Van Wingerden, Jan-Willem

DOE OSTI2024

Instantaneous mesh load factor ( K γ ) measurements in a wind turbine gearbox using fiber-optic strain sensors

The mesh load factor, K γ , describes how loads are shared between planet gears and has become one of the key design challenges in modern wind turbine gearboxes. Planet load sharing directly impacts tooth root stresses, a critical driver of torque density and gearbox reliability. Experimental evaluation of K γ is typically performed from sun gear tooth root strain gauge measurements, which are complex. Furthermore, such measurements can only provide an average value of load sharing. The present study describes an alternative method to evaluate the mesh load factor in wind turbine gearboxes based on fiber-optic strain sensors installed on the outer surface of the fixed ring gear. We present the results of an extensive measurement campaign to evaluate this novel sensing solution installed on the input planetary stage of a 2-MW wind turbine gearbox at the National Renewable Energy Laboratory's Flatirons Campus (Colorado, USA). The number of strain sensors on the ring gear was selected as an integer multiple of the number of planets, which has enabled an instantaneous evaluation of the mesh load factor. The effect of operating conditions on the planet load-sharing behavior of the gearbox has been investigated. The mesh load factor measured for operating conditions close to rated was below 1.05, well below IEC 61400-4 standard requirements.

17 WIND ENERGY↗

DOE OSTI2019

A Tutorial on the Synthesis and Validation of a Closed-Loop Wind Farm Controller Using a Steady-State Surrogate Model

In wind farms, wake interaction leads to losses in power capture and accelerated structural degradation when compared to freestanding turbines. One method to reduce wake losses is by misaligning the rotor with the incoming flow using its yaw actuator, thereby laterally deflecting the wake away from downstream turbines. However, this demands an accurate and computationally tractable model of the wind farm dynamics. This problem calls for a closed-loop solution. This tutorial paper fills the scientific gap by demonstrating the full closed-loop controller synthesis cycle using a steady-state surrogate model. Furthermore, a novel, computationally efficient and modular communication interface is presented that enables researchers to straight-forwardly test their control algorithms in large-eddy simulations. High-fidelity simulations of a 9-turbine farm show a power production increase of up to 11% using the proposed closed-loop controller compared to traditional, greedy wind farm operation.

17 WIND ENERGY↗