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DOE OSTI2022

A Boundary Topology Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance has become a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization for light-weighting electric machines using traditional approaches typically explore a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods like cell-based density approaches suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the IEA-15MW radial flux direct-drive wind turbine generator. The free-from boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with upto 20-ton reduction in electrical steel mass.

additive manufacturing↗

DOE OSTI2020

Dynamic Modeling of Full Converter Adjustable-speed Pumped Storage Hydropower (FC AS-PSH)

Full converter adjustable-speed pumped storage hydropower (FC AS-PSH) technology, as one of advanced-PSH technology, is developed from wind turbine technology. By making the synchronous machine connect to the grid through a full-size converter, FC AS-PSH has a wider adjustment range of speed and a better reactive power control capability compared with a doubly-fed asynchronous generator AS-PSH technology. When it plays as an energy backup in the power system, FC AS-PSH can provide a much faster response than conventional-PSH (C-PSH) which makes this technology provide better ancillary service for a high renewable penetrated system. In this paper, the dynamic modeling of FC AS-PSH is fully studied. We develop a detailed model of this technology in the IEEE 14-bus system based on GE Positive Sequence Load Flow (PSLF) platform. Especially, the first governor model is developed based on the Engineer’s Program Control Language (EPCL) user-defined model in this platform. All operation modes are validated and studied under a system contingency. Besides, comparison cases between FC AS-PSH and C-PSH are studied to show advantages providing from FC AS-PSH when it works with renewable energy.

50 EE - Wind and Water Power Program - Water (EE-4↗

DOE OSTI2020

Downwind coning concept rotor for a 25 MW offshore wind turbine

The size of offshore wind turbines over the next decade is expected to continually increase due to reduced balance of station costs per MW and also the higher wind energy at increased altitudes that can lead to higher capacity factors. However, there are challenges that may limit the degree of upscaling which is possible. In this paper, a two-bladed downwind turbine system is upscaled from 13.2 MW to 25 MW, by redesigning aerodynamics, structures, and controls. In particular, three 25 MW rotors have been developed: V1 is the upscaled model, V2 is a partial redesigned model, and V3 is a fully redesigned model. Despite their radically large sizes, it is found that these 25 MW turbine rotors satisfy this limited set of design drivers at the rated condition and that larger blade lengths are possible with cone-wise load-alignment. In addition, flapwise morphing (varying the cone angle with a wind-speed schedule) is investigated in terms of minimizing mean and fluctuating root bending loads using steady inflow proxies for the maximum and damage equivalent load moments. The resulting series of 25 MW rotors, which are the largest ever designed, can be a useful baseline for additional development and assessment.

17 WIND ENERGY↗

DOE OSTI2022

Numerical investigation of the influence of shear and thermal stratification on the wind turbine tip‐vortex stability

Summary The interaction between wind turbine wakes and atmospheric turbulence is characterised by complex dynamics. In this study, two major components of the atmospheric boundary layer dynamics have been isolated, namely, the mean velocity profile shear and the thermal stratification, to examine their impact on the near‐wake development by undertaking a series of highly resolved large‐eddy simulations. Subsequently, instantaneous flow fields are extracted from the simulations and used to conduct Fourier analysis and proper orthogonal decomposition (POD) and compute the mean kinetic energy fluxes by different POD modes to better understand the tip‐vortex instability mechanisms. Our findings indicate that shear can significantly affect the breakup of the wind turbine tip‐vortices and the shape and stable length of the wake, whereas thermal stratification seems to only have limited contribution to the spatial development of the near‐wake field. Finally, our analysis shows that the applied perturbation frequency determines the tip‐vortex breakup location as it controls the onset of the mutual inductance instability.

17 WIND ENERGY↗

DOE OSTI2023

Rigid-flexible coupling multi-body dynamics modeling of a semi-submersible floating offshore wind turbine

A 14-degree-of-freedom (14-DOF) flexible multibody dynamics model is developed and verified for a semi-submersible floating offshore wind turbine (FOWT). The model considers the coupled dynamics of the platform, tower, nacelle, blades, and mooring subjected to external wind and wave loads. The platform is simplified as a rigid body connected to the seabed by the mooring system. The tower and blade are modeled as flexible cantilever beams. The energy method is used to derive the governing equations of motion, where the kinetic energy, potential energy, and work done by external wind-wave forces are all deduced in a global coordinate system. The 5-MW baseline semi-submersible FOWT is used to verify the derived model against the results simulated from FAST developed by the US National Renewable Energy Laboratory (NREL) at two scenarios: free decay state and different wind-wave load cases. Results show that the established FOWT model can well reflect the vibration characteristics of FAST model. The application of the model to the control of platform pitch with a tuned mass damper is studied. Furthermore, the simplified model could provide a low-order method for the structural dynamics analysis and advanced vibration control design for the multi-body components of the semi-submersible FOWT in the future.

17 WIND ENERGY↗

DOE OSTI2021

Flow Redirection and Induction in Steady State (FLORIS) Wind Plant Power Production Data Sets

This dataset contains turbine- and plant-level power outputs for 252,500 cases of diverse wind plant layouts operating under a wide range of yawing and atmospheric conditions. The power outputs were computed using the Gaussian wake model in NREL's FLOw Redirection and Induction in Steady State (FLORIS) model, version 2.3.0. The 252,500 cases include 500 unique wind plants generated randomly by a specialized Plant Layout Generator (PLayGen) that samples randomized realizations of wind plant layouts from one of four canonical configurations: (i) cluster, (ii) single string, (iii) multiple string, (iv) parallel string. Other wind plant layout parameters were also randomly sampled, including the number of turbines (25-200) and the mean turbine spacing (3D-10D, where D denotes the turbine rotor diameter). For each layout, 500 different sets of atmospheric conditions were randomly sampled. These include wind speed in 0-25 m/s, wind direction in 0 deg.-360 deg., and turbulence intensity chosen from low (6%), medium (8%), and high (10%). For each atmospheric inflow scenario, the individual turbine yaw angles were randomly sampled from a one-sided truncated Gaussian on the interval 0 deg.-30 deg. oriented relative to wind inflow direction. This random data is supplemented with a collection of yaw-optimized samples where FLORIS was used to determine turbine yaw angles that maximize power production for the entire plant. To generate this data, a subset of cases were selected (50 atmospheric conditions from 50 layouts each for a total of additional 2,500 cases) for which FLORIS was re-run with wake steering control optimization. The IEA onshore reference turbine, which has a 130 m rotor diameter, a 110 m hub height, and a rated power capacity of 3.4 MW was used as the turbine for all simulations. The simulations were performed using NREL's Eagle high performance computing system in February 2021 as part of the Spatial Analysis for Wind Technology Development project funded by the U.S. Department of Energy Wind Energy Technologies Office. The data was collected, reformatted, and preprocessed for this OEDI submission in May 2023 under the Foundational AI for Wind Energy project funded by the U.S. Department of Energy Wind Energy Technologies Office. This dataset is intended to serve as a benchmark against which new artificial intelligence (AI) or machine learning (ML) tools may be tested. Baseline AI/ML methods for analyzing this dataset have been implemented, and a link to their repository containing those models has been provided. The .h5 data file structure can be found in the GitHub repository under explore_wind_plant_data_h5.ipynb.

AI↗

DOE OSTI2024

Impedance sources (Z sources) with inherent fault protection for resilient and fire-free electricity grids

Modern societies would not survive without electricity and at the same time electrical faults could cause and have caused many catastrophes—mainly deadly fires—to our societies. There are two types of electricity sources: the voltage source such as generators, charged batteries and capacitors, and the current source such as charged inductors, current-regulated rectifiers, and superconducting magnetic energy storage. An “ideal” voltage source—that is often-sought-or-intentionally engineered—generates a constant voltage irrespective of its load current, and an “ideal” current source injects a constant current irrespective of its load voltage. However, two problems exist: (1) voltage or current sources do not represent many emerging natural/renewable energy sources such as wind turbine generators, photovoltaic cells, and fuel cells, whose output voltage and current are strongly dependent on each other, and (2) a short-circuit fault to an artificially-made and controlled “ideal” voltage source or an open-circuit fault to an “ideal” current source can cause catastrophic failures of the source itself and its surrounding circuits due to large (theoretically infinite) short-circuit current or open-circuit voltage. Here we introduce an impedance source concept to represent, characterize, and model those electricity sources whose output voltage and current are strongly dependent on each other. First, we found that many electric sources with no feedback (or active) control of their output voltage and/or current are a natural impedance source with inherent fault protection at short-circuit or open-circuit faults. Second, any electrical source can be artificially controlled to mimic a natural impedance source. Finally, we show how to apply natural impedance sources and nature-mimicking artificially-controlled sources to the electricity grid—the most complex machine ever made by human beings—to realize electricity grids that are naturally stable, self-protected against electrical faults, and resilient to natural and human-made events.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

RAFT (Response Amplitudes of Floating Turbines) [SWR-22-40]

RAFT is a Python code for frequency-domain analysis of floating wind turbines. RAFT works in the frequency domain to provide efficient computations of a floating wind system's response spectra accounting for platform hydrodynamics, quasi-static mooring reactions, rotor aerodynamics, and linearized control. It can be used to calculate response amplitude operators (RAO's), power spectral densities, mean/static properties, and response metrics based on mean and root-mean-square values of each output. RAFT serves as the Level 1 model in the WEIS (Wind Energy with Integrated Servo-control) toolkit, and features an OpenMDAO wrapper.

Hall, Matthew↗

DOE OSTI2025

Final Technical Report of a Feasibility Investigation of a Hydropower Flexibility Upgrade Kit

The project studied the feasibility of a concept for a flexibility upgrade kit called h-Dynamyk to improve the flexibility of U.S. hydropower plants and assessed its potential impact on the U.S. hydropower industry. This concept addresses the growing need for grid flexibility amid rising renewable energy adoption, such as wind and solar, which often introduce intermittency. The upgrade kit is intended to address challenges posed by aging turbine designs in meeting modern grid demands for flexibility services like frequency response, voltage control, spinning reserve, and black-start capabilities. Key features of the h-Dynamyk kit include siphon turbine assemblies, medium-voltage variable frequency drives (VFDs), and smart controls integrated with plant systems to optimize operations and extend equipment life. This nine-month discovery project successfully achieved its objectives by defining a baseline design and performance metrics for the h-Dynamyk flexibility upgrade kit, analyzing this baseline, and incorporating lessons learned from this analysis into a modified set of metrics and recommendations for future design and testing, which were further guided by field site studies.

13 HYDRO ENERGY↗

DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary optimization where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The new approach to shape optimization resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗

DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing: Preprint

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The free-form boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗

DOE OSTI2025

Dynamometer Facts

The National Renewable Energy Laboratory's (NREL's) Flatirons Campus features four dynamometers that can perform research validation on wind turbine systems and ocean energy devices. These dynamometers can validate wave and water power systems over capacity ratings ranging from 1 kilowatt (kW) to 5 megawatts (MW) by replacing water with a controllable, electric motor. By combining these capabilities with other tools, such as the controllable grid interface (https://www.nrel.gov/grid/controllable-grid-interface.html), researchers can verify how their device interacts with the grid or integrates with other technologies.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Electrical Validation Testing for ORPC MHK Generator, Modification 6: ORPC SBV for MHK Generator System (CRADA Final Report)

For the U.S. Department of Energy’s (DOE) 2016 Small Business Voucher for Marine and Hydrokinetic (MHK) System, Second Round 2016, ORPC intends to work with the National Renewable Energy Laboratory (NREL) to perform dynamometer testing of the MHK generator systems and its associated controls and inverters. ORPC will provide the generator, variable frequency drives (VFD), controls, and inverter for this testing. NREL will utilize the NREL Energy Systems Integration Facility (ESIF) and dynamometer facilities at the National Wind Technology Center (NWTC) for this work. Modification 6: Additionally, NREL will conduct a feasibility study for implementing passive DC rectification at the turbine.

17 WIND ENERGY↗

DOE OSTI2026

OC6 Project Phase IV: Validation of Numerical Models for Novel Floating Offshore Wind Support Structures

The fourth phase of the Offshore Code Comparison, Collaboration, Continued, with Correlation and unCertainty (OC6) aims to assess the ability of the tools to model a novel floating wind design. The design that was selected for this project is the TetraSpar designed by Stiesdal Offshore Technologies. The platform is a unique design that features a spar like stability with a very low center of gravity, but does not require deep-water ports. This combination is achieved with a system made of two separate steel structures, a hull at the water’s surface that supports the wind turbine tower, and a keel that is suspended below the main body. This lower keel has a very high density and drives the total platform’s low center of gravity. Scaled model tests of the TetraSpar design were performed in 2018-2019 by the University of Maine. The tests were performed with 1:43 Froude scaling. The data collected in the model tests provide a detailed description of the response of the platform in various controlled and relatively well understood conditions. Comparison with these data provides a good opportunity for validation of numerical models. The OC6 Phase IV work will focus on the specific parameters used in these scaled model tests. The load cases (LC) considered in this project are as follows: LC 1.X - Equilibrium and Static Offset Tests LC 2.X - Platform Free Decays LC 3.X - Turbine Thrust (Wind Only) LC 4.X - Regular and Irregular Waves (Wave only) LC 5.X - Combined Wind and Wave Loading

17 WIND ENERGY↗

DOE OSTI2022

Machine-learning identification of the variability of mean velocity and turbulence intensity for wakes generated by onshore wind turbines: Cluster analysis of wind LiDAR measurements

Light detection and ranging (LiDAR) measurements of isolated wakes generated by wind turbines installed at an onshore wind farm are leveraged to characterize the variability of the wake mean velocity and turbulence intensity during typical operations, which encompass a breadth of atmospheric stability regimes and rotor thrust coefficients. The LiDAR measurements are clustered through the k-means algorithm, which enables identifying the most representative realizations of wind turbine wakes while avoiding the imposition of thresholds for the various wind and turbine parameters. Considering the large number of LiDAR samples collected to probe the wake velocity field, the dimensionality of the experimental dataset is reduced by projecting the LiDAR data on an intelligently truncated basis obtained with the proper orthogonal decomposition (POD). The coefficients of only five physics-informed POD modes are then injected in the k-means algorithm for clustering the LiDAR dataset. The analysis of the clustered LiDAR data and the associated supervisory control and data acquisition and meteorological data enables the study of the variability of the wake velocity deficit, wake extent, and wake-added turbulence intensity for different thrust coefficients of the turbine rotor and regimes of atmospheric stability. Furthermore, the cluster analysis of the LiDAR data allows for the identification of systematic off-design operations with a certain yaw misalignment of the turbine rotor with the mean wind direction.

17 WIND ENERGY↗

DOE OSTI2022

A Hybrid Reinforcement Learning-MPC Approach for Distribution System Critical Load Restoration: Preprint

This paper proposes a hybrid control approach for distribution system critical load restoration, combining deep reinforcement learning (RL) and model predictive control (MPC) aiming at maximizing total restored load following an extreme event. RL determines a policy for quantifying operating reserve requirements, thereby hedging against uncertainty, while MPC models grid operations incorporating RL policy actions, i.e., the reserve requirement, renewable (wind and solar) power predictions, and load demand forecasts. We formulate the reserve requirement determination problem as a sequential decision making problem based on the Markov Decision Process (MDP) and design an RL learning environment based on the OpenAI Gym framework and MPC. The RL agent reward and MPC objective function aim to maximize and monotonically increase total restored load and minimize load shedding and renewable power curtailment. The RL algorithm is trained off-line using historical forecast of renewable generation and load demand. The method is tested using a modified IEEE 13-bus distribution test feeder containing wind turbine, photovoltaic, microturbine and battery. Case studies demonstrated that the proposed method outperforms other operating reserve determination methods.

distribution system↗

DOE OSTI2022

Development of a Control Co-Design Modeling Tool for Marine Hydrokinetic Turbines: Preprint

This report describes the ongoing and planned development of the software package CT-Opt (Current/Tidal Optimization), a control co-design modeling tool for marine hydrokinetic turbines. The commercialization of these turbines has faced significant challenges due to the complex, multidisciplinary nature of their design and the extreme environmental conditions of their operation. This project aims to create a modeling tool that will enable the efficient design of robust, cost-competitive hydrokinetic turbine systems. Rather than using traditional optimization methods, CT-Opt combines multiple models across a range of fidelities to enable coupled optimization of the system design and system controller via a control co-design approach. With this method, the parameters that affect system performance are considered more comprehensively at every stage of the design process. The lowest-fidelity, frequency-domain model called by CT-Opt is RAFT (Response Amplitudes of Floating Turbines), which was originally developed by the National Renewable Energy Laboratory (NREL) to model response amplitudes of floating offshore wind turbines. The highest-fidelity, time-domain model is OpenFAST, which was developed by NREL for land-based and offshore wind turbines. As part of the CT-Opt project, new functionalities will be added to RAFT and OpenFAST to enable the accurate simulation of fixed and floating marine hydrokinetic turbines. In addition to expanding the capabilities of RAFT and OpenFAST, new midfidelity models will be developed. These models will be based on RAFT and OpenFAST and will consist of linearized, state-space models derived from the fully coupled, nonlinear OpenFAST equations and derivative function surrogate models that approximate the nonlinear system behavior. Each model will be coupled with controllers to allow control co-design methods to be applied both within models and across fidelity levels, enabling efficient system optimization.

control co-design↗

DOE OSTI2020

Power Prediction of Airborne Wind Energy Systems Using Multivariate Machine Learning

Kites can be used to harvest wind energy at higher altitudes while using only a fraction of the material required for conventional wind turbines. In this work, we present the kite system of Kyushu University and demonstrate how experimental data can be used to train machine learning regression models. The system is designed for 7 kW traction power and comprises an inflatable wing with suspended kite control unit that is either tethered to a fixed ground anchor or to a towing vehicle to produce a controlled relative flow environment. A measurement unit was attached to the kite for data acquisition. To predict the generated tether force, we collected input–output samples from a set of well-designed experimental runs to act as our labeled training data in a supervised machine learning setting. We then identified a set of key input parameters which were found to be consistent with our sensitivity analysis using Pearson input–output correlation metrics. Finally, we designed and tested the accuracy of a neural network, among other multivariate regression models. The quality metrics of our models show great promise in accurately predicting the tether force for new input/feature combinations and potentially guide new designs for optimal power generation.

17 WIND ENERGY↗