reliability testing tools and methods for wind turbine drive trains
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Reliability Testing Tools and Methods for Wind Turbine Drive Trains. Robert Orange, Systems Engineer MTS Systems Corporation. MTS: Mechanical Test & Simulation Solution Supplier. Ground Vehicles Aero Structures Materials & Structures Includes Wind Applications Sensors. - PowerPoint PPT PresentationTRANSCRIPT
Reliability Testing Tools and Methods for Wind Turbine Drive Trains
Robert Orange, Systems Engineer
MTS Systems Corporation
04/19/2023
MTS: Mechanical Test & Simulation Solution Supplier
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» Ground Vehicles» Aero Structures» Materials & Structures
– Includes Wind Applications
» Sensors
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Presentation Outline
» Review the Mechanical Testing Rationale & Requirements» Highlight Some Characteristics of Reliability Testing» Review Aero Structural & Ground Vehicle Testing» Introduce Additional Test Methods
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Reliability Review - Loads vs. Susceptibility
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Development & Testing
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Conceptual Design
Sub-System Specifications
Component Specifications
System Validation
Sub-System Validation
Component Validation
Component DesignLoadsDefinition Subsystem
Testing
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Test Types
» HALT (Highly Accelerated Life Test)– Robustness test to identify weak points
in the design
» ALT (Accelerated Life Test)– Get reliability (failure rate) information
» Others– Loads Definition Tests, etc.
» Acceleration Methods:– Time Compression & Load Amplification
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Loads >> Service
Loads Max Service
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Summary – Reliability Tests
» Know both– Service loading (at critical component level)
and– Component “strength” (know failure modes)
» Can use testing for many purposes– Make sure the test rig / test plan meets the requirement.
» Test Acceleration is necessary but dangerous
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Aerospace Structures» Flight Envelope Defines
Static Limits
» Service Life + Flight Envelope is basis for fatigue testing
» Tests:– Massively multi-axial– Go from one balanced state to another balanced state
» Acceleration Methods: – Time Compression– Load Amplification (choosing edges of flight envelope)
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Ground Vehicles» Use Time Histories
(rough road data)» Multi-Axial & Dynamic
» Testing at system, sub-system and component levels– Loads definitions flow down from
initial road load data & tests on model and/or proxy test article
– System reliability built up from components, final tests at system level
» Acceleration Methods: – Time compression (fatigue based editing)– Load Amplification (start from rough road conditions on full vehicle)
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Common Characteristics: Aero/Ground Vehicles
» Rationale for loading starts from external environment
» Used at all levels of development (V diagram):– Loads definitions – Component Testing – Integration Testing
» Tests– All loads of significance are present in the test– Load relationships match service conditions – Load Amplification is at the limit of expected service loads
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Tools/Methods
» Time Compression
» Load Replication– RPC (Remote Parameter Control)– Hybrid Simulation
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Fatigue-based Editing
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Edit time history data basedon regions selected from thedamage time history
Damage time historyshows where damagingcycles occur in the data
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Load Replication – RPC
» Remote Parameter Control– Method to reproduce:
» Parameters: loads/strains/accelerations/displacements» At remote location: Gbx bearing races, Gbx Mounting, Main bearing
– Get high fidelity of loads at critical components
– Real or constructed (IEC DLC) demand waveforms
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Test RigNacelle
+
RPC Iterations
Continue until response error 0
Drive
Response
Desired Response
Response ErrorFRF-1Drive
Correction -
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Load Replication - Hybrid Simulation
» Combination of math model, test rig and system under test
» For drive train test rig:– Input: Transient Wind Field ( could come from IEC DLCs)– Model: Blades, Hub, Tower, Foundation, Pitch & Yaw Response– Real:
» Nacelle with controller» Test Rig
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Nacelle & WTC Controller
WTC Pitch & Yaw Cmds
Test Rig
Rig Commands
Pitch & Yaw Models
Blade Model
Wind AnemometerHub Forces & Moments
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Hybrid Simulation
» Benefits– Most accurate replication of events
» WTG controller strategies will effect response to transient wind and affect loads
– No iteration steps to converge on solution; real time
» Costs– Most sophisticated test setup– Highest demand on the rig controller and mechanical system– Accuracy dependent upon model fidelity
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Summary
» To Achieve Higher Reliability:– Need to link service loads to test loads– Need to integrate testing into all phases of the design cycle– Do more than HALT testing
» Consider using tools that are well developed in other industries:– Fatigue-based editing– Remote Parameter Control (RPC)– Hybrid Simulation
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Thank You!
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Photos courtesy of:» Cessna Aircraft Corporation» University of Minnesota» Airbus Military » Fraunhofer Institute LBF