dana martin/daniel zalkind - 50 mw segmented ultralight morphing rotor (sumr): design concept and...

50MWSegmentedUltralightMorphingRotor(SUMR):DesignConceptandControlsStrategies

DanaMartinandDanielZalkind

AdvancedResearchProjectsAgency-Energy(ARPA-E)

• Fundhigh-potential,high-impactenergytechnologiesthataretooearlyforprivate-sectorinvestment

2

FloDesign’sShroudedWindTurbineAccioEnergy’sElectrohydrodynamic(EHD)windenergyGenerationSystemMakaniPower’sAirborneWindTurbine

Reduce Emissions

Improve Energy

Efficiency

Reduce Energy Imports

9/19/16 2016SandiaBladeWorkshop

ExtremeScaleTurbines

9/19/16 2016SandiaBladeWorkshop 3

Largerturbinesmeanmoreenergycapturedandreduces“plant”&“utility-integration”costs

FigurecourtesyofEricLoth

SegmentedUltralightMorphingRotors(SUMR)

4

• Alignsbladealongaxialloads• Reducesrotormass&facilitates

segmentation• Enableslightweight,extremescale

turbines,e.g.13-50MW

Downwind Morphingwind

Metric Conv-13 SUMR-13 SUMR-50

RotorRadius 102.5m 107.5m 200m

Ratedpower 13.2MW 13.2MW 50MW

Rotormass 148.5Mg 72.3Mg TBD

LevelizedCostofEnergySavings 0% 33% 50%

𝝍

*Source:Steeleet.al.,AerodynamicsofanUltralightLoad-AlignedRotorforExtreme-ScaleWindTurbines


ProjectTimeline

5

• Initialdesign

• Goal:25%rotormassreduction

CONR-13

• OptimizebasedonexperiencefromSUMR-13i

• Goal:25%LCOEreduction

SUMR-13i

Applylessonsfrompreviousrotorsto

designof50MWrotor

SUMR-50

Design,fabricate,configure

andexecuteaNRELfield

test

SUMR-DCONR:conventionalrotorLCOE:levelized costofenergySUMR:segmented,ultra-light,morphing rotor

April2016 April2017 April2018 April2019

• Systemdesign• Aerodynamicdesign• Structuraldesign• Controldesign


SystemDesign

• Outputs– Morphingschedule– Turbineconfiguration

6

SystemDesign[UVA]

AerodynamicDesign[UIUC]

StructuralDesign[Sandia]

ControlSystemDesign

[CSM&UCB]

Hingedactuation(active)

Aero-elasticdeformation(passive)

[EricLoth,CarlosNoyes,ChrisQin,UniversityofVirginia]

• Morphingconcept– Designhingemechanism– Testhingemechanism(watertunnel)


cvcvc

c

NacelleC.M. Overhang

Pre-coneTowerHt.

WindSpeed/Rated

ConingAngle(d

eg.)

InitialConingSchedule forSUMR-13i

AerodynamicDesign

SystemDesign[UVA]



ControlSystemDesign

[CSM&UCB]

F1-4846-1226

F1-3856-0738

F1-2655-0262

F1-2040-0087

F1-1822-0041

[GavinAnanda,Suraj Bansal,MichaelSelig,Universityof IllinoisUrbana-Champaign]

• Coningrotordesigncode&validation

• Aerodynamicdesign– PROFOIL

Airfoil,rotorinfo.


StructuralDesign

8

SystemDesign[UVA]



ControlSystemDesign

[CSM&UCB]

(1) Maximum Strain

(2) Tip Deflection

(3) Fatigue(4) Buckling

(5) Dynamics and Flutter

üWillnotbreak

Willnotstriketower

üGreaterthan20yrsüStablestructure

üNoturbinevibrationsüAero-elasticstability

[D.ToddGriffith,ChrisKelley,SandiaNationalLaboratories]

Bladestructuralparameters


ControlSystemDesign

• Controlarchitecture– Gains,set-points

• Time-seriessimulationanalysisusingFASTv8– Loads– Deflections– Powerproduction

9

SystemDesign[UVA]



ControlSystemDesign

[CSM&UCB]

[KathrynJohnson,DanaMartin, LucyPao,DanielZalkind,CSM,UCB]Controlsystem,validationofturbineconfiguration


FieldTesting&CostAnalysis

10

SystemDesign[UVA]



ControlSystemDesign

[CSM&UCB]

Source:NRELImageGallery

LCOE =CapEx ∗ Finance + OpEx

AEPnet

[RickDamiani,LeeJayFingersh, PatrickMoriarty,TylerStehly,NREL]


MinimumControlRequirements

• Givenarotordesign,ourgoalistodesignreal-timecontrollersthat:– “basedontheinformationabouttheconditionofthewindturbineand/oritsenvironment,

– adjusttheturbineinordertomaintain itwithinitsoperatinglimits.”*

11

*Source:IEC61400-1


Note:turbinesarenottypicallycontrolled fromthenacelle

PerformanceMetrics

• Theseoperatinglimitsaredefinedbythewindturbinedesigner,whichinclude– Generatoroverspeed,overloadorfault

– Ultimatebladeloadsandblade-to-towerclearanceinextremeorextrapolatedevents,and

– Designlifetimeduetofatigueloading.

12

Gen.speedthreshold

Maximumgen.speed

Ratedgen.speedGe

n.Speed(rpm

)

Time(s)BladeRo

otBend.M

oment(kN

m)


ControlOverview– OperatingRegions


0 5 10 15 20 250

0.5

1

1.5

2

2.5

3

Wind Speed (m/s)

Pow

er (M

W)

Example Power Curves for 2.5 MW Wind Turbine

Region1

• Region1:Lowwindspeed–Windturbinesnotrun,becausepoweravailableinwindislowcomparedtolossesinturbinesystem

• Region2:Mediumwindspeeds– Variable-speedturbinesvaryspeedtomaximizeaerodynamicefficiency

• Region3:Highwindspeeds– Variable-pitchturbineslimitpowertoavoidexceedingsafeelectricalandmechanicalloadlimits

WindPower

Available

MaxPowerCoeff » 0.50Region2

Region3

ExpectedTurbinePower

(SlidecourtesyofProf.LucyPao)

BaselineControl

• Jonkman etal.,“Definitionofa5-MWRef.WindTurbineforOffshoreSystemDevelopment,”2005. BaselineController

ParametersofNREL5-MW

Parameter Value

BladeLength 63m

RotorInertia 3.87x107 kg-m2

RatedTorque 47 kNm

RatedRotorSpeed

12.1rpm

Configuration Upwind,3-bladed,2.5° coning

Cp Surface

5-MWRef.Params.SNL100-03Params.

ParametersofSNL100-03

Parameter Value

BladeLength 102.5 m


RatedTorque 115kNm

RatedRotorSpeed

7.43rpm

Configuration Upwind,3-bladed,2.5° coning

Cp Surface

Parameter Value

BladeLength 102.5 m


RatedTorque 115kNm

RatedRotorSpeed

7.43rpm

Configuration Downwind, 2-bladed, var.coning

Cp Surface

SNL100-03(D2)Params.

ParametersofSNL100-03(D2)

Parameter Value

BladeLength ~100m

RotorInertia ??

RatedTorque ~115kNm

RatedRotorSpeed

~7 rpm

Configuration ??

Cp Surface

SUMR-13iParams.

??

ParametersofSUMR-13i

NREL5-MW

SNL10013.2MW

SNL100(D2)

SNL100(coning)

SUMR-13i

SUMR-13SUMR-DSUMR-50


• Transferfunctiondescribesinput/outputdynamicsinthefrequencydomain

• Inthiscase,thepolesrepresentatimeconstantfortheresponseofthesystemtothecontrolledinput(i.e.generatortorque).

• Linearizedsystematseveralconingangle,windspeedpairs

• Pole-ZeroMap• Effects:

• Dynamicschangewithconingangle

• Differentgainsneedtobecalculatedforsamepower&speedregulation

𝐺 𝑠 =𝑌(𝑠)𝑈(𝑠)

IncorporatingConing– Dynamics


RealAxis(seconds-1)

Pole-ZeroMap

ImaginaryAx

is(secon

ds-1)

IncorporatingConing– SteadyPrecone

• Implementedsteady-statepre-coneschedule(right)

• RanturbulentsimulationsusingFASTv8

16*Source:UniversityofVirginia

WindSpeed/Rated

ConingAngle(d

eg.)

Turbine CharacteristicsNumber ofBlades Airfoil Rated Torque(kN-m) RatedPower(MW) RotorDirection

2 SNL100-03FB 115 13.2 Down Wind

12.5°



IncorporatingConing– RotorTorque

17



AverageRo

torTorqu

e(kN-m

)

AverageRotorTorquevs.WindSpeed

WindVelocity(m/s)

AeroTorquevs.ConingAngle

ConingAngle(degrees)

AeroTo

rque

@10m

/swind(kN-m

)

2016SandiaBladeWorkshop9/19/16

MaximumandMinimumTipDisplacements

TipDisplacemen

t(m)IncorporatingConing– Extreme

Loads

18

Turbine CharacteristicsNumber ofBlades

Airfoil Rated Torque(kN-m)

RatedPower(MW)

RotorDirection Design LoadCaseTested

2 SNL100-03FB 115 13.2 Down Wind Extreme TurbulenceModel(ETM)

Constantvs.ScheduledMax.Displacements

%Cha

ngeinOutofP

lane

Disp

.

RootMomentBendingLoads

RootM

omen

ts(kN-m

)

Constantvs.ScheduledMax.Loads

%Cha

ngeinOOPBld.Roo

tMom

.

IncorporatingConing-AverageLoads




Avg.OutofP

lane

Blade

Roo

tMom

.(kN

-m)

WindVelocity(m/s) WindVelocity(m/s)

Avg.InPlane

Blade

Roo

tMom

.(kN

-m)

AdvancedControlMethodsforReducingLoads

• Power&speedregulation

• Oscillations

• Bladeloads

• Incomingwindmeasurement

20

BaselineController

RotorParams.

DT&TowerDamper

Indiv.PitchControl

FeedforwardControl

Actuators

Lidar


ControlChallenge:Modelling

21

Hub

Drivetrain

Blades

Hinges

• Rotorlayout

• Degreesoffreedom,states

• Controlinputs

• Disturbances

Rotorspeed

Tipdeflection

Gen.torqueWind Bladepitch

Flapangle


ControlChallenges:WindResource

• Shear– Unevenrotorloading– Sheareffectsshouldincreasewithrotordiameter

• Turbulence– Turbulentlengthscale~bladelength

• Normallyassumedtobemuchlarger• Introducesuncorrelatedloadingalongblade

22

𝝎

Loads

Deflections


ControlOpportunity:EquationsofMotion

• �̇� = 𝑓 𝑥, 𝑢, 𝑑 → �̇� = 𝐴𝑥 + 𝐵𝑢 + 𝐸𝑑

• 𝑦 = ℎ 𝑥, 𝑢, 𝑑→𝑦 = 𝐶𝑥 +𝐷𝑢 + 𝐹𝑑

• Stability• Controllability

– Canyouchangethestateusingtheinputs(andwhichones)?

• Observability– Canyoudeterminethestateby

viewingtheoutput(andwhichones)?

23

Blades:𝑀K�̈�K + 𝐷K�̇�K + 𝐾K𝑥K = 𝑓N(𝜃, 𝜆)

Tower(notshown):𝑀N�̈�N + 𝐷N�̇�N + 𝐾N𝑥N = 𝑓N 𝜃, 𝜆

Drivetrain&Control:𝜔 = R

S 𝜏U − 𝜏W𝜃 = 𝐾X 𝜔 −𝜔Y + 𝐾Z∫ 𝜔 −𝜔Y 𝑑𝑡

𝑥K

𝜔

𝜃

𝜃


𝑥N

ControlChallenges:Structures

• Loads– Massreduction→increaseddeflection– Coning&sizeincrease→increasein-planeloads

• Actuators– Whatarethedemands(e.g.timedelays)andcantheybemetwithcurrenttech.?• Largerbladesrequiremorepowerfulpitchactuators• Implementationofapitch/coningactuatorsystem


ControlOpportunity:SmartRotorControl

• Controlsurfaces– Partialpitch,flaps,microtabs,vortexgenerators,etc.

• Actuators– Fasterbandwidthstodampenaerodynamicdisturbances&structuralvibrations

• Sensors– Forinflowvelocities,pressures,accelerations,deflectionsandstrains

• Control– Centralized→Distributed


ProjectTimeline

26

• Initialdesign• Goal:25%rotormassreduction

CONR-13•OptimizedesignbasedonexperiencefromSUMR-13i

• Goal:25%LCOEreduction

SUMR-13i

Applylessonsfrompreviousrotorstodesignof50MWrotor

SUMR-50

Design,fabricate,configureandexecuteaNREL

fieldtestSUMR-D

April2016 April2017 April2018 April2019

Wearehere


ThankYou!QuestionsorComments?


Contact:DanaMartin/[email protected]/[email protected]

Extra


AdvancedControl- LPVLinearParameterVarying(LPV)ControlisacontrolmethodwhichutilizesLinearizedStateSpaceMatricesaroundseveralOperatingPointscontainedwithintheplantoperationenvelopeinordertoschedulecontrolgains.

29

OperatingPoints

�̇� = 𝑨(𝑣_)𝑥 + 𝑩(𝑣_)𝑢y= 𝑪(𝑣_)𝑥 + 𝑫(𝑣_)𝑢


PerformanceMetricSummary• Theseoperatinglimitsaredefinedbythewindturbinedesigner…

30*Source:IEC61400-1

TurbineParameters

Electrical Mechanical• GeneratorPower

§ RMSPower§ Frequencyabove

rated§ Maximum

Threshold

• TurbineComponentLoads§ UltimateLoads§ FatigueLoads

• TurbineComponentDisplacements§ Towerfore-aft§ Towerside-side§ Bladeinplaneandout-of-plane


PerformanceMetricSummary• Givenarotordesign,ourgoalistodesignreal-timecontrollersthat,“basedontheinformationabouttheconditionofthewindturbineand/or itsenvironment,adjusttheturbineinordertomaintainitwithinitsoperating limits.”*

31*Source:IEC61400-1

Controller

Environment

+

TurbineParameters

ConingAngle

PitchAngles

GeneratorTorque

SensorMeasurements(i.e.bladeloads,bladedisplacements,RotorSpeed)

WindTurbine


ControlOpportunities

• Differentmodel/controlsynthesistechniques– HerewemighttalkaboutSSmodelsforwindturbines&howtheyarechangedwhensizeincreasesandweightisreduced

– Also,controllersynthesis:LPV,MPC– Stilllearningwhatchallengesexist


IncorporatingConing-Mechanism

33*Source:UniversityofVirginia

Aero-elasticDeformation (passive) HingedActuation(Active)

vs


IncorporatingConing- Method

• Apivotaltopicofresearchishowtoimplementtheconing.– Aero-elasticdeflectionor– Activeconingactuatedbyanactivehinge• Singlepointofconing• Multiplepointsalongblade

34*Source:“Amorphingdownwind-alignedrotorconceptbasedona13-MWwindturbine”


IncorporatingConing- Schedule

• Theconingscheduleisdesignedtodecreaseaveragerootbladebendingmomentsandprotectturbinebladesduringhurricaneforcewinds

35*Source:“Amorphingdownwind-alignedrotorconceptbasedona13-MWwindturbine”


0 5 10 15 20 250

0.5

1

1.5

2

2.5

3

Wind Speed (m/s)

Pow

er (M

W)


Region1

OperatingRegions• Region1:Lowwindspeed(below6m/s=21.6km/h)– Windturbinesnotrun,becausepoweravailableinwindislowcomparedtolossesinturbinesystem

• Region2:Mediumwindspeeds(6m/sto11.7m/s)– Variable-speedturbinesvaryspeedtomaximizeaerodynamicefficiency

v Region3:Highwindspeeds(above11.7m/s=42.1km/h)§ Variable-pitchturbinesvarythepitchofbladestolimitpowertoavoidexceedingsafeelectricalandmechanicalloadlimits

WindPower

Available


Region3

Lucy Pao August2016



0 5 10 15 20 250

0.5

1

1.5

2

2.5

3

Wind Speed (m/s)

Pow

er (M

W)


Region1

OperatingRegions• Region1:Lowwindspeed(below6m/s)– Windturbinesnotrun,becausepoweravailableinwindislowcomparedtolossesinturbinesystem

• Region2:Mediumwindspeeds(6m/sto11.7m/s)– Variable-speedturbinesvaryspeedtomaximizeaerodynamicefficiency

v Region3:Highwindspeeds(above11.7m/s)§ Variable-pitchturbinesvarythepitchofbladestolimitpowertoavoidexceedingsafeelectricalandmechanicalloadlimits

WindPower

Available

Region3

De-ratedTurbinePower

Lucy Pao August2016




50MWSegmentedUltralightMorphingRotors(SUMR)forWindEnergy

2016 – 2019[E.Loth,D.T.Griffith,K.Johnson,P.Moriarty,L.Pao,M.Selig]

Lucy Pao August2016

wind


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