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DOE OSTI2022

Invertible Neural Networks for Aerodynamic Design of Wind Turbine Blades

The state-of-the-practice methods for aerodynamic design of wind turbine blads use linearized blade element momentum theory (BEM) to optimize the twist and chord profiles from a pre-selected set of 2D airfoil shapes. In this work, we apply invertible neural network (INN) tools to enable the rapid inverse aerodynamic design of wind turbine blades including component airfoils. The INN is trained on data obtained through the use of robust automated mesh generation and the HAMSTR computational fluid dynamics solver with advanced turbulence and transition models validated for turbine applications. Our design technique is a significant improvement over the state-of-the-practice linearized blade element momentum (BEM) techniques in capturing 3D nonlinear aerodynamic effects that are critical for optimal design of the rotors. This is made possible by developing sparse, invertible neural networks (INNs) for inverse design and optimization that realize a 100x cost reduction compared to adjoint-based computational fluid dynamics (CFD) approaches, while enabling increased robustness of the final design. We demonstrate the INN tool for design of a section of the NREL 5-MW blade. All generated shapes satisfy the desired aerodynamic characteristics, demonstrating the success of the INN approach for inverse design of wind turbine blades.

aerodynamic design↗

NASA NTRS1996

Effects of Shrouded Stator Cavity Flows on Multistage Axial Compressor Aerodynamic Performance

Experiments were performed on a low-speed multistage axial-flow compressor to assess the effects of shrouded stator cavity flows on aerodynamic performance. Five configurations, which involved changes in seal-tooth leakage rates and/or elimination of the shrouded stator cavities, were tested. Data collected enabled differences in overall individual stage and the third stage blade element performance parameters to be compared. The results show conclusively that seal-tooth leakage ran have a large impact on compressor aerodynamic performance while the presence of the shrouded stator cavities alone seemed to have little influence. Overall performance data revealed that for every 1% increase in the seal-tooth clearance to blade-height ratio the pressure rise dropped up to 3% while efficiency was reduced by 1 to 1.5 points. These observed efficiency penalty slopes are comparable to those commonly reported for rotor and cantilevered stator tip clearance variations. Therefore, it appears that in order to correctly predict overall performance it is equally important to account for the effects of seal-tooth leakage as it is to include the influence of tip clearance flows. Third stage blade element performance data suggested that the performance degradation observed when leakage was increased was brought about in two distinct ways. First, increasing seal-tooth leakage directly spoiled the near hub performance of the stator row in which leakage occurred. Second, the altered stator exit now conditions caused by increased leakage impaired the performance of the next downstream stage by decreasing the work input of the downstream rotor and increasing total pressure loss of the downstream stator. These trends caused downstream stages to progressively perform worse. Other measurements were acquired to determine spatial and temporal flow field variations within the up-and-downstream shrouded stator cavities. Flow within the cavities involved low momentum fluid traveling primarily in the circumferential direction at about 40% of the hub wheel speed. Measurements indicated that the flow within both cavities was much more complex than first envisioned. A vortical flow structure in the meridional plane, similar to a driven cavity, existed within the upstream cavity Furthermore, other spatial and temporal variations in Row properties existed. the most prominent being caused by the upstream potential influence of the downstream blade. This influence caused the fluid within cavities near the leading edges of either stator blades in space or rotor blades in time to be driven radially inward relative to fluid near blade mid-pitch. This influence also produced large unsteady velocity fluctuations in the downstream cavity because of the passing of the downstream rotor blade.

Wellborn, Steven R.↗

NASA NTRS1959

Experimental Investigation of a 0.35 Hub-Tip Radius Ratio Transonic Axial Flow Rotor Designed for 40 Pounds per Second per Square Foot with a Design Tip Diffusion Factor of 0.20

In order to determine the effect of a low design diffusion factor on the performance of a transonic axial-flow compressor rotor, a high-specific-flow rotor with a 0.35 hub-tip radius ratio was designed, fabricated and tested. This rotor used a design tip diffusion factor of 0.20 with a design corrected specific weight flow of 40 pounds per second per square foot of frontal area, a total-pressure ratio of 1.27, and an adiabatic efficiency of 0.96. The design, rotor performance, and blade element performance are presented with a discussion on rotor shock losses and a comparison with a similarly designed rotor with a tip diffusion factor of 0.35. At the design corrected tip speed of 1100 feet per second, a peak rotor adiabatic efficiency of 0.88 was attained at a corrected specific weight flow of 39 pounds per second per square foot of frontal area with a mass-averaged total-pressure ratio of 1.27. The blade element tip diffusion factor was 0.281, which is 0.08 higher than the design value of 0.20. Peak efficiencies of 0.95, 0.91, 0.89, and 0.85 were obtained at 70, 80, 90, and 110 percent of design speed, respectively. Comparison of the performance of the rotor reported herein and a similarly designed rotor with increased blade loading indicates that higher blade loading results in a more desirable rotor because of a higher pressure ratio and equivalent efficiency. Computed values of shock losses at the rotor tip section indicate that the losses at peak efficiency are primarily a function of shock losses since the profile losses are only a small percentage of the total loss.

Yasaki, Paul T.↗

NASA NTRS1982

Acoustic measurements on aerofoils moving in a circle at high speed

Features of the test apparatus, research objectives and sample test results at the Stanford University rotor aerodynamics and noise facility are described. A steel frame equipped to receive lead shot for damping vibrations supports the drive shaft for rotor blade elements. Sleeve bearings are employed to assure quietness, and a variable speed ac motor produces the rotations. The test stand can be configured for horizontal or vertical orientation of the drive shaft. The entire assembly is housed in an acoustically sealed room. Rotation conditions for hover and large angles of attack can be studied, together with rotational and blade element noises. Research is possible on broad band, discrete frequency, and high speed noise, with measurements taken 3 m from the center of the rotor. Acoustic signatures from Mach 0.3-0.93 trials with a NACA 0012 airfoil are provided.

Wright, S. E.↗

NASA NTRS1977

Propeller design by numerical optimization

A computer program designed to optimize propeller characteristics was developed by combining two main programs: the first is the optimization program based on the gradient algorithm; the second is based on a propeller blade element theory and uses an aerodynamics subprogram to approximate the lift and drag characteristics of the NACA 16-series airfoil section. To evaluate the propeller program alone (with its aerodynamics subprogram), propeller characteristics were computed and compared to those from wind tunnel investigations conducted on three different NACA propellers. Although the thrust and power coefficients which were computed using the blade element theory were generally higher than the experimental results for two of the three propellers, the corresponding efficiencies showed good agreement for all three propellers. The propeller optimization program was then used to study the NACA 4-(5)(08)-03 propeller at various Mach numbers from 0.175 to 0.60. Improvements in propeller efficiency and thrust were obtained through the use of the propeller optimization program.

Mendoza, J. P.↗

NASA NTRS1974

Performance of a 1.15-pressure-ratio axial-flow fan stage with a blade tip solidity of 0.5

The overall and blade-element performance of a low-solidity, low-pressure-ratio, low-tip-speed fan stage is presented over the stable operating range at rotative speeds from 90 to 120 percent of design speed. At design speed a stage peak efficiency of 0.836 was obtained at a weight flow of 30.27 kilograms per second and a pressure ratio of 1.111. The pressure ratio was less than design pressure ratio, and the design energy input into the rotor was not achieved. A mismatch of the rotor and stator blade elements resulted due to the lower than design pressure ratio of the rotor.

Osborn, W. M.↗

DOE OSTI2024

Modeling the effect of wind speed and direction shear on utility‐scale wind turbine power production

Abstract Wind speed and direction variations across the rotor affect power production. As utility‐scale turbines extend higher into the atmospheric boundary layer (ABL) with larger rotor diameters and hub heights, they increasingly encounter more complex wind speed and direction variations. We assess three models for power production that account for wind speed and direction shear. Two are based on actuator disc representations, and the third is a blade element representation. We also evaluate the predictions from a standard power curve model that has no knowledge of wind shear. The predictions from each model, driven by wind profile measurements from a profiling LiDAR, are compared to concurrent power measurements from an adjacent utility‐scale wind turbine. In the field measurements of the utility‐scale turbine, discrete combinations of speed and direction shear induce changes in power production of −19% to +34% relative to the turbine power curve for a given hub height wind speed. Positive speed shear generally corresponds to over‐performance and increasing magnitudes of direction shear to greater under‐performance, relative to the power curve. Overall, the blade element model produces both higher correlation and lower error relative to the other models, but its quantitative accuracy depends on induction and controller sub‐models. To further assess the influence of complex, non‐monotonic wind profiles, we also drive the models with best‐fit power law wind speed profiles and linear wind direction profiles. These idealized inputs produce qualitative and quantitative differences in power predictions from each model, demonstrating that time‐varying, non‐monotonic wind shear affects wind power production.

Energy & Fuels↗

NASA NTRS2003

Analysis and Design of Rotors at Ultra-Low Reynolds Numbers

Design tools have been developed for ultra-low Reynolds number rotors, combining enhanced actuator-ring / blade-element theory with airfoil section data based on two-dimensional Navier-Stokes calculations. This performance prediction method is coupled with an optimizer for both design and analysis applications. Performance predictions from these tools have been compared with three-dimensional Navier Stokes analyses and experimental data for a 2.5 cm diameter rotor with chord Reynolds numbers below 10,000. Comparisons among the analyses and experimental data show reasonable agreement both in the global thrust and power required, but the spanwise distributions of these quantities exhibit significant deviations. The study also reveals that three-dimensional and rotational effects significantly change local airfoil section performance. The magnitude of this issue, unique to this operating regime, may limit the applicability of blade-element type methods for detailed rotor design at ultra-low Reynolds numbers, but these methods are still useful for evaluating concept feasibility and rapidly generating initial designs for further analysis and optimization using more advanced tools.

Kunz, Peter J.↗

NASA NTRS1980

Stability of large horizontal-axis axisymmetric wind turbines

The stability of large horizontal axis, axi-symmetric, power producing wind turbines was examined. The analytical model used included the dynamic coupling of the rotor, tower and power generating system. The aerodynamic loading was derived from blade element theory. Each rotor blade was permitted tow principal elastic bending degrees of freedom, one degree of freedom in torsion and controlled pitch as a rigid body. The rotor hub was mounted in a rigid nacelle which may yaw freely or in a controlled manner. The tower can bend in two principal directions and may twist. Also, the rotor speed can vary and may induce perturbation reactions within the power generating equipment. Stability was determined by the eigenvalues of a set of linearized constant coefficient differential equations. All results presented are based on a 3 bladed, 300 ft. diameter, 2.5 megawatt wind turbine. Some of the parameters varied were; wind speed, rotor speed structural stiffness and damping, the effective stiffness and damping of the power generating system and the principal bending directions of the rotor blades. Unstable or weakly stable behavior can be caused by aerodynamic forces due to motion of the rotor blades and tower in the plane of rotation or by mechanical coupling between the rotor system and the tower.

Hirschbein, M. S.↗

DOE OSTI2019

Shape optimization under uncertainty for rotor blades of horizontal axis wind turbines

We present a computational framework for the shape optimization of a Horizontal-Axis Wind Turbine (HAWT) rotor blade under uncertainty. Our framework integrates aerodynamic simulations based on the blade element method which utilizes reduced order models of the blade structure and wind load with design sensitivity analysis and nonlinear programming. The wind velocity is modeled as a stochastic process to account for variations in time and space. An additional stochastic process accounts for uncertainties in the structural material properties. The uncertainty propagation is based on a non-intrusive polynomial chaos expansion that allows accurate estimation of stochastic performance metrics such as generated power and structural compliance. Sensitivities of cost and constraint functions with respect to shape parameters namely twist angles are computed with an efficient scheme to enable gradient based optimization. To demonstrate the effect of uncertainty, designs obtained from optimization under uncertainty are compared to those obtained from deterministic optimization.

42 ENGINEERING↗

NASA NTRS1984

Studies in a transonic rotor aerodynamics and noise facility

The design, construction and testing of a transonic rotor aerodynamics and noise facility was undertaken, using a rotating arm blade element support technique. This approach provides a research capability intermediate between that of a stationary element in a moving flow and that of a complete rotating blade system, and permits the acoustic properties of blade tip elements to be studied in isolation. This approach is an inexpensive means of obtaining data at high subsonic and transonic tip speeds on the effect of variations in tip geometry. The facility may be suitable for research on broad band noise and discrete noise in addition to high-speed noise. Initial tests were conducted over the Mach number range 0.3 to 0.93 and confirmed the adequacy of the acoustic treatment used in the facility to avoid reflection from the enclosure.

Wright, S. E.↗

NASA NTRS1992

APPLE - An aeroelastic analysis system for turbomachines and propfans

This paper reviews aeroelastic analysis methods for propulsion elements (advanced propellers, compressors and turbines) being developed and used at NASA Lewis Research Center. These aeroelastic models include both structural and aerodynamic components. The structural models include the typical section model, the beam model with and without disk flexibility, and the finite element blade model with plate bending elements. The aerodynamic models are based on the solution of equations ranging from the two-dimensional linear potential equation for a cascade to the three-dimensional Euler equations for multi-blade configurations. Typical results are presented for each aeroelastic model. Suggestions for further research are indicated. All the available aeroelastic models and analysis methods are being incorporated into a unified computer program named APPLE (Aeroelasticity Program for Propulsion at LEwis).

Reddy, T. S. R.↗

NASA NTRS1993

A Review of Recent Aeroelastic Analysis Methods for Propulsion at NASA Lewis Research Center

This report reviews aeroelastic analyses for propulsion components (propfans, compressors and turbines) being developed and used at NASA LeRC. These aeroelastic analyses include both structural and aerodynamic models. The structural models include a typical section, a beam (with and without disk flexibility), and a finite-element blade model (with plate bending elements). The aerodynamic models are based on the solution of equations ranging from the two-dimensional linear potential equation to the three-dimensional Euler equations for multibladed configurations. Typical calculated results are presented for each aeroelastic model. Suggestions for further research are made. Many of the currently available aeroelastic models and analysis methods are being incorporated in a unified computer program, APPLE (Aeroelasticity Program for Propulsion at LEwis).

Reddy, T. S. R.↗

NASA NTRS1988

Vibration and flutter characteristics of the SR7L large-scale propfan

An investigation of the vibration characteristics and aeroelastic stability of the SR7L Large-Scale Advanced Propfan was performed using a finite element blade model and an improved aeroelasticity code. Analyses were conducted for different blade pitch angles, blade support conditions, number of blades, rotational speeds, and freestream Mach numbers. A finite element model of the blade was used to determine the blade's vibration behavior and sensitivity to support stiffness. The calculated frequencies and mode shape obtained with this model agreed well with the published experimental data. A computer code recently developed at NASA Lewis Research Center and based on three-dimensional, unsteady, lifting surface aerodynamic theory was used for the aeroelastic analysis to examine the blade's stability at a cruise condition of Mach 0.8 at 1700 rpm. The results showed that the blade is stable for that operating point. However, a flutter condition was predicted if the cruise Mach number was increased to 0.9.

August, Richard↗

NASA NTRS1994

Design and aerodynamic performance evaluation of a high-work mixed flow turbine stage

As axial and radial turbine designs have been pushed to their aerothermodynamic and mechanical limits, the mixed-flow turbine (MFT) concept has been projected to offer performance and durability improvements, especially when ceramic materials are considered. The objective of this NASA/U.S. Army sponsored mixed-flow turbine (AMFT) program was to determine the level of performance attainable with MFT technology within the mechanical constraints of 1997 projected ceramic material properties. The MFT geometry is similar to a radial turbine, exhibiting a large radius change from inlet to exit, but differing in that the inlet flowpath is not purely radial, nor axial, but mixed; it is the inlet geometry that gives rise to the name 'mixed-flow'. The 'mixed' orientation of the turbine inlet offers several advantages over radial designs by allowing a nonzero inlet blade angle yet maintaining radial-element blades. The oblique inlet not only improves the particle-impact survivability of the design, but improves the aerodynamic performance by reducing the incidence at the blade inlet. The difficulty, however, of using mixed-flow geometry lies in the scarcity of detailed data and documented design experience. This paper reports the design of a MFT stage designed with the intent to maximize aerodynamic performance by optimizing design parameters such as stage reaction, rotor incidence, flowpath shape, blade shape, vane geometry, and airfoil counts using 2-D, 3-D inviscid, and 3-D viscous computational fluid dynamics code. The aerodynamic optimization was accomplished while maintaining mechanical integrity with respect to vibration and stress levels in the rotor. A full-scale cold-flow rig test was performed with metallic hardware fabricated to the specifications of the hot ceramic geometry to evaluate the stage performance.

Neri, Remo N.↗

DOE OSTI2024

Going beyond BEM with BEM: an insight into dynamic inflow effects on floating wind turbines

Blade element momentum (BEM) theory is the backbone of many industry-standard wind turbine aerodynamic models. To be applied to a broader set of engineering problems, BEM models have been extended since their inception and now include several empirical corrections. These models have benefitted from decades of development and refinement and have been extensively used and validated, proving their adequacy in predicting aerodynamic forces of horizontal-axis wind turbine rotors in most scenarios. However, the analysis of floating offshore wind turbines (FOWTs) introduces new sets of challenges, especially if new-generation large and flexible machines are considered. In fact, due to the combined action of wind and waves and their interaction with the turbine structure and control system, these machines are subject to unsteady motion and thus unsteady inflow on the wind turbine's blades, which could put BEM models to the test. Consensus has not been reached on the accuracy limits of BEM in these conditions. This study contributes to the ongoing research on the topic by systematically comparing four different aerodynamic models, ranging from BEM to computational fluid dynamics, in an attempt to shed light on the unsteady aerodynamic phenomena that are at stake in FOWTs and whether BEM is able to model them appropriately. Simulations are performed on the UNAFLOW 1:75 scale rotor during imposed harmonic surge and pitch motion. Experimental results are available for these conditions and are used for baseline validation. The rotor is analyzed in both rated operating conditions and low wind speeds, where unsteady aerodynamic effects are expected to be more pronounced. Results show that BEM, despite its simplicity, can adequately model the aerodynamics of FOWTs in most conditions if augmented with a dynamic inflow model.

17 WIND ENERGY↗

NASA NTRS1982

System for slicing wafers

A newly patented process for slicing silicon wafers that has distinct advantages over methods now widely used is described. The primary advantage of the new system is that it allows the efficient slicing of a number of ingots simultaneously at high speed. The cutting action is performed mechanically, most often with diamond particles that are transported to the cutting zone by a fluid vehicle or have been made an integral part of the blade by plating or impregnation. The new system uses a multiple or ganged band saw, arranged and spaced so that each side, or length, segment of a blade element, or loop, provides a cutting function. Each blade is maintained precisely in position by guides as it enters and leaves each ingot. The cutting action is performed with a conventional abrasive slurry composed of diamond grit suspended in an oil- or water-based vehicle. The distribution system draws the slurry from the supply reservoir and pumps it to the injection tubes to supply it to each side of each ingot. A flush system is provided at the outer end of the work-station zone. In order to reduce potential damage, a pneumatically driven flushing fluid is provided.

Source record↗

NASA NTRS1942

Contribution to the ideal efficiency of screw propellers

The stipulation of best thrust distribution is applied to the annular elements of the screw propeller with infinitely many blades in frictionless, incompressible flow and an ideal jet propulsion system derived possessing hyperbolic angular velocity distribution along the blade radius and combining the advantage of uniform thrust distribution over the section with minimum slipstream and rotation losses. This system is then compared with a propeller possessing the same angular velocity at all blade elements and the best possible thrust distribution secured by means of an induced efficiency varying uniformly over the radius. Lastly, the case of the lightly loaded propeller also is discussed.

Hoff, Wilhelm↗