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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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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Development of an open-source segmented blade design tool

As wind turbines continue to grow ever larger to reduce the cost of energy, their blades follow suit, with the largest commercial offshore blades extending past 100 m. Massive blades such as these raise key transportation and manufacturing challenges, especially for land-based turbines. Segmented blades are one solution and are garnering increased industry and research interest. In this work, a detailed mechanical joint model is integrated into the Wind-Plant Integrated System Design and Engineering Model (WISDEM ® ), which will facilitate future segmented blade research and optimization. WISDEM is used to design a wind turbine with 100-m segmented blades. This wind turbine design is compared to other machines with 100-m monolithic blades designed for rail-transportability. The designs are compared in terms of blade mass and cost, turbine capital cost, annual energy production, and levelized cost of energy, with monolithic designs being the lightest and most economical. However, this result may vary by wind plant location. A variety of segmentation joint types exist, and they will inevitably vary in parameters such as cost, spanwise location, and physical characteristics. This work examines the sensitivity of wind turbine design drivers and annual energy production to a variety of the aforementioned parameters, using the open-source wind turbine design codes OpenFAST and WISDEM, finding that joint mass, stiffness, and location can have significant effects on design drivers.

17 WIND ENERGY↗
DOE OSTI2022

Design and analysis of a segmented blade for a 50 MW wind turbine rotor

Extreme-size wind turbines face logistical challenges due to their sheer size. A solution, segmentation, is examined for an extreme-scale 50 MW wind turbine with 250 m blades using a systematic approach. Segmentation poses challenges regarding minimizing joint mass, transferring loads between segments and logistics. We investigate the feasibility of segmenting a 250 m blade by developing design methods and analyzing the impact of segmentation on the blade mass and blade frequencies. This investigation considers various variables such as joint types (bolted and bonded), adhesive materials, joint locations, number of joints and taper ratios (ply dropping). Segmentation increases blade mass by 4.1%–62% with bolted joints and by 0.4%–3.6% with bonded joints for taper ratios up to 1:10. Cases with large mass growth significantly reduce blade frequencies potentially challenging the control design. We show that segmentation of an extreme-scale blade is possible but mass reduction is necessary to improve its feasibility.

Escalera Mendoza, Alejandra S.↗
NASA NTRS2003

Drive system for the retraction/extension of variable diameter rotor systems

A drive system for a variable diameter rotor (VDR) system includes a plurality of rotor blade assemblies with inner and outer rotor blade segments. The outer blade segment being telescopically mounted to the inner blade segment. The VDR retraction/extension system includes a drive housing mounted at the root of each blade. The housing supports a spool assembly, a harmonic gear set and an electric motor. The spool assembly includes a pair of counter rotating spools each of which drive a respective cable which extends through the interior of the inboard rotor blade section and around a pulley mounted to the outboard rotor blade section. In operation, the electric motor drives the harmonic gear set which rotates the counter rotating spools. Rotation of the spools causes the cables to be wound onto or off their respective spool consequently effecting retraction/extension of the pulley and the attached outboard rotor blade section relative the inboard rotor blade section. As each blade drive system is independently driven by a separate electrical motor, each independent VDR blade assembly is independently positionable.

Gmirya, Yuriy↗
NASA NTRS1976

Computational aspects of real-time simulation of rotary-wing aircraft

A study was conducted to determine the effects of degrading a rotating blade element rotor mathematical model suitable for real-time simulation of rotorcraft. Three methods of degradation were studied, reduction of number of blades, reduction of number of blade segments, and increasing the integration interval, which has the corresponding effect of increasing blade azimuthal advance angle. The three degradation methods were studied through static trim comparisons, total rotor force and moment comparisons, single blade force and moment comparisons over one complete revolution, and total vehicle dynamic response comparisons. Recommendations are made concerning model degradation which should serve as a guide for future users of this mathematical model, and in general, they are in order of minimum impact on model validity: (1) reduction of number of blade segments; (2) reduction of number of blades; and (3) increase of integration interval and azimuthal advance angle. Extreme limits are specified beyond which a different rotor mathematical model should be used.

Houck, J. A.↗
NASA NTRS1976

Effects of rotor model degradation on the accuracy of rotorcraft real time simulation

The effects are studied of degrading a rotating blade element rotor mathematical model to meet various real-time simulation requirements of rotorcraft. Three methods of degradation were studied: reduction of number of blades, reduction of number of blade segments, and increasing the integration interval, which has the corresponding effect of increasing blade azimuthal advance angle. The three degradation methods were studied through static trim comparisons, total rotor force and moment comparisons, single blade force and moment comparisons over one complete revolution, and total vehicle dynamic response comparisons. Recommendations are made concerning model degradation which should serve as a guide for future users of this mathematical model, and in general, they are in order of minimum impact on model validity: (1) reduction of number of blade segments, (2) reduction of number of blades, and (3) increase of integration interval and azimuthal advance angle. Extreme limits are specified beyond which the rotating blade element rotor mathematical model should not be used.

Houck, J. A.↗
NASA NTRS2001

Rotor Broadband Noise Prediction with Comparison to Model Data

This paper reports an analysis and prediction development of rotor broadband noise. The two primary components of this noise are Blade-Wake Interaction (BWI) noise, due to the blades' interaction with the turbulent wakes of the preceding blades, and "Self" noise, due to the development and shedding of turbulence within the blades' boundary layers. Emphasized in this report is the new code development for Self noise. The analysis and validation employs data from the HART program, a model BO-105 rotor wind tunnel test conducted in the German-Dutch Wind Tunnel (DNW). The BWI noise predictions are based on measured pressure response coherence functions using cross-spectral methods. The Self noise predictions are based on previously reported semiempirical modeling of Self noise obtained from isolated airfoil sections and the use of CAMRAD.Modl to define rotor performance and local blade segment flow conditions. Both BWI and Self noise from individual blade segments are Doppler shifted and summed at the observer positions. Prediction comparisons with measurements show good agreement for a range of rotor operating conditions from climb to steep descent. The broadband noise predictions, along with those of harmonic and impulsive Blade-Vortex Interaction (BVI) noise predictions, demonstrate a significant advance in predictive capability for main rotor noise.

Brooks, Thomas F.↗
NASA NTRS1982

Establishment of a rotor model basis

Radial-dimension computations in the RSRA's blade-element model are modified for both the acquisition of extensive baseline data and for real-time simulation use. The baseline data, which are for the evaluation of model changes, use very small increments and are of high quality. The modifications to the real-time simulation model are for accuracy improvement, especially when a minimal number of blade segments is required for real-time synchronization. An accurate technique for handling tip loss in discrete blade models is developed. The mathematical consistency and convergence properties of summation algorithms for blade forces and moments are examined and generalized integration coefficients are applied to equal-annuli midpoint spacing. Rotor conditions identified as 'constrained' and 'balanced' are used and the propagation of error is analyzed.

Mcfarland, R. E.↗
NASA NTRS1987

Main rotor broadband noise study in the DNW

An acoustics test of a 2/5 scale model BO-105 helicopter main rotor was conducted in the Duits-Nederlandse Windtunnel (DNW). A range of operating conditions was tested from hover to moderately high flight speeds for various climb and descent rates at different thrust settings. Diagnostic tests including rotor speed and blade geometry changes were made to better isolate and study particular broadband self noise sources. Acoustic data in the form of acoustic pressure time histories and power spectra are used to demonstrate the regions of importance of the different broadband noise sources and their sensitivity to operating conditions. To help interpret the data, comparisons are made to predictions of rotor broadband noise. The predictions are based on self noise data previously obtained from isolated airfoil sections and the use of the NASA ROTONET program to define rotor performance and to sum contributions of noise from individual blade segments. An important result herein is the identification and articulation of a previously unheralded rotor broadband noise source. This source is blade-turbulent wake interaction (BWI) noise which dominates the spectra in the mid-frequencies for off-peak blade-vortex interaction (BVI) noise flight conditions.

Brooks, Thomas F.↗
NASA NTRS1949

Response of a Rotating Propeller to Aerodynamic Excitation

The flexural vibration of a rotating propeller blade with clamped shank is analyzed with the object of presenting, in matrix form, equations for the elastic bending moments in forced vibration resulting from aerodynamic forces applied at a fixed multiple of rotational speed. Matrix equations are also derived which define the critical speeds end mode shapes for any excitation order and the relation between critical speed and blade angle. Reference is given to standard works on the numerical solution of matrix equations of the forms derived. The use of a segmented blade as an approximation to a continuous blade provides a simple means for obtaining the matrix solution from the integral equation of equilibrium, so that, in the numerical application of the method presented, the several matrix arrays of the basic physical characteristics of the propeller blade are of simple form, end their simplicity is preserved until, with the solution in sight, numerical manipulations well-known in matrix algebra yield the desired critical speeds and mode shapes frame which the vibration at any operating condition may be synthesized. A close correspondence between the familiar Stodola method and the matrix method is pointed out, indicating that any features of novelty are characteristic not of the analytical procedure but only of the abbreviation, condensation, and efficient organization of the numerical procedure made possible by the use of classical matrix theory.

Arnoldi, Walter E.↗
NASA NTRS1981

Helicopter rotor trailing edge noise

An experimental and theoretical study was conducted to assess the importance of trailing edge noise as a helicopter main rotor broadband noise source. The noise mechanism was isolated by testing a rotor blade segment in an open jet acoustic wind tunnel at close to full scale Reynolds numbers. Boundary layer data and acoustic data were used to develop scaling laws and assess a first principles trailing edge noise theory. Conclusions from the isolated blade study were analytically transformed to the rotating frame coordinate system to develop a generalized rotor noise prediction. Trailing edge noise was found to contribute significantly to the total helicopter noise spectrum at high frequencies.

Schlinker, R. H.↗
DOE OSTI2021

Big Adaptive Rotor Phase I (Final Report)

The Big Adaptive Rotor (BAR) project was initiate by DOE in 2018 with the goal of identifying novel technologies that can enable large (>100m) blades for low specific power (SP) turbines. Five distinct tasks were completed to achieve this goal: 1. Assess trends, impacts, and value of low-SP turbines, 2. Wind turbine blade cost reduction roadmap study, 3. Research and Development (R&D) opportunity screening, 4. Detailed design and analysis, and 5. Low-cost carbon fiber. These tasks were completed by the national lab team consisting of Sandia National Laboratories (SNL), the National Renewable Energy Laboratory (NREL), and Lawrence Berkeley National Laboratory (LBNL). The objective of Task 1 was to assess the historical trends of low-SP of onshore deployments, and to assess the impact and value of low-SP turbines. Analysis under this task showed that there is significant value for low-SP turbines, especially in markets where there is a higher saturation of wind energy on the grid. This has to do with the fact that low-SP turbines have increased capacity factors, and can contribute more reliable energy to the grid, even in lower wind conditions. This bodes well as higher renewable scenarios are likely in the coming years. Task 2 was a detailed analysis on the logistical challenges of deploying very large (>100m) onshore blade. This work was completed by experts at DNV-GL. The report looked at various ways to get around the current transportation constraints which are estimated to be around 75m in length. The report concluded that there are viable solutions to this issue including: segmented blades (which the industry is already pursuing), lighter than air (LTA) transportation, on-site manufacturing, and controlled bending of blades on rail. The final option was recommended for further analysis and study by DOE and the national labs because keeping a single piece blade reduces manufacturing and operations and maintenance (O&M) costs. Task 3 focused on identifying novel concepts that are capable of enabling a cost effective 5MW 206m rotor for onshore deployment. The findings from the first two tasks were considered in the analysis, in that the concepts identified must be able to overcome the transportation logistics challenges. Around 20 concepts were identified and evaluated by experts within the industry. Additionally, science and engineering challenges were identified for each concept. Based on these evaluations six concepts were deemed the most impactful and were selected for further analysis in Task 4. The concepts were: highly flexible rail transportable blades, downwind rotors, distributed aerodynamic control (DAC) devices, inflatable blade, bi-wing blade, and 4/5 bladed rotors. Task 4 conducted detailed design, optimization, and analysis on the selected BAR concepts. A modeling gaps analysis was conducted, and modeling improvements were implemented that allowed for the study and design of the novel concepts. The BAR team established a set of baseline designs by which to compare the selected designs through a technoeconomic analysis. It was found that the highly flexible rail transportable blade, the downwind rotor, and the DAC devices have the most promise to deliver the BAR targets. A Phase II for BAR has been proposed to further mature these concepts and address the open science and engineering challenges identified in Task 3. Task 5 conducted research on optimized carbon fiber materials that were used throughout the BAR Phase I project. Overall, the BAR project has identified low-SP turbines as important to continued LCOE reductions for onshore turbines. Furthermore, the project has identified viable solutions to the technical and logistical challenges to realizing these goals. The most promising technologies that were identified in Phase I of the project will be further matured and de-risked in Phase II of the BAR project.

17 WIND ENERGY↗
DOE OSTI2021

An open-endcap blade trap for radial-2D ion crystals

We present the design and experimental demonstration of an open-endcap radio frequency trap to confine ion crystals in the radial-two dimensional (2D) structural phase. The central axis of the trap is kept free of obstructions to allow for site-resolved imaging of ions in the 2D crystal plane, and the confining potentials are provided by four segmented blade electrodes. We discuss the design challenges, fabrication techniques, and voltage requirements for implementing this open-endcap trap. Finally, we validate its operation by confining up to 29 ions in a 2D triangular lattice, oriented such that both in-plane principal axes of the 2D crystal lie in the radial direction.

74 ATOMIC AND MOLECULAR PHYSICS↗
NASA NTRS1971

Computer program for calculating aerodynamic forces on blade sections

Calculation is taken from pressure or velocity distribution along blade surface. Blade sections have either one or two /tandem/ blade segments. Program is recommended primarily for use with ideal flow pressure distributions where forces in drag direction are neglected.

Mcnally, W. D.↗
NASA NTRS1981

Helicopter rotor trailing edge noise

A two dimensional section of a helicopter main rotor blade was tested in an acoustic wind tunnel at close to full-scale Reynolds numbers to obtain boundary layer data and acoustic data for use in developing an acoustic scaling law and testing a first principles trailing edge noise theory. Results were extended to the rotating frame coordinate system to develop a helicopter rotor trailing edge noise prediction. Comparisons of the calculated noise levels with helicopter flyover spectra demonstrate that trailing edge noise contributes significantly to the total helicopter noise spectrum at high frequencies. This noise mechanism is expected to control the minimum rotor noise. In the case of noise radiation from a local blade segment, the acoustic directivity pattern is predicted by the first principles trailing edge noise theory. Acoustic spectra are predicted by a scaling law which includes Mach number, boundary layer thickness and observer position. Spectrum shape and sound pressure level are also predicted by the first principles theory but the analysis does not predict the Strouhal value identifying the spectrum peak.

Schlinker, R. H.↗
NASA NTRS1989

An acoustic experimental and theoretical investigation of single disc propellers

An experimental study of the acoustic field associated with two, three, and four blade propeller configurations with a blade root angle of 50 deg was performed in the Texas A&M University 5 ft. x 6 ft. acoustically-insulated subsonic wind tunnel. A waveform analysis package was utilized to obtain experimental acoustic time histories, frequency spectra, and overall sound pressure level (OASPL) and served as a basis for comparison to the theoretical acoustic compact source theory of Succi (1979). Valid for subsonic tip speeds, the acoustic analysis replaced each blade by an array of spiraling point sources which exhibited a unique force vector and volume. The computer analysis of Succi was modified to include a propeller performance strip analysis which used a NACA 4-digit series airfoil data bank to calculate lift and drag for each blade segment given the geometry and motion of the propeller. Theoretical OASPL predictions were found to moderately overpredict experimental values for all operating conditions and propeller configurations studied.

Bumann, Elizabeth A.↗
NASA NTRS1985

A note on blade wake interaction influence on compressor stator row aerodynamic performance

Attention is given to the effect of blade wake interactions on the performance of an axial flow compressor's stator row, for the case of compressor and fan stator flows without shocks. The measured midspan loss of total pressure can be related to stator surface boundary layers, the chopped rotor wakes passing through the stator row, and the interaction between these flows. The interaction between rotor blade wake segments and stator blade surface boundary layers generates much higher losses than expected in both the stator wake and in the region of flow between stator boundary layers/wakes, if interaction effects are ignored.

Okiishi, T. H.↗
NASA NTRS1985

Automatically Dressing Blades in Silicon-Wafer Cutting

Inserts incorporated in support beams for silicon ingots automatically "dress" cutting blade during wafer slicing. Segments of blade-dressing material placed at regular intervals in graphite beam. Blade cuts into segments and dressed without operator intervention and without interrupting regular machine operation. Manual dressing eliminated, and production rates increased.

Morrison, A. D.↗
DOE OSTI2022

Land-based wind turbines with flexible rail-transportable blades – Part 2: 3D finite element design optimization of the rotor blades

Abstract. Increasing growth in land-based wind turbine blades to enable higher machine capacities and capacity factors is creating challenges in design, manufacturing, logistics, and operation. Enabling further blade growth will require technology innovation. An emerging solution to overcome logistics constraints is to segment the blades spanwise and chordwise, which is effective, but the additional field-assembled joints result in added mass and loads, as well as increased reliability concerns in operation. An alternative to this methodology is to design slender flexible blades that can be shipped on rail lines by flexing during transport. However, the increased flexibility is challenging to accommodate with a typical glass-fiber, upwind design. In a two-part paper series, several design options are evaluated to enable slender flexible blades: downwind machines, optimized carbon fiber, and active aerodynamic controls. Part 1 presents the system-level optimization of the rotor variants as compared to conventional and segmented baselines, with a low-fidelity representation of the blades. The present work, Part 2, supplements the system-level optimization in Part 1 with high-fidelity blade structural optimization to ensure that the designs are at feasible optima with respect to material strength and fatigue limits, as well as global stability and structural dynamics constraints. To accommodate the requirements of the design process, a new version of the Numerical Manufacturing And Design (NuMAD) code has been developed and released. The code now supports laminate-level blade optimization and an interface to the International Energy Agency Wind Task 37 blade ontology. Transporting long, flexible blades via controlled flapwise bending is found to be a viable approach for blades of up to 100 m. The results confirm that blade mass can be substantially reduced by going either to a downwind design or to a highly coned and tilted upwind design. A discussion of active and inactive constraints consisting of material rupture, fatigue damage, buckling, deflection, and resonant frequencies is presented. An analysis of driving load cases revealed that the downwind designs are dominated by loads from sudden, abrupt events like gusts rather than fatigue. Finally, an analysis of carbon fiber spar caps for downwind machines finds that, compared to typical carbon fibers, the use of a new heavy-tow carbon fiber in the spar caps is found to yield between 9 % and 13 % cost savings.

17 WIND ENERGY↗