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A wind rotor is disclosed that produces energy optimally for a given thrust overturning moment. By designing rotors with suboptimal aerodynamic efficiency, they can have optimal thrust performance, which will reduce the substructure cost and/or enable greater energy capture for a given substructure.
Abstract. Wind turbines are complex multidisciplinary systems that are challenging to design because of the tightly coupled interactions between different subsystems. Computational modeling attempts to resolve these couplings so we can efficiently explore new wind turbine systems early in the design process. Low-fidelity models are computationally efficient but make assumptions and simplifications that limit the accuracy of design studies, whereas high-fidelity models capture more of the actual physics but with increased computational cost. This paper details the use of multifidelity methods for optimizing wind turbine designs by using information from both low- and high-fidelity models to find an optimal solution at reduced cost. Specifically, a trust-region approach is used with a novel corrective function built from a nonlinear surrogate model. We find that for a diverse set of design problems – with examples given in rotor blade geometry design, wind turbine controller design, and wind power plant layout optimization – the multifidelity method finds the optimal design using 38 %–58 % of the computational cost of the high-fidelity-only optimization. The success of the multifidelity method in disparate applications suggests that it could be more broadly applied to other wind energy or otherwise generic applications.
Large wind turbines yield more energy but demand careful aeroelastic blade design. Coupled multiphysics design strategies can reduce wind energy costs by exploiting fluid-structure interactions. This work presents the first high-fidelity aerostructural optimization study of a large wind turbine rotor. We use blade-resolved fluid dynamics and structural solvers in a monolithic gradient-based optimization framework to explore steady-state torque and blade mass tradeoffs. The coupled-adjoint approach computes gradients efficiently, enabling the optimization of over 100 structural and geometric parameters simultaneously. Our optimization study modifies a DTU 10 MW benchmark with a simplified structure and isotropic material properties. The tightly coupled optimizations increase torque by 14% while reducing rotor mass by 9% or reduce blade mass by 27% while maintaining torque. Blade-resolved models provide greater design freedom, enabling 5% higher mass reductions than conventional parameterizations at equal torque. This framework paves the way for more detailed high-fidelity optimization studies to complement conventional design approaches.
The Mod-0 100 kW experimental wind turbine was tested to determine the effects of yaw on rotor power, blade loads and teeter response. The wind turbine was operated for extended periods at yaw angles up to 49 deg to define average or mean response to yaw. It was determined that the effect of yaw on rotor power can be approximated by the cube of the velocity normal to the rotor disc as long as the yaw angle is less than 30 deg. Blade bending loads were relatively unaffected by yaw, but teeter angle increased with wind speed as the magnitude of the yaw angle exceeded 30 deg indicating a potential for teeter stop impacts at large yaw angles. No other adverse effects due to yaw were noted during the tests.
Advances in wind-plant control have often focused on more effectively balancing power between neighboring turbines. Wake steering is one such method that provides control-based improvements in a quasi-static way, but this does little to fundamentally change the wake recovery process, and thus, it has limited potential. This study investigates use of another control paradigm known as dynamic wake control (DWC) to excite the mutual inductance instability between adjacent tip-vortex structures, thereby accelerating the breakdown of the structures. The current work carries this approach beyond the hypothetical by applying the excitation via turbine control vectors that already exist on all modern wind turbines: blade pitch and rotor speed control. The investigation leverages a free-vortex wake method (FVWM) that allows a thorough exploration of relevant frequencies and amplitudes of harmonic forcing for each control vector (as well as the phase difference between the vectors for a tandem configuration) while still capturing the essential tip-vortex dynamics. The FVWM output feeds into a Fourier stability analysis working to pinpoint candidate DWC strategies suggesting fastest wake recovery. Near-wake length reductions of >80% are demonstrated, although without considering inflow turbulence. Analysis is provided to interpret these predictions considering the presence of turbulence in a real atmospheric inflow.
Abstract. This paper provides a summary of the work done within Phase III of the Offshore Code Comparison Collaboration, Continued, with Correlation and unCertainty (OC6) project, under the International Energy Agency Wind Technology Collaboration Programme Task 30. This phase focused on validating the aerodynamic loading on a wind turbine rotor undergoing large motion caused by a floating support structure. Numerical models of the Technical University of Denmark 10 MW reference wind turbine were validated using measurement data from a 1:75 scale test performed during the UNsteady Aerodynamics for FLOating Wind (UNAFLOW) project and a follow-on experimental campaign, both performed at the Politecnico di Milano wind tunnel. Validation of the models was performed by comparing the loads for steady (fixed platform) and unsteady (harmonic motion of the platform) wind conditions. For the unsteady wind conditions, the platform was forced to oscillate in the surge and pitch directions under several frequencies and amplitudes. These oscillations result in a wind variation that impacts the rotor loads (e.g., thrust and torque). For the conditions studied in these tests, the system aerodynamic response was almost steady. Only a small hysteresis in airfoil performance undergoing angle of attack variations in attached flow was observed. During the experiments, the rotor speed and blade pitch angle were held constant. However, in real wind turbine operating conditions, the surge and pitch variations would result in rotor speed variations and/or blade pitch actuations, depending on the wind turbine controller region that the system is operating. Additional simulations with these control parameters were conducted to verify the fidelity of different models. Participant results showed, in general, a good agreement with the experimental measurements and the need to account for dynamic inflow when there are changes in the flow conditions due to the rotor speed variations or blade pitch actuations in response to surge and pitch motion. Numerical models not accounting for dynamic inflow effects predicted rotor loads that were 9 % lower in amplitude during rotor speed variations and 18 % higher in amplitude during blade pitch actuations.
Wind energy is recognized worldwide as cost-effective and environmentally friendly and is among the fastest-growing sources of electrical energy. To further decrease the cost of wind energy, wind turbines are being designed at ever larger scales, which is challenging due to greater structural loads and deflections. Large-scale systems such as modern wind turbines increasingly require a control co-design approach, whereby the system design and control design are performed in a more integrated fashion. We overview a two-bladed downwind morphing rotor concept that is expected to lower the cost of energy at wind turbine sizes beyond 13 megawatts (MW) compared with continued upscaling of traditional three-bladed upwind rotor designs. We describe an aero-structural-control co-design process that we have used in designing such extreme-scale wind turbines, and we discuss how we were able to achieve a 25% reduction in levelized cost of energy for our final turbine design compared to a conventional upwind three-bladed rotor design.
A rotor loads computer program was used to define the steady state and cyclic loads acting on 60 ft long metal blades designed for the ERDA/NASA 100 kW wind turbine. Blade load and stress analysis used to support the structural design are presented. For the loading conditions examined, the metal blades are structurally adequate for use, within the normal operating range, as part of the wind turbine system.
In mid-1979, NASA contracted with Kaman Aerospace Corporation for the design, manufacture, and ground testing of two 100 foot composite rotor blades intended for operation on the Mod-1 wind turbine. The Mod-1 blades have been completed and are currently stored at the Kaman facility. The design, tooling, fabrication, and testing phases which have been carried out to date, as well as testing still planned are described. Discussed are differences from the 150 foot blade which were introduced for cost and manufacturing improvement purposes. Also included is a description of the lightning protection system installed in the blades, and its development program. Actual costs and manhours expended for Blade No. 2 are provided as a base, along with a projection of costs for the blade in production. Finally, cost drivers are identified relative to future designs.
A two-bladed downwind turbine system was upscaled from 13.2 MW to 25 MW by redesigning aerodynamics, structures, and controls. In particular, three 25-MW rotors were developed, and the final version is a fully redesigned model of the original rotor. Despite their radically large sizes, it was found that these 25-MW turbine rotors satisfy this limited set of structural design drivers at the rated condition and that larger blade lengths are possible with conewise load-alignment. In addition, flapwise morphing (varying the cone angle with a wind-speed schedule) was investigated to minimize mean and fluctuating blade root bending loads using steady inflow proxies for the maximum and lifetime damage equivalent load moments. Compared to the fixed coned rotor case, morphing can provide an Annual Energy Production (AEP) increase of 6%, and the maximum blade root flapwise bending moment increases 21% (still under the constraint, i.e., 10% of the ultimate moments) as a trade-off. The resulting series of 25-MW rotors can be a valuable baseline for further development and assessment of ultra-large-scale wind turbines.
An analytical model is proposed for calculating the rotor performance and aerodynamic blade forces for Darrieus wind turbines with curved blades. The method of analysis uses a multiple-streamtube model, divided into two parts: one modeling the upstream half-cycle of the rotor and the other, the downstream half-cycle. The upwind and downwind components of the induced velocities at each level of the rotor were obtained using the principle of two actuator disks in tandem. Variation of the induced velocities in the two parts of the rotor produces larger forces in the upstream zone and smaller forces in the downstream zone. Comparisons of the overall rotor performance with previous methods and field test data show the important improvement obtained with the present model. The calculations were made using the computer code CARDAA developed at IREQ. The double-multiple streamtube model presented has two major advantages: it requires a much shorter computer time than the three-dimensional vortex model and is more accurate than multiple-streamtube model in predicting the aerodynamic blade loads.
FAST.Farm is a new midfidelity engineering tool developed by the National Renewable Energy Laboratory targeted at accurately and efficiently predicting wind turbine power production and structural loading in wind farm settings, including wake interactions between turbines. FAST.Farm is based on some of the principles of the Dynamic Wake Meandering model—including passive tracer modeling of wake meandering—but addresses many of the limitations of previous Dynamic Wake Meandering (DWM) implementations. Previous FAST.Farm verification studies show the similarities and differences between FAST.Farm and large-eddy simulations for rigid and flexible turbines. In this validation study, FAST.Farm turbine responses are compared to multiturbine measurements from a subset of a full-scale wind farm. FAST.Farm predictions of turbine generator power, rotor speed, and blade pitch for five-turbine simulations are compared to supervisory control and data acquisition results. Results reveal that FAST.Farm generator power mean and standard deviation results reasonably match measured data for upstream and downstream turbines, as well as the mean rotor speed and blade pitch above rated wind speeds. However, FAST.Farm generally underpredicts the mean rotor speed and overpredicts the mean blade pitch below rated operation. These errors are likely related to inaccuracies in the generic controller simulated. Despite controller differences, FAST.Farm predicts the same overall relative rotor power trends for all waked turbines at all wind speeds.
Wind-driven turbine generators are being evaluated as an alternative source of electric energy. Areas of favorable location for the wind-driven turbines (high wind density) coincide with areas of high incidence of thunderstorm activity. These locations, coupled with the 30-m or larger diameter rotor blades, make the wind-driven turbine blades probable terminations for lightning strikes. Several candidate systems of lightning accommodation for composite-structural-material blades were designed and their effectiveness evaluated by submitting the systems to simulated lightning strikes. The test data were analyzed and system design were reviewed on the basis of the analysis.
A series of tests is currently being conducted using the DOE/NASA 100 kW Experimental Wind Turbine with a two-bladed, teetered rotor with 30% span tip control. Preliminary evaluation test results indicates that the teetered rotor significantly decreases loads on the yaw drive mechanism and reduces blade cyclic flapwise bending moments by 25% at the 20% span location when compared to rigid hub rotor. The teetered hub performed well but did impact the teeter stops on occasion as wind speed and/or direction varied rapidly. The tip-controlled rotor performed satisfactorily with some expected loss of control when compared to the full span pitchable blade. The performance results indicate that a review of techniques used to calculate rotor power is in order.
The Aeroacoustic Assessment project aims to quantify changes in aeroacoustic noise generation by a utility scale wind turbine operating under imposed yaw offsets common for wake steering and wind plant control strategies. Active plant control utilizing wake deflection control strategies have been shown experimentally and computationally to reliably produce 1-2% of additional annual energy production (AEP) without significant changes in turbine structural loads, the potential impact on aeroacoustic emissions has yet to be quantified or completely understood. Yawed operation of a wind turbine changes the three-dimensional aerodynamic interaction between the rotor blades and the incoming atmospheric flow, leading to changes in noise generation. This work quantifies the extent to which active control induces additional aeroacoustic emissions from additional separation and other flow interaction dynamic effects. Given public concerns about wind turbine noise and the need for observational data required for regulators to establish noise restrictions, we must understand potential acoustic emissions resulting from active control prior to commercial deployment and the development of practical noise reduction methods and technologies. The work outlined in this report details the new aeroacoustic measurement capability developed at NREL and its application to making full-field observations of noise from a utility-scale wind turbine. Preliminary noise modeling with the aeroacoustics module in OpenFAST helped to establish the design of the experiment, specifically targeting the noise observed at observers distributed around the DOE-owned GE 1.5 MW wind turbine. Low-frequency and infrasound measurement capability implemented in this project establish an operational baseline for the wind turbine, setting the stage for future control, rotor blade, and turbine design research.
The performance and loading of a large wind rotor, 38.4 m in diameter and composed of two low-cost steel spar blades were examined. Two blades were fabricated at Lewis Research Center and successfully operated on the Mod-0 wind turbine at Plum Brook. The blades were operated on a tower on which the natural bending frequency were altered by placing the tower on a leaf-spring apparatus. It was found that neither blade performance nor loading were affected significantly by this tower softening technique. Rotor performance exceeded prediction while blade loads were found to be in reasonable agreement with those predicted. Seventy-five hours of operation over a five month period resulted in no deterioration in the blade.
Development and construction of three 50 m rotor blades for a 3 MW wind turbine are described. A hybrid concept was chosen, i.e., a load carrying inflexible steel spar and a glass fiber reinforced plastic skin. A test blade was constructed and static loading tests, dynamic vibration tests and fatigue tests on critical welds as well as at the connection between spar and blade skin were performed. All test results show good accordance with calculated values, and were taken into consideration during the construction of two rotor blades.
To enable the fast growth of the floating offshore wind industry, simulation models must be validated with experimental data. Floating wind model-scale experiments in wind–wave facilities have been performed over the last two decades with varying levels of fidelity and limitations. However, the turbine controls in these experiments have considered only limited control strategies and implementations. To allow for control co-design, this research focuses on implementing and experimentally validating more advanced turbine control actions and strategies in a wind–wave basin for a 1:70-scale model of the International Energy Agency’s wind 15 MW reference wind turbine. The control strategies analyzed include torque control, collective pitch control, and transition region control (setpoint smoothing). Our experimental and numerical results include the effects of varying rotor speeds, blade pitches, and wind environments on the turbine thrust and torque. Numerical models from three different software tools are presented and compared to the experimental results. Their ability to effectively represent the aero-dynamic response of the wind turbine to the control actions is successfully validated. Finally, turbine controller tuning parameters based on the derivatives of thrust and torque are derived to allow for improved offshore wind turbine dynamics and to validate the ability of modeling tools to model the dynamics of floating offshore wind turbines with control co-design.