Integrated Design and System Analysis at S di Sandia 2010 Sandia Wind Turbine Blade Workshop Brian Resor T hi lSt ff D i T lL d T echnical Staff , Design T ools Lead Wind & Water Power Technologies Sandia National Laboratories brresor@sandia.gov Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy’s National Nuclear Security Administration under contract DE-AC04-94AL85000. (505) 284-9879
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Integrated Design and eg a ed es g a dSystem Analysis at
S diSandia2010 Sandia Wind Turbine Blade Workshopp
Brian ResorT h i l St ff D i T l L dTechnical Staff, Design Tools LeadWind & Water Power Technologies
Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company,for the United States Department of Energy’s National Nuclear Security Administration
under contract DE-AC04-94AL85000.
@ g(505) 284-9879
Modeling and Simulation MotivationModeling and Simulation Motivation
Smaller turbines → Larger turbines
$ → $$$
B ild B k R d i → Ad d Si l iBuild, Break, Redesign → Advanced Simulation
Paper airplaneCommercial Aircraft
Wind Turbine Design Elementsg
Blade Analysis
Full System
Material Properties & Layup
Full 3D Blade Structural Analysis
Full System SimulationAerodynamics
Shapes
Blade Flutter
Aerodynamic Loads
Advanced Performance
Data
Shapes
ControlsInflow
Recently Supported Research Projectsy pp j
The use of design tools at Sandia provides a bridge between research and application by supporting our projects:research and application by supporting our projects:
SMART rotor technology• System simulations with active reduction of loads • System simulations and blade analysis to support SMART
Blade designbl d i i i CX-100 sensor blade activities
• Blade test definitions• Sensor placements• Sensor placements
“Certification” of the 100m blade design concept Blade fatigue failure modelingg g
Wind Turbine Design Elementsg
Blade Analysis
Full System
Material Properties & Layup
Full 3D Blade Structural Analysis
Full System SimulationAerodynamics
Shapes
Blade Flutter
Aerodynamic Loads
Advanced Performance
Data
Shapes
ControlsInflow
Blade Design with NuMADANSYS FE ModelNuMAD ANSYS Analysis
1
X
Y
Z
*
Modal
ANSYS FE ModelNuMADNuMAD:Numerical ManufacturingAnd Design Tool
ANSYS Analysis
pseudoSERI8
Blade Geometry
Buckling
Materials & Layups
Stress &Strain
2 000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
FlpStff (kN/m^2)
EdgStff (kN/m^2)
Stack Placement
Beam Properties
0
1,000
2,000
0 0.2 0.4 0.6 0.8 1
BlFract
Use of Offset-Thickness Shell Nodesf ff
Offset-thickness nodes are most desirable for wind turbine blade FE models
The outer blade surface is the specified surface
Offset Node Shell Element Problemsff
Work by Daniel Laird, and others, documented in 2005 uncovered significant problems with the use of offset-node shell elementsproblems with the use of offset-node shell elements
The wind industry sought other solutions for blade models: The wind industry sought other solutions for blade models:• Restrictions to mid-thickness node shell elements • Entire wind turbine blades modeled with solid elements
h f d l l l h• High fidelity cross sectional analysis, such as VABS
New shell formulation in ANSYS 12.0Very good news!Very good news!
Motivation: Efficient aeroelastic analysis for design and certificationcertification• Time marching system response simulation• Stability analyses• Blade test design and setup
i l i f h f ll i di ib i Typical outputs consist of the following distributions• Bending, torsion and axial stiffness• Coupled stiffness• Coupled stiffness• Shear center coordinates• Tension center coordinates• Inertial properties: masses and center of mass
Property Distribution ComputationsProperty Distribution ComputationsTwo-Dimensional Approach Pros
Three-Dimensional Approach Pros
• Readily and freely available• Computationally efficient
Cons
• Includes three dimensional effects Cons
• Requires creation of the finite element d l• Limited to 2D understanding
• Simple examples below:
model
0
1
2
Undisplaced nodesDisplaced nodes (exaggerated)
= dxdyxyxEflapEI 2),(_ ,3
4
5
6
7-0 4-0.2
00.2
Blade Span= dxdyyyxEedgeEI 2),(_ ,
+= dxdyyxyxGGJ ))(,( 22 and
= dxdyyxEEA )(
Useful Tool: PreComp• Created by Gunjit Bir, NREL
Useful Tool: Beam Property Extraction (BPE)
• Created by David Malcolm GEC
7
-0.2 0 0.2 0.4 0.6 0.8
-0.4
Chord
= dxdyyxEEA ),(
• Created by David Malcolm, GEC• Distributed with NuMAD (Sandia Labs)
Required inputs: lift curve slope and pitch axis location along with information taken from ad.IPT and blade.DAT files utilized by FAST
• Fortran executable Determines necessary mass stiffness and damping matrix additions due to aerodynamic Determines necessary mass, stiffness, and damping matrix additions due to aerodynamic
effects (Theodorsen) Generates additional Nastran decks for the complex eigenvalue solve
The analyst iterates on operating speed, following the complex modes, to find the fl tt dflutter speed