Crane

    Fault Simulation

    Ladle Crane

  • SIMPACK AG 2012 All rights reserved. Page 24September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    Modeling Elements

    Meshing Frequencies

    Misalignments

    Profile and Flank Modification

    Gear Pairs

  • SIMPACK AG 2012 All rights reserved. Page 25September 2012 Steve Mulski

    SIMPACK Wind and Drivetrain Conference

    Modeling Elements

    Spline Coupling

  • SIMPAC