Wind and Drivetrain Conference 2012 - SIMPACK · Wind and Drivetrain Conference 2012 ... SIMPACK...

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SIMPACK AG 2012, All rights reserved. General Steve Mulski Director Wind Energy Solutions Wind and Drivetrain Conference 2012 Modeling Elements, Database Management, DLC Calculations

Transcript of Wind and Drivetrain Conference 2012 - SIMPACK · Wind and Drivetrain Conference 2012 ... SIMPACK...

Page 1: Wind and Drivetrain Conference 2012 - SIMPACK · Wind and Drivetrain Conference 2012 ... SIMPACK Wind and Drivetrain Conference 5 ... Calculating Markov matrix with Rainflow Counting

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 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

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SIMPACK Wind and Drivetrain Conference

Aerodynamics

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

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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

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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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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

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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

7

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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SIMPACK Wind and Drivetrain Conference

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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SIMPACK Wind and Drivetrain Conference

Modeling Elements

Flexible Bodies – Rotorblades

• Rotorblade Generator (SIMBEAM)

• Import from FE

Advanced

Basic

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SIMPACK Wind and Drivetrain Conference

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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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

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SIMPACK Wind and Drivetrain Conference

Modeling Elements

• Torque Converters

• FVA Models

• Detailed SIMPACK Gear Pair

Gear Pairs

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

SIMPACK Wind and Drivetrain Conference

Modeling Elements

• Ladle Crane

• Fault Simulation

Ladle Crane

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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

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SIMPACK Wind and Drivetrain Conference

Modeling Elements

Spline Coupling

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Modeling Elements

Wind Turbine Gearboxes

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SIMPACK Wind and Drivetrain Conference

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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SIMPACK Wind and Drivetrain Conference

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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SIMPACK Wind and Drivetrain Conference

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

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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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SIMPACK Wind and Drivetrain Conference

FreeWheeling

GrideConnect

Drivetrain Reaction

Co-Simulation “SIMAT”, Generator Controller

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SIMPACK Wind and Drivetrain Conference

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

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SIMPACK AG 2012 All rights reserved. Page 38September 2012 Steve Mulski

SIMPACK Wind and Drivetrain Conference

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

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SIMPACK Wind and Drivetrain Conference

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

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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

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SIMPACK Wind and Drivetrain Conference

Thanks

Thank You for Your Attention