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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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DOE OSTI2024

2022 Component Innovation Awardee: Pecos Wind Power

Distributed wind energy systems supply electricity for nearby homes and businesses, often in remote and rural regions. Systems capable of capturing energy in areas with low wind speeds make it possible to deploy these clean energy systems in many geographic locations. Pecos Wind Power's 85-kilowatt (kW) horizontal-axis PW85 wind turbine shows potential to reduce the levelized cost of energy by approximately 55% when compared to typical small wind systems while achieving utility-scale capacity factors of more than 40% in areas with lower wind speeds. To maximize cost competitiveness, the Pecos Wind Power turbine needs a blade optimized for low wind speeds. Through its 2022 Competitiveness Improvement Project (CIP) award, Pecos Wind Power and partner Wetzel Wind Energy Services will model, optimize, fabricate, and validate a 14.5-meter wind turbine blade made specifically for these applications. Three prior CIP awards supported Pecos Wind Power's initial development of the PW85 turbine.

CIP↗
DOE OSTI2022

Turbine scale and siting considerations in wind plant layout optimization and implications for capacity density

Improvements in wind energy technology, reduced costs, and ambitious clean energy goals have led to projections of high wind contribution in coming years. Developing methodologies to design wind plants with a variety of siting constraints and turbine sizes helps enable high wind penetration, and gain a better understanding of how wind plants are sensitive to setback constraints and turbine design. In this paper, we present a two-step optimization method to simultaneously determine the optimal number of turbines and their locations in a wind plant domain divided into many small, discrete parcels. We present the optimized performance metrics of a wind plant optimized with different turbine sizes and ratings, and with different siting restrictions within the wind plant. Our results indicate that taller and larger turbines are more sensitive to increasing siting constraints. We also compare the optimal wind plant layouts and performance for wind plants optimized for minimum COE and maximum profit. Wind plants optimized for profit had 130%-190% of the capacity of plants optimized for COE, which demonstrates that the optimal results are greatly affected by the objective function, which should be carefully considered. Finally, in this paper we demonstrate the effect of increasing siting constraints on wind plant capacity density, and how the results change when different land areas are used to calculate capacity density. When using the entire wind plant boundary area to determine capacity density, increasing siting constraints decreases the capacity density. However, when we only use the available area (the area left after removing the siting constraints) to calculate the capacity density, increasing the siting constraints increases capacity density. This is a critical insight because of how capacity density is typically defined and used in research, and has important implications for assessment of technical potential and capacity expansion modeling, as well as future wind deployment potential.

17 WIND ENERGY↗
DOE OSTI2022

Wind Turbine Gearbox Failure Detection Through Cumulative Sum of Multivariate Time Series Data

The wind energy industry is continuously improving their operational and maintenance practice for reducing the levelized costs of energy. Anticipating failures in wind turbines enables early warnings and timely intervention, so that the costly corrective maintenance can be prevented to the largest extent possible. It also avoids production loss owing to prolonged unavailability. One critical element allowing early warning is the ability to accumulate small-magnitude symptoms resulting from the gradual degradation of wind turbine systems. Inspired by the cumulative sum control chart method, this study reports the development of a wind turbine failure detection method with such early warning capability. Specifically, the following key questions are addressed: what fault signals to accumulate, how long to accumulate, what offset to use, and how to set the alarm-triggering control limit. We apply the proposed approach to 2 years’ worth of Supervisory Control and Data Acquisition data recorded from five wind turbines. We focus our analysis on gearbox failure detection, in which the proposed approach demonstrates its ability to anticipate failure events with a good lead time.

17 WIND ENERGY↗
DOE OSTI2025

Load assessment of a wind farm considering negative and positive yaw misalignment for wake steering

Wake steering strategies are employed to increase the overall power production of wind farms by deflecting wakes of upstream turbines away from downstream ones. The gain in net power comes at the expense of increased fatigue loads experienced by downstream turbines. In this work we investigate performance and fatigue loading characteristics of a small farm consisting of five aligned International Energy Agency Wind Technology Collaboration Programme 15 MW wind turbines. A parametric study is performed where, for every wind direction from −20 to 20°, the yaw misalignment angle varies from −25 to 25°. This setup allows us to investigate asymmetries and identify optimal conditions for a given wind direction. In general, we find that positive yaw configurations are preferred and that yaw configurations that result in attractive power differences when compared to a baseline no-yaw scenario (25 %) come with significant increase in fatigue loading (we use the standard deviation and damage-equivalent load (DEL) of the blade-root, low-speed shaft, and tower-base moments as proxies for fatigue load). We find that for any given positive wind inflow angle, yaw angles between −2.5 and 15° yield power differences of 10 %–20 % over a no-yaw baseline, and positive yaw is preferred because of lower fatigue loading. For any given negative wind inflow angles, positive yaw also results in lower magnitudes of standard deviation and DEL for the channels investigated. A small power loss of up to 2 % is observed for some positive yaw angles under negative wind directions (as compared to symmetric negative yaw and positive wind cases), but improvements in terms of loads exceed 25 % and may be enough to justify a positive yaw configuration under negative winds as well. We show that such behavior can be explained by partial waking and the direction of the rotation of the rotor.

17 WIND ENERGY↗
DOE OSTI2024

Advanced Permanent Magnet Generator Topologies Using Multimaterial Shape Optimization and 3D Printing: Preprint

A vast majority of utility-scale wind turbine generators in the United States are dependent on foreign- sourced rare-earth permanent magnets that are vulnerable to supply chain uncertainties. Many small wind original equipment manufacturers are motivated to pursue continuous improvements to the generator design to lower the material and production costs and improve performance by lowering cogging torque and increasing the efficiency. Traditional design and manufacturing offer limited opportunities. In this work, we demonstrate advanced design approaches for a 15-kW baseline wind turbine generator by making use of recent progress in three-dimensional (3D) printing of polymer- bonded magnets and, electrical and structural steel. We explore three methods of magnet parametrization using Bezier curves resulting in symmetric, asymmetric and multimaterial magnet designs. We employ a multiphysics approach combining parametric computer-aided design modeling, finite- element analysis and targeted sampling to identify novel designs with more opportunities for reducing rare-earth material, improving efficiency and minimizing cogging torque. The results show that asymmetric-pole design and multimaterial-pole designs offer a greater opportunity to minimize rare-earth magnet materials by up to 35% with similar performance as the baseline generator, suggesting newer opportunities with design freedom beyond traditional limits of symmetry and as allowed by 3D printing.

Bezier curves↗
NASA NTRS1983

Progress in Wind-Wheel Turbines

New wind turbine offers important advantages over conventional propeller wind turbines according to theoretical studies and tests of small working models. Project results are described in final report now available. Windwheel turbines consists of bladed wheel, main housing, two forward ducts (front concentrators), two side ducts (side concentrators) and base to support and elevate housing.

Frost, W.↗
DOE OSTI2024

ExaWind: Open‐source CFD for hybrid‐RANS/LES geometry‐resolved wind turbine simulations in atmospheric flows

Abstract Predictive high‐fidelity modeling of wind turbines with computational fluid dynamics, wherein turbine geometry is resolved in an atmospheric boundary layer, is important to understanding complex flow accounting for design strategies and operational phenomena such as blade erosion, pitch‐control, stall/vortex‐induced vibrations, and aftermarket add‐ons. The biggest challenge with high‐fidelity modeling is the realization of numerical algorithms that can capture the relevant physics in detail through effective use of high‐performance computing. For modern supercomputers, that means relying on GPUs for acceleration. In this paper, we present ExaWind, a GPU‐enabled open‐source incompressible‐flow hybrid‐computational fluid dynamics framework, comprising the near‐body unstructured grid solver Nalu‐Wind, and the off‐body block‐structured‐grid solver AMR‐Wind, which are coupled using the Topology Independent Overset Grid Assembler. Turbine simulations employ either a pure Reynolds‐averaged Navier–Stokes turbulence model or hybrid turbulence modeling wherein Reynolds‐averaged Navier–Stokes is used for near‐body flow and large eddy simulation is used for off‐body flow. Being two‐way coupled through overset grids, the two solvers enable simulation of flows across a huge range of length scales, for example, 10 orders of magnitude going from O(μm) boundary layers along the blades to O(10 km) across a wind farm. In this paper, we describe the numerical algorithms for geometry‐resolved turbine simulations in atmospheric boundary layers using ExaWind. We present verification studies using canonical flow problems. Validation studies are presented using megawatt‐scale turbines established in literature. Additionally presented are demonstration simulations of a small wind farm under atmospheric inflow with different stability states.

17 WIND ENERGY↗
DOE OSTI2025

An accumulation method for early fault warning and its application to wind turbine systems

Unexpected failures in engineering systems lead to expensive maintenance actions and should be avoided if at all possible. This is particularly true for wind turbine systems for which unexpected failures not only demand costly repairs but also cause long downtime. Motivated by this need, we present an accumulation method for fault early warning and failure anticipation. Here, our research shows that one critical element allowing the ability of early warning is to accumulate the small-magnitude symptoms resulting from gradual changes in an engineering system like wind turbines. Our idea is inspired by the classical cumulative sum method, or CUSUM, but we have to redesign the accumulation mechanism for tackling unique challenges in wind turbine data. The new accumulation method is applied to two real wind turbine datasets, one with gearbox failures and the other with generator failures, and demonstrates superior performance as compared with CUSUM.

17 WIND ENERGY↗
DOE OSTI2023

2022 Small Turbine Certification Awardee: Ryse Energy LLC - Americas

To meet the growing demands of the distributed wind market and comply with current U.S. standards, Ryse Energy LLC-Americas (Ryse Energy, formerly Primus Wind Power) plans to update all six products in its AIR Range family of micro wind turbines. A new, more cost-effective circuit board will be paired with other hardware upgrades, advanced control algorithms, and a Bluetooth function that allows users to more easily program and control the turbine. This Competitiveness Improvement Project (CIP) award will fund certification testing of the new circuit board to make sure it meets American National Standards Institute/American Clean Power Association (ANSI/ACP) and UL Federal Communications Commission (FCC) safety and quality standards. Primus Wind Power developed the prototype for the new circuit board with an earlier round of CIP funding, and Primus has received CIP awards supporting other certification and optimization projects.

CIP↗
DOE OSTI2020

Sensitivity of Wind Turbine Array Downstream Effects to the Parameterization Used in WRF

The Weather Research and Forecasting (WRF) Model has been extensively used for wind energy applications, and current releases include a scheme that can be applied to examine the effects of wind turbine arrays on the atmospheric flow and electricity generation from wind turbines. Herein we present a high-resolution simulation using two different wind farm parameterizations: 1) the “Fitch” parameterization that is included in WRF releases and 2) the recently developed Explicit Wake Parameterization (EWP) scheme. We compare the schemes using a single yearlong simulation for a domain centered on the highest density of current turbine deployments in the contiguous United States (Iowa). Pairwise analyses are applied to diagnose the downstream wake effects and impact of wind turbine arrays on near-surface climate conditions. On average, use of the EWP scheme results in small-magnitude wake effects within wind farm arrays and faster recovery of full WT array wakes. This in turn leads to smaller impacts on near-surface climate variables and reduced array–array interactions, which at a systemwide scale lead to summertime capacity factors (i.e., the electrical power produced relative to nameplate installed capacity) that are 2%–3% higher than those from the more commonly applied Fitch parameterization. It is currently not possible to make recommendations with regard to which wind farm parameterization exhibits higher fidelity or to draw inferences with regard to whether the relative performance may vary with prevailing climate conditions and/or wind turbine deployment configuration. However, the sensitivities documented herein to the wind farm parameterization are of sufficient magnitude to potentially influence wind turbine array siting decisions. Thus, our research findings imply high value in undertaking combined long-term high-fidelity observational studies in support of model validation and verification.

17 WIND ENERGY↗
DOE OSTI2023

Impact of Aerodynamic Modeling Assumptions on Flutter Speeds of Vertical-Axis Wind Turbines

Theodorsen’s unsteady aerodynamic theory has been used extensively in flutter speed prediction of wind turbine blades. In this study, three key assumptions of Theodorsen theory (thin airfoil, flat wake, and small angle of attack) have been revisited, and all three assumptions have been addressed in combination to obtain new lift and moment equations that are subsequently applied in flutter calculations for full-scale vertical-axis wind turbine (VAWT) rotors, not just of an individual airfoil or blade. Furthermore, edgewise aerodynamics terms are added to the lift and moment equations to include their effects on flutter speeds. The newly obtained equations were implemented in the OWENS (Offshore Wind ENergy Simulation) toolkit, which is an FEM (Finite Element Method)-based toolkit for aeroelastic analysis of VAWTs. The effect of modifying each of these assumptions has been studied for the flutter RPM prediction of three primary modes of flutter of VAWTs: propeller, butterfly, and tower modes. For the land-based case, the most change was observed for the flutter RPM of the propeller mode, with a maximum increase of 2.62% for the two-bladed UTD 5 MW VAWT case. For the floating offshore case, the primary flutter modes (tower and platform pitch) were not significantly affected.

Engineering↗
NASA NTRS1979

Evaluation of turbo-propulsion simulators as a testing technique for fighter aircraft

Ames Research Center has under way a program to develop the technology for using turbine-powered jet engine simulators as a test technique for simulating installed jet engine characteristics in small-scale wind-tunnel models of complete VSTOL fighter configurations. The program consists of three key elements: (1) static testing SN003 prototype turbine engine simulator (MAPS), (2) the development of the Propulsion Simulator Calibration Laboratory at Ames, and (3) the design, fabrication, and testing of a twin-engine 'closely coupled' V/STOL fighter wind-tunnel model. The model will use the Compact Multi-mission Propulsion Simulator (CMAPS) and will also be tested in flow-through and jet-effects modes to assess the effect of simultaneous inlet and nozzle flow simulation. This paper includes a description of the planned effort and anticipated future tasks.

Bailey, R. O.↗
DOE OSTI2022

Stochastic agent-based model for predicting turbine-scale raptor movements during updraft-subsidized directional flights

Rapid expansion of wind energy development across the world has highlighted the need to better understand turbine-caused avian mortality. The risk to golden eagles (Aquila chrysaetos) is of particular concern due to their small population size and conservation status. Golden eagles subsidize their flight in part by soaring in orographic updrafts, which can place them in conflict with wind turbines utilizing the same low-altitude wind resource. Understanding the behavior of soaring raptors in varying atmospheric conditions can therefore be relevant to predicting and mitigating their risk of collision. We present a predictive movement model that simulates individual paths of golden eagles during directional flight (such as migration) that is subsidized by orographic updraft. We modeled eagles in a 50 km by 50 km study area in Wyoming containing three wind power plants with documented golden eagle collisions with turbines. The movement model is applicable to any region where ground elevation is known at turbine scale (50 m) and wind conditions are known at facility scale (3 km). For a given set of atmospheric conditions, the model simulates movements of thousands of orographic soaring eagles to produce a density map quantifying the relative probability of eagle presence. We validated the simulated tracks with GPS telemetry data showing four directional tracks made by golden eagles transiting through the area in 2019 and 2020. For each eagle track, validation was performed using the ratio of the model-simulated eagle presence likelihood with uniform eagle presence and the presence computed using directed random-walk movements. We found that the predictive performance of the model was significantly better (likelihood ratio 1) for low-altitude movements than high-altitude movements that can involve thermal-soaring. We employed the model to produce seasonal presence maps for migrating golden eagles. We found significant turbine-level variations in eagle presence between northerly and southerly migration routes through the study area. Overall, the proposed model offers a generalizable, probabilistic, and predictive tool to assist wind energy developers, ecologists, wildlife managers, and industry consultants in estimating the potential for conflict between soaring birds and wind turbines, thereby reducing the need for site-specific data on golden eagle movements.

17 WIND ENERGY↗
DOE OSTI2021

SSRS (Stochastic Soaring Raptor Simulator)

SSRS (Stochastic Soaring Raptor Simulator) is a generalizable, probabilistic, and predictive tool for wind energy developers, ecologists, wildlife managers and industry consultants to estimate the potential for soaring raptors to interact with operating wind turbines, without the need for site-specific data collection. Rapid expansion of wind energy development across the world has exposed the risk of turbine collisions for birds and bats. The risk to obligate soaring raptors such as golden eagles is of particular concern due to their small population and influence on ecological balance. Golden eagles rely heavily on updrafts to subsidize their flight, putting them in direct conflict with operational wind turbines that utilize the same wind resource. Understanding the behavior of soaring raptors with varying atmospheric conditions is crucial for predicting and mitigating the risk of turbine collision. This software contains a predictive movement model that simulates individual flight paths of golden eagles during updraft-subsidized long-distance flight, including migration. For a given set of atmospheric conditions, the model simulates thousands of eagles at turbine-scale spatial resolution (50m) to produce a relative presence density map. The simulated eagles rely on updrafts to pursue uninterrupted directional flight with minimal energy expenditure, following fluid-flow principles. The simulator includes a stochastic model of eagle behavior and a systematic method of accounting for spatiotemporal variations in atmospheric conditions. This framework only requires publicly available atmospheric data to estimate orographic and thermal updrafts, ensuring general usability.

Sandhu, Rimple↗
DOE OSTI2025

OpenFAST simulation of floating wind turbines with large heading change

Previous versions of OpenFAST, the physics-based wind turbine engineering and design tool developed by the National Renewable Energy Laboratory, were limited to small rotations of the floating platform. This prevented OpenFAST from being used to simulate important events, such as the loss of a mooring line, or specific floater concepts that might experience large platform yaw motion. To overcome this limitation, we modify the structural dynamics and hydrodynamics modules of OpenFAST to allow unrestricted platform yaw motion. We apply the improved version of OpenFAST to simulate the drifting of a floating wind turbine system after the loss of a mooring line. The results, including both global motion and the internal structural loads at selected locations, appear credible and consistent with expectations.

17 WIND ENERGY↗
NASA NTRS1981

Dynamics of an experimental two bladed horizontal axis wind turbine with blade cyclic pitch variation

The turbine under study incorporates the combination of two features: the application of blade cyclic pitch variation; and the use of yaw angle control for rotor speed and torque regulation. Due to its emasculation by passive cyclic pitch variation the rotor can be rapidly yawed without encountering gyroscopic and aerodynamic hub moments and without noticeable out of plane excursions. The two bladed upwind rotor is vane stabilized and of very simple and rugged design. The principle was first checked out with a small scale wind tunnel model and then tested in the atmosphere with a 7.6 meter diameter experimental fully instrumented wind turbine driving a 3 phase alternator. The test results are summarized with respect to structural dynamics and yaw dynamics.

Hotenemser, K. H.↗
DOE OSTI2023

Blockage and speedup in the proximity of an onshore wind farm: A scanning wind LiDAR experiment

To maximize the profitability of wind power plants, wind farms are often characterized by high wind turbine density leading to operations with reduced turbine spacing. As a consequence, the overall wind farm power capture is hindered by complex flow features associated with flow modifications induced by the various wind turbine rotors. In addition to the generation of wakes, the velocity of the incoming wind field can reduce due to the increased pressure in the proximity of a single turbine rotor (named induction); a similar effect occurs at the wind-farm level (global blockage), which can have a noticeable impact on power production. On the other hand, intra-wind-farm regions featuring increased velocity compared to the freestream (speedups) have also been observed, which can be a source for a potential power boost. To quantify these rotor-induced effects on the incoming wind velocity field, three profiling LiDARs and one scanning wind LiDAR were deployed both before and after the construction of an onshore wind turbine array. The different wind conditions are classified according to the ambient turbulence intensity and streamwise/spanwise spacing among wind turbines. The analysis of the mean velocity field reveals enhanced induction and speedup under stably stratified atmospheric conditions. Additionally, a reduced horizontal area between adjacent turbines has a small impact on the induction zone but increases significantly the speedup between adjacent rotors.

17 WIND ENERGY↗
DOE OSTI2024

Advanced multimaterial shape optimization methods as applied to advanced manufacturing of wind turbine generators

Abstract Currently, many utility‐scale wind turbine generator original equipment manufacturers are dependent on imported rare earth permanent magnets, which are susceptible to market risks from cost instability. To lower the production costs of these generators and stay competitive in the market, several small wind manufacturers are pursuing continuous improvements to both generator design and manufacturing. However, traditional design and manufacturing methods have yielded marginal improvements in wind power performance. This work presents novel methods to redesign a baseline 15‐kW wind turbine generator with reduced rare‐earth permanent magnets by leveraging cutting‐edge three‐dimensional (3D) printed polymer‐bonded permanent magnets and steel. Symmetric, asymmetric, and multimaterial‐magnet parametrization methods are introduced for shape optimization. We extend the symmetric and asymmetric methods to the back iron in the stator to further investigate the impact and opportunities for performance improvements with lesser active materials. We employ a design‐of‐experiments approach with parametric computer‐aided design for shape generation and evaluate different designs by magneto‐thermal modeling and finite‐element analysis. We use adaptive sampling technique to identify better performing designs with lesser magnet mass, higher efficiency, and lower cogging torque when compared with the baseline generator. Asymmetric pole designs resulted in a magnet mass in the range of 4.77–5.37 kg, which was 27%–35% lighter than the baseline generator, suggesting that a new design freedom exists that can be enabled by advanced manufacturing, such as 3D printing. Shaping the back iron in the stator resulted in material savings in electrical steel of up to 14.62 kg, which was 20% lighter than the baseline stator. We conducted a structural analysis to evaluate an optimized asymmetric rotor design from the point of view of mechanical integrity and air‐gap stiffness. The magnetically optimal shape profile was shown as having a positive impact on the radial stiffness, and an optimal solution was discovered to reduce the structural mass by nearly 30 kg, which was 29% lighter than the baseline.

17 WIND ENERGY↗