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Hardware-in-the-loop Drive Train Control Mohsen Neshati, Adam Zuga 3rd Annual International Workshop on Grid Simulator Testing of Energy Systems and Wind Turbine Power Trains November 2015, Tallahassee, Florida in Dynamic Nacelle Laboratory

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Hardware-in-the-loop Drive Train Control

Mohsen Neshati, Adam Zuga

3rd Annual International Workshop on Grid Simulator Testing of Energy Systems

and Wind Turbine Power Trains

November 2015, Tallahassee, Florida

in Dynamic Nacelle Laboratory

Dynamic Nacelle Laboratory (DyNaLab)

© Fraunhofer 2

10 MW Nominal Drive Power Suitable for 2-8 MW Wind Energy Converters (WEC)

44 MVA Grid Simulator with Fault-ride-through Capability

8.6 MNm Nominal Drive Train Torque at Low Nominal Speed of 11 rpm

Mechanical Wind Loads Emulation in Six Degrees of Freedom (DOF)

Hardware-in-the-loop (HiL) Test Environment

Torsional Performance Evaluation of WEC Drive Train as Device Under Test (DUT)

Technology Development, Model Validation, Reliability Testing, etc.

© Fraunhofer 3

Hardware-in-the-loop (HiL) Framework

Real-time Aero-elastic Model

Software

Hardware

Rotor

Tower

Turbulent Wind Field

Measurements

Set Points

Drive Train Control Load Application System Grid Simulator Measurement Systems

Real-time Simulation Platform

© Fraunhofer 4

Emulation of the Missing Rotor and its Interaction with WEC Nacelle

• Rotor Torque Dynamics

• Rotor Torque Steady-state

• Validation in Comparison with CAE Tools

HiL Drive Train Control Requirement

Frequency (Hz)

From: Input Torque To: Output Torque

Ideal WEC

Drive Train

FAST

Mag

nitu

de (d

B)

Ideal Wind Energy Converter (WEC) Equivalent Lumped-mass Model

Overall Test Rig Drive Train Lumped-mass Model

© Fraunhofer 5

Test Rig Drive Train Discrete Mass Structure

• Prime Mover Rotor • Torque Limiter • Flexible Coupling • Moment Bearing

Finite Elasticity of Couplings

Torsional Chain Oscillator

Inertia Distribution Rate

2 21

14 55

Frequency (Hz)

Mag

nitu

de (d

B)

Bode Diagrams From: Air-gap Torque To: Flange Torque

© Fraunhofer 6

HiL Drive Train Control Objective

Drive Train Active Vibration Damping

Desired Frequency Response In and Around Torsional Modes

Influence on Torque Transmission Characteristic of the Drive Train

Enough DOF Required to Modify Torsional Modes of the Overall System

Equivalent Rotor Model

𝑣𝑤 𝑀𝑓𝑙∗ 𝑀𝑎

Measurements

HiL Control

Observer/Filter

© Fraunhofer 7

HiL Approach-1 Simplified Lumped-mass Model

Generator Side (DUT) Measurement (Angular Velocity)

Emulation of the Virtual Rotor Torsional Mode

Emulation of the Equivalent DUT Drive Train Torsional Mode

DyNaLab Drive Train Torque Transmission Characteristic to be Controlled

Overall Drive Train Performance is to be Similar to that of an Ideal WEC

© Fraunhofer 8

Test Rig Side Measurement (Angular Acceleration)

Emulation of the Virtual Rotor Torsional Mode

DyNaLab Drive Train Torque Transmission Characteristic to be Controlled

DyNaLab Drive Train Performance is to be Similar to that of the Virtual Rotor

HiL Approach-2 Simplified Lumped-mass Model

© Fraunhofer 9

HiL Drive Train Control Solution

Model Based Approach with State-space Solution

Optimal Control • Constrained Model Predictive Control (MPC) • Linear-quadratic-gaussian (LQG)

Time-varying Kalman Filter as Observer

© Fraunhofer 10

Simulation Results

Frequency Response – Direct Drive Specimen

Frequency (Hz)

Mag

nitu

de (d

B)

Bode Diagram From: Aerodynamic Torque To: Flange Torque

© Fraunhofer 11

Frequency (Hz)

Mag

nitu

de (d

B)

Bode Diagram From: Aerodynamic Torque To: Flange Torque

Simulation Results

Frequency Response – Geared Specimen (5MW NREL)

© Fraunhofer 12

Bode Diagram From: Air-gap Torque To: Flange Torque

Frequency (Hz)

Mag

nitu

de (d

B)

Bode Diagram From: Aerodynamic Torque To: Flange Torque

Frequency (Hz)

Simulation Results

Frequency Response Analysis (5MW NREL DUT)

© Fraunhofer 13

Step Response (Torque) Generator Speed Step Response

Simulation Results

Step Response (5MW NREL DUT)

© Fraunhofer 14

Flange Torque Response Omega Rotor Response

Simulation Results

System Response for an Input Wind Speed (5MW NREL DUT)

Conclusion

© Fraunhofer 15

Practicable HiL Concept Presented

Effective Control Structure designed for the Introduced HiL Framework

Virtual Rotor Model Required for Control Design

Enough DOF Required to Influence Drive Train and Virtual Rotor Dynamics

Validation Using CAE Tools for Future Work

Control Design in Frequency Domain for Future Work

© Fraunhofer 16

Any questions? Mohsen Neshati [email protected] Adam Zuga [email protected]

Allgemeines schönes WEA Bild

Thank You For

Your Attention