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At least 19 records

Functional Requirements for the WEIS Toolset to Enable Controls Co-Design of Floating Offshore Wind Turbines

The goal of the new Wind Energy with Integrated Servo-control (WEIS) toolset under development is to provide the offshore wind industry and research communities with an open-source, user-friendly, flexible tool to enable true controls co-design (CCD) of the physical design of a floating offshore wind turbine together with the controller. WEIS will use a multifidelity library of models built on the foundations of WISDEM® and OpenFAST formerly known as FAST). This paper presents the WEIS development plan, including the functional requirements of WEIS (including improvements to WISDEM and OpenFAST) together with associated rationale for their establishment and a qualitative description of the modeling approaches that will be implemented to address these functional requirements. The development of WEIS is a project under the Aerodynamic Turbines Lighter and Afloat with Nautical Technologies and Integrated Servo-control program funded by the U.S. Department of Energy Advanced Research Projects Agency – Energy.

27 ARPA - Advanced Research Projects Agency-Energy↗

Functional Requirements for the WEIS Toolset to Enable Controls Co-Design of Floating Offshore Wind Turbines: Preprint

The goal of the new Wind Energy with Integrated Servo-control (WEIS) toolset under development is to provide the offshore wind industry and research communities with an open-source, user-friendly, and flexible tool to enable true Controls Co-Design (CCD) of the physical design of a floating offshore wind turbine (FOWT) together with the controller. WEIS will utilize a multifidelity library of models built upon the foundations of WISDEM and OpenFAST (formerly known as FAST). This paper presents the WEIS development plan, including the functional requirements of WEIS (including improvements to WISDEM and OpenFAST) together with associated rationale for their establishment, and a qualitative description of the modeling approaches that will be implemented to address these functional requirements. The development of WEIS is a project under the Aerodynamic Turbines, Lighter and Afloat, with Nautical Technologies and Integrated Servo-control (ATLANTIS) program funded by the U.S. Department of Energy (DOE) Advanced Research Projects Agency - Energy (ARPA-E).

27 ARPA - Advanced Research Projects Agency-Energy↗

WEIS and FAST.Farm Advancements Beyond Wind Turbine Aeroelasticity

Presentation at the 7th Wind Energy Systems Engineering workshop from NREL principal engineer Jason Jonkman, Ph.D., on NREL's numerical tools Wind Energy with Integrated Servo-control (WEIS), which focuses on the integrated design of floating wind turbines, and FAST.Farm, a simulation tool for multi-turbine wind farms based on popular aero-servo-hydro-elastic solver OpenFAST. The presentation discusses recent advancements beyond wind turbine aero-elasticity.

17 WIND ENERGY↗

Computationally Efficient Control Co-Design Optimization Framework with Mixed-Fidelity Fluid and Structure Analysis: OpenTurbineCoDe (OTCD) - ARPA-E ATLANTIS Phase I Project (Final Technical Report)

The goal of the Department of Energy (DOE) Advanced Research Projects Agency-Energy (ARPA-E) Aerodynamic Turbines Lighter and Afloat with Nautical Technologies and Integrated Servo-control (ATLANTIS) Program is to develop new technologies for floating offshore wind turbines, or wind farms, using the discipline of control co-design (CCD.) In this context, our goal is to develop a computationally efficient optimization framework for design of floating offshore wind turbines. Our specific aim is to utilize high-fidelity structural, aerodynamic, aero-structural tools, and to derive control-oriented reduced- or low-order models directly from the high-fidelity tools. We proposed a mixed-fidelity modeling approach which means that we are also using low- and mid-fidelity tools when necessary. This research is conducted by a multidisciplinary team consisting of Rutgers University, University of Michigan, Brigham Young University, and the National Renewable Energy Laboratory (NREL). The computational framework, called OpenTurbineCoDe, is designed to integrate, where possible, traditional structural, aerodynamic, aeroelastic models (e.g., OpenFAST) and advanced control algorithms with higher fidelity simulation tools including Reynolds-averaged Navier–Stokes (RANS) solvers, and three-dimensional structural finite element solvers. All the high-fidelity tools used in this research provide numerically exact gradients to facilitate both efficient optimization and local linearization for control implementation.

17 WIND ENERGY↗

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↗

Utah FORGE: Fault Shear Reactivation Experimental Data for Fluid Injection-Rate Controls on Seismic Moment

Included are experimental data recorded from shear experiments that specifically explore the link between fluid-injection rate and seismic moment resulting from shear reactivation of laboratory faults. Raw mechanical data from three experiments are included alongside corresponding MATLAB scripts that import and plot the data, as well as use it to calculate shear and normal stress. Experiments are performed on 2.5-3 inch long granitoid cores from the Utah FORGE EGS demonstration site, containing a single inclined fracture with small-scale roughness added to the fracture surface. The raw data included here were recorded from an aluminum triaxial pressure vessel (TEMCO) configured with three independent servo-controlled pumps, with distilled water used as the working fluid. The pumps control confining pressure, upstream pore pressure, and axial pressure, with each pump connected to a LabView interface to record applied pressures, cumulative injected water volumes, and pump flow rates. The downstream outlet from the fracture is closed to allow pressurization, which is measured by an external pressure transducer. A linear variable differential transformer (LVDT) attached to the axial piston measures axial displacement, from which we calculate shear displacement along the fracture. Additionally, P-wave transducers are used to record acoustic signatures, where acoustic emission events and maximum amplitudes are compared against seismic moment and shear slip velocity. Fluid injection rates range between 0.05 mL/min, 0.25 mL/min, and 0.75 mL/min for each experiment. Along-fault pressure distributions are progressively less uniform as injection rates increase, representing a switch from steady-state to transient conditions. Triggered shear displacement is used as a proxy for seismic moment and is indexed against cumulative injection volume and rate. Each experiment is performed under constant shear stress conditions, and the sample is fully saturated with DI water. Axial and confining stresses are applied to 3 MPa through pressure-stepping in 500 kPa increments. The pore pressure is held constant at 200 kPa prior to initiating the experiment, and initial axial displacement is recorded. The axial stress is then increased to initiate shear mobilization during the loading phase (run-in) until a peak steady state is achieved. The initial shear stress is reduced to approximately 80% of the peak shear stress by decreasing the axial stress, then held constant for the duration of each experiment.

15 GEOTHERMAL ENERGY↗

Processed Lab Data for Neural Network-Based Shear Stress Level Prediction

Machine learning can be used to predict fault properties such as shear stress, friction, and time to failure using continuous records of fault zone acoustic emissions. The files are extracted features and labels from lab data (experiment p4679). The features are extracted with a non-overlapping window from the original acoustic data. The first column is the time of the window. The second and third columns are the mean and the variance of the acoustic data in this window, respectively. The 4th-11th column is the the power spectrum density ranging from low to high frequency. And the last column is the corresponding label (shear stress level). The name of the file means which driving velocity the sequence is generated from. Data were generated from laboratory friction experiments conducted with a biaxial shear apparatus. Experiments were conducted in the double direct shear configuration in which two fault zones are sheared between three rigid forcing blocks. Our samples consisted of two 5-mm-thick layers of simulated fault gouge with a nominal contact area of 10 by 10 cm^2. Gouge material consisted of soda-lime glass beads with initial particle size between 105 and 149 micrometers. Prior to shearing, we impose a constant fault normal stress of 2 MPa using a servo-controlled load-feedback mechanism and allow the sample to compact. Once the sample has reached a constant layer thickness, the central block is driven down at constant rate of 10 micrometers per second. In tandem, we collect an AE signal continuously at 4 MHz from a piezoceramic sensor embedded in a steel forcing block about 22 mm from the gouge layer The data from this experiment can be used with the deep learning algorithm to train it for future fault property prediction.

15 GEOTHERMAL ENERGY↗

Aero‐servo‐elastic co‐optimization of large wind turbine blades with distributed aerodynamic control devices

Abstract This work introduces automated wind turbine optimization techniques based on full aero‐servo‐elastic models and investigates the potential of trailing edge flaps to reduce the levelized cost of energy (LCOE) of wind turbines. The Wind Energy with Integrated Servo‐control (WEIS) framework is improved to conduct the presented research. Novel methods for the generic implementation and tuning of trailing edge flap devices and their controller are also introduced. Primary flap and controller parameters are optimized to demonstrate potential maximum blade tip deflection reductions of 21 % . Concurrent design optimization (i.e., co‐design) of a novel segmented wind turbine blade with trailing edge flaps and its controller is then conducted to demonstrate blade cost savings of 5 % . Additionally, rotor diameter co‐design optimization is demonstrated to reduce the LCOE by 1.3 % without significant load increases to the tower. These results demonstrate the efficacy of control co‐design optimization using trailing edge flaps, and the entirety of this work provides a foundation for numerous control co‐design‐oriented studies for distributed aerodynamic control devices.

17 WIND ENERGY↗

SMC Reinforced by Recycled or Textile Carbon Fiber

There is a significant need to expand material options for SMC that has traditionally used glass fibers for decades. There are several integral issues related to chopping and conveying a range of materials including glass, carbon, basalt, thermoplastic tapes, and recycled fibers. These are in a variety of forms including continuous tows, discontinuous agglomerates such as pyrolyzed carbon fibers that could be used to produce a range of SMC intermediates. Standard/conventional SMC processing is limited to cutting rotors specifically for glass and compounding with thermoset polyesters and some epoxies. The multi-material, multi-format line developed in this project is flexible to enable custom conveying and uses an interchangeable rotor dedicated for specific material types. The overall tasks undertaken in this project included: evaluation of the fiber feed mechanism, effect of textile grade carbon, evaluating servo motor controlling of conveyor, evaluate doctor box resin feed, evaluate compaction unit, evaluation of different formulations, and develop automation such as PLC programming. The new multi-material SMC line Version 2 (SCM-V2) incorporated servo motors over induction motors which gave the overall cutter system precision control and made it quiet. The addition of a 14-roll compaction unit at the end of the line in SMC-V2 enabled higher material wet out which was a limitation in the SMC Version 1 (SMC-V1). The cutters were further updated to reduce the cantilever overhang of the fiber which enabled more uniform cut lengths for glass, carbon, and basalt fibers. The overall instrumentation and system control including a remote control operation was enabled in the SMC-V2. The line speed is capable of 10-20 ft/minute. The cutting modules were designed and engineered for cutting glass, basalt and textile grade carbon in 300k and 450-600k format widths. The cutting trials were established for a range of fiber types. The study also demonstrated the utility of the line to cut and produce basalt fiber SMC. Initial trials were conducted on the properties from recycled carbon fiber (rCF) mats in epoxy resin. Overall, the Covid19 situation constrained the team from accessing the SMC line for over 18 months. Despite this challenge major advancements were made.

36 MATERIALS SCIENCE↗

Embedded EPICS server for PowerPMAC motion controllers

An embedded server layer of Experimental Physics and Industrial Control System (EPICS) for PowerPMAC motion controllers has been developed and deployed at two undulator beamlines of the National Institute of General Medical Sciences and the National Cancer Institute (GM/CA) Structural Biology Facility at the Advanced Photon Source (APS). This compact, open source solution makes the power and versatility of PowerPMAC motion controls directly accessible to distributed EPICS clients. At GM/CA the system controls about 200 servo and stepper motors — both encoded and unencoded — and multiple digital and analog I/O accessories. The server stack comprises two sublayers: a lower-level driver and database that communicates directly with PowerPMAC, and a facility-specific soft sublayer built on top. The paper describes installing EPICS on PowerPMAC, the implementation of both layers and client examples, including on-the-fly scanning.

EPICS↗

New Insertion Device Control System for the APS Upgrade

New Hybrid Permanent Magnet Undulators (HPMUs) have been designed and manufactured using servo motors for precise and reliable gap motion control for the Advanced Photon Source Upgrade (APS-U) project. Meanwhile, existing HPMUs equipped with legacy stepper motors are systematically replaced with servo motors. In parallel with mechanical modifications of the undulators, a comprehensive upgrade has been implemented for the control of the devices. This upgrade includes integration of standardized industrial components for replacement of motor controllers and motor drives using the Kollmorgen Programmable Controller Multi-axis Master (PCMM) controllers and the AKD2G series servo drives. Soft Input Output Controllers (IOCs) are developed and deployed to replace the legacy VME-based IOCs for both single-period undulators and Revolver undulators. In this paper, we will present the architecture of the new insertion device control system, including control mechanisms, interlock protocols, and tools for diagnostics and troubleshooting.

Li, W.↗

Space Nuclear Power Autonomous Control Algorithm and Control Element Test Bed

Nuclear thermal rockets are currently NASA’s preferred option for use in a manned mission to Mars in the 2040s. The communication delay between an Earth ground station and a spacecraft heading toward Mars can be up to 20 min. Therefore, controlling the nuclear rocket engine would require either a full-time reactor operator on the mission or an autonomous control system for the reactor. The latter idea of making space nuclear reactors fully autonomous has drawn more interest from stakeholders, but such an autonomous control system must be rigorously tested and validated before it is certified for human use. The cost of a full ground test for a space nuclear reactor is tremendous, so a nonnuclear mock reactor test bed was created to test and validate control elements and control algorithms for space nuclear reactors. The test bed consists of control element hardware that inputs physical measurement data into a reactor emulator to produce the reactor’s performance under steady-state, transient, and fault conditions. The control element hardware consists of six full-sized control drums equipped with servo drives and motors and is instrumented with optical encoders, resolvers, and torque sensors for drum movement characterization. In addition to the drums, a two-phase flow loop was designed and built to mimic the valves and turbomachinery associated with the propellant flow through a nuclear thermal rocket engine; components such as pressure sensors, flow meters, thermocouples, and tachometers are instrumented throughout the loop to characterize the fluid flow, valve, and turbomachinery behavior of the system. The data from the physical hardware (e.g., drum position, propellant flow rates) are input to a nuclear reactor simulator to determine the actual nuclear reactor parameters, and the data are sent back to a control algorithm to complete the control loop. The ability to conduct numerous tests of the control systems and autonomous algorithms can help validate the instrumentation and control aspects for a space nuclear reactor for every possible fault situation.

Wilson, Brandon↗

Machine Vision-based Robot Manipulators for Nuclear Applications - 20370

Decommissioning and dismantling of nuclear facilities are major challenges facing the nuclear industry. Robot manipulators with capabilities of restoring nuclear structures and significantly prolonging nuclear power generation in addition to their applications in decommissioning and dismantling (D and D) would immensely ease the above-mentioned challenge. Ability to remotely sense/monitor and analyze dangerous and hazardous environments such as nuclear reactors as well as performing reparatory tasks in such environments using robot manipulators require additional information from vision sensors. Structural sample collection and inspection as well as restoration require object and position information. Computer vision is used to obtain precise 3D position information. The current work uses the Sawyer robot with the integrated Cognex camera. The research presents an approach to facilitate and improve operations in a nuclear reactor using robotic vision control. The vision control system is modeled with Augmented Image Space-based visual servoing approach. Results showing accurate robot control. Object recognition is used to recognize the image and calculate it poses. To transform coordinates of the object's pose from the camera frame to the robotic frame transformation matrices are employed. Future work will employ a 3D camera (with depth information) using Denso robot. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

An investigation into the effects of cyclic strain rate on the high cycle and very high cycle fatigue behaviors of wrought and additively manufactured Inconel 718

Additive Manufacturing (AM) has increasingly been used to fabricate parts in aerospace applications, which may require service lives beyond ten-million cycles due to the imposed high loading frequencies. Understanding the very high cycle fatigue (VHCF) behavior of these additive manufactured (AM) parts is an important step towards their design and qualification processes. This study focuses on the high cycle fatigue (HCF) and VHCF behaviors of both wrought and laser beam-powder bed fusion (LB-PBF) fabricated Inconel 718 in machined/polished surface condition, emphasizing on the influence of test frequency (i.e., cyclic strain rate). Uniaxial, fully-reversed force- and stress-controlled fatigue tests were conducted utilizing a servo-hydraulic and an ultrasonic test system operating at 5 Hz and 20 kHz, respectively, on wrought as well as LB-PBF vertically and diagonally built specimens. Fatigue cracks in the majority of the specimens were found to initiate from intra-granular slip bands near or at the surface, which gives rise to strong anisotropy in fatigue resistance in LB-PBF specimens due to the presence of columnar grains along the build directions. Longer fatigue lives were obtained at 20 kHz, which was ascribed to possibly lower-than-intended stresses applied in the ultrasonic tests. The corrected stress-life fatigue data at 20 kHz were found to converge to the one obtained from conventional testing at 5 Hz, implying no effect of cyclic strain rate on the fatigue behavior of Inconel 718 regardless of the fabrication process. The findings of this work confirm the use of ultrasonic fatigue testing to expedite generation of AM materials data to keep up with the current demand; however, the applied stress may need to be corrected.

36 MATERIALS SCIENCE↗

Simultaneous optimal system and controller design for multibody systems with joint friction using direct sensitivities

Abstract Real-world multibody systems are often subject to phenomena like friction, joint clearances, and external events. These phenomena can significantly impact the optimal design of the system and its controller. This work addresses the gradient-based optimization methodology for multibody dynamic systems with joint friction using a direct sensitivity approach. The Brown–McPhee model has been used to characterize the joint friction in the system. This model is suitable for the study due to its accuracy for dynamic simulation and its compatibility with sensitivity analysis. This novel methodology supports codesign of the multibody system and its controller, which is especially relevant for applications like robotics and servo-mechanical systems, where the actuation and design are highly dependent on each other. Numerical results are obtained using a software package written in Julia with state-of-the-art libraries for automatic differentiation and differential equations. Three case studies are provided to demonstrate the attractive properties of simultaneous optimal design and control approach for certain applications.

Verulkar, Adwait↗

Control System Upgrade for Canal ARC SAW

Upgrading the specific components of the Arc Saw, such as the HMI, the components of the chassis involving the I/O modules, servo motor modules, and PLC modules offers numerous advantages. By enhancing the HMI, the operators will benefit having a user-friendly interface, enabling smoother control and monitoring of the ARC SAW’s functionality. Upgrading the modules will contribute to an improved precision and responsiveness in changing modes of the ARC SAW as well as the adjusting the saw blades position, further enhancing the system's overall performance. These upgrades, while maintaining the same functionality, enable the latest technological advancements without needing significant changes or disruptions to existing operations.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Reinforcement Learning for Small Autonomous Ground Vehicle

Microcontroller: • ESP-WROOM 32 control board • Wi-Fi 802.11 b/g/n Actuators: • 2 Futaba S3003 Servos • Commanded angles of 0 to 180 • Effectors • Piano wire “legs” and “feet” • Current, Voltage, Power Sensor: • Adafruit INA260 • Range Finder (1D LiDAR) Sensor: • SparkFun VL53L1X • Power Supply: • Battery powered, Adafruit UN3480 Li Ion Polymer 1200 mAh • Adafruit JST 2 PH power breakout board • Body: • Additively manufactured frame

Wells, William Willie↗

Modeling, Validation, and Control of the IEA‐15 MW Reference Wind Turbine and VolturnUS‐S Platform

This paper presents the acausal modeling, validation, and control of floating offshore wind turbines (FOWTs). The model simulates the IEA‐15 MW reference turbine and the semi‐submersible VolturnUS‐S platform utilizing a Control‐oriented, Reconfigurable, and Acausal Floating Turbine Simulator (CRAFTS), which integrates the key coupled aero‐hydro‐elasto‐servo dynamics and is being developed by authors at the University of Central Florida. Verification and validation are conducted using numerical data from the industry‐standard simulation platform OpenFAST and experimental data from the Floating Offshore‐wind and Controls Advanced Laboratory (FOCAL) project, in which the authors were involved. Numerical results demonstrate the model's ability to qualitatively capture loads and responses across various load cases, highlighting the impact of the control system under different wind and wave conditions and opening new opportunities for optimizing FOWT designs. This paper provides wind turbine researchers with valuable insights into system characteristics, system frequencies, damping effects, and internal reaction forces, serving as a reference for future studies in FOWT modeling and control.

17 WIND ENERGY↗