Dana Martin/Daniel Zalkind - 50 MW Segmented Ultralight Morphing Rotor (SUMR): Design Concept and Controls Strategies
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The document describes a segmented ultralight morphing rotor (SUMR) concept for extreme-scale wind turbines between 13-50 MW. The SUMR aims to reduce rotor mass by up to 50% through segmentation and morphing capabilities. This would enable lighter and larger turbines to reduce costs. The project involves design of the morphing hinges, aerodynamic modeling, structural analysis, and development of advanced control strategies to regulate loads and optimize performance under changing wind conditions. Field testing of a 13 MW prototype is planned to validate the SUMR concept.
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Dana Martin/Daniel Zalkind - 50 MW Segmented Ultralight Morphing Rotor (SUMR): Design Concept and Controls Strategies
- 4. Segmented Ultralight Morphing Rotors (SUMR) 4 • Aligns blade along axial loads • Reduces rotor mass & facilitates segmentation • Enables lightweight, extreme scale turbines, e.g. 13-50 MW Downwind Morphingwind Metric Conv-13 SUMR-13 SUMR-50 Rotor Radius 102.5 m 107.5 m 200 m Rated power 13.2 MW 13.2 MW 50 MW Rotor mass 148.5Mg 72.3 Mg TBD Levelized Cost of Energy Savings 0% 33% 50% 𝝍 *Source: Steele et. al., Aerodynamics of an Ultralight Load-Aligned Rotor for Extreme- Scale Wind Turbines 9/19/16 2016 Sandia Blade Workshop
- 5. Project Timeline 5 • Initial design • Goal: 25% rotor mass reduction CONR-13 • Optimize based on experience from SUMR-13i • Goal: 25% LCOE reduction SUMR-13i Apply lessons from previous rotors to design of 50 MW rotor SUMR-50 Design, fabricate, configure and execute a NREL field test SUMR-D CONR: conventional rotor LCOE: levelized cost of energy SUMR: segmented, ultra-light, morphing rotor April 2016 April 2017 April 2018 April 2019 • System design • Aerodynamic design • Structural design • Control design 9/19/16 2016 Sandia Blade Workshop
- 6. System Design • Outputs – Morphing schedule – Turbine configuration 6 System Design [UVA] Aerodynamic Design [UIUC] Structural Design [Sandia] Control System Design [CSM & UCB] Hinged actuation (active) Aero-elastic deformation (passive) [Eric Loth, Carlos Noyes, Chris Qin, University of Virginia] • Morphing concept – Design hinge mechanism – Test hinge mechanism (water tunnel) 9/19/16 2016 Sandia Blade Workshop cvcvc c Nacelle C.M. Overhang Pre-cone Tower Ht. Wind Speed / Rated Coning Angle (deg.) Initial Coning Schedule for SUMR-13i
- 7. Aerodynamic Design System Design [UVA] Aerodynamic Design [UIUC] Structural Design [Sandia] Control System Design [CSM & UCB] F1-4846-1226 F1-3856-0738 F1-2655-0262 F1-2040-0087 F1-1822-0041 [Gavin Ananda, Suraj Bansal, Michael Selig, University of Illinois Urbana-Champaign] • Coning rotor design code & validation • Aerodynamic design – PROFOIL Airfoil, rotor info. 9/19/16 2016 Sandia Blade Workshop 7
- 8. Structural Design 8 System Design [UVA] Aerodynamic Design [UIUC] Structural Design [Sandia] Control System Design [CSM & UCB] (1) Maximum Strain (2) Tip Deflection (3) Fatigue (4) Buckling (5) Dynamics and Flutter üWill not break Will not strike tower üGreater than 20 yrs üStable structure üNo turbine vibrations üAero-elastic stability [D. Todd Griffith, Chris Kelley, Sandia National Laboratories] Blade structural parameters 9/19/16 2016 Sandia Blade Workshop
- 9. Control System Design • Control architecture – Gains, set-points • Time-series simulation analysis using FASTv8 – Loads – Deflections – Power production 9 System Design [UVA] Aerodynamic Design [UIUC] Structural Design [Sandia] Control System Design [CSM & UCB] [Kathryn Johnson, Dana Martin, Lucy Pao, Daniel Zalkind, CSM, UCB] Control system, validation of turbine configuration 9/19/16 2016 Sandia Blade Workshop
- 10. Field Testing & Cost Analysis 10 System Design [UVA] Aerodynamic Design [UIUC] Structural Design [Sandia] Control System Design [CSM & UCB] Source: NREL Image Gallery LCOE = CapEx ∗ Finance + OpEx AEPnet [Rick Damiani, Lee Jay Fingersh, Patrick Moriarty, Tyler Stehly, NREL] 9/19/16 2016 Sandia Blade Workshop
- 11. Minimum Control Requirements • Given a rotor design, our goal is to design real-time controllers that: – “based on the information about the condition of the wind turbine and/or its environment, – adjust the turbine in order to maintain it within its operating limits.”* 11 *Source: IEC 61400-1 9/19/16 2016 Sandia Blade Workshop Note: turbines are not typically controlled from the nacelle
- 12. Performance Metrics • These operating limits are defined by the wind turbine designer, which include – Generator overspeed, overload or fault – Ultimate blade loads and blade-to- tower clearance in extreme or extrapolated events, and – Design lifetime due to fatigue loading. 12 Gen. speed threshold Maximum gen. speed Rated gen. speed Gen. Speed (rpm) Time (s)Blade Root Bend. Moment (kNm) 9/19/16 2016 Sandia Blade Workshop
- 13. Control Overview – Operating Regions 9/19/16 2016 Sandia Blade Workshop 13 0 5 10 15 20 25 0 0.5 1 1.5 2 2.5 3 Wind Speed (m/s) Power(MW) Example Power Curves for 2.5 MW Wind Turbine Region 1 • Region 1: Low wind speed – Wind turbines not run, because power available in wind is low compared to losses in turbine system • Region 2: Medium wind speeds – Variable-speed turbines vary speed to maximize aerodynamic efficiency • Region 3: High wind speeds – Variable-pitch turbines limit power to avoid exceeding safe electrical and mechanical load limits Wind Power Available Max Power Coeff » 0.50 Region 2 Region 3 Expected Turbine Power (Slide courtesy of Prof. Lucy Pao)
- 14. Baseline Control • Jonkman et al., “Definition of a 5-MW Ref. Wind Turbine for Offshore System Development,” 2005. Baseline Controller Parameters of NREL 5-MW Parameter Value Blade Length 63 m Rotor Inertia 3.87x107 kg-m2 Rated Torque 47 kNm Rated Rotor Speed 12.1 rpm Configuration Upwind, 3-bladed, 2.5° coning Cp Surface 5-MW Ref. Params.SNL 100-03 Params. Parameters of SNL 100-03 Parameter Value Blade Length 102.5 m Rotor Inertia 2.66x108 kg-m2 Rated Torque 115 kNm Rated Rotor Speed 7.43 rpm Configuration Upwind, 3-bladed, 2.5° coning Cp Surface Parameter Value Blade Length 102.5 m Rotor Inertia 1.77x108 kg-m2 Rated Torque 115 kNm Rated Rotor Speed 7.43 rpm Configuration Downwind, 2- bladed, var. coning Cp Surface SNL 100-03 (D2) Params. Parameters of SNL 100-03 (D2) Parameter Value Blade Length ~100 m Rotor Inertia ?? Rated Torque ~115 kNm Rated Rotor Speed ~7 rpm Configuration ?? Cp Surface SUMR-13i Params. ?? Parameters of SUMR-13i NREL 5-MW SNL 100 13.2 MW SNL 100 (D2) SNL 100 (coning) SUMR- 13i SUMR-13SUMR-DSUMR-50 9/19/16 2016 Sandia Blade Workshop 14
- 15. • Transfer function describes input/output dynamics in the frequency domain • In this case, the poles represent a time constant for the response of the system to the controlled input (i.e. generator torque). • Linearized system at several coning angle, wind speed pairs • Pole-Zero Map • Effects: • Dynamics change with coning angle • Different gains need to be calculated for same power & speed regulation 𝐺 𝑠 = 𝑌(𝑠) 𝑈(𝑠) Incorporating Coning – Dynamics 159/19/16 2016 Sandia Blade Workshop Real Axis (seconds-1) Pole-Zero Map Imaginary Axis (seconds-1)
- 16. Incorporating Coning – Steady Precone • Implemented steady-state pre- cone schedule (right) • Ran turbulent simulations using FASTv8 16 *Source: University of Virginia Wind Speed / Rated Coning Angle (deg.) Turbine Characteristics Number of Blades Airfoil Rated Torque (kN-m) Rated Power (MW) Rotor Direction 2 SNL100-03 FB 115 13.2 Down Wind 12.5° 9/19/16 2016 Sandia Blade Workshop
- 17. 9/19/16 2016 Sandia Blade Workshop Incorporating Coning – Rotor Torque 17 Turbine Characteristics Number of Blades Airfoil Rated Torque (kN-m) Rated Power (MW) Rotor Direction 2 SNL100-03 FB 115 13.2 Down Wind Average Rotor Torque (kN-m) Average Rotor Torque vs. Wind Speed Wind Velocity (m/s) Aero Torque vs. Coning Angle Coning Angle (degrees) Aero Torque @ 10m/s wind (kN-m)
- 18. 2016 Sandia Blade Workshop9/19/16 Maximum and Minimum Tip Displacements Tip Displacement (m) Incorporating Coning – Extreme Loads 18 Turbine Characteristics Number of Blades Airfoil Rated Torque (kN-m) Rated Power (MW) Rotor Direction Design Load Case Tested 2 SNL100-03 FB 115 13.2 Down Wind Extreme Turbulence Model (ETM) Constant vs. Scheduled Max. Displacements % Change in Out of Plane Disp. Root Moment Bending Loads Root Moments (kN-m) Constant vs. Scheduled Max. Loads % Change in OOP Bld. Root Mom.
- 19. Incorporating Coning-Average Loads 199/19/16 2016 Sandia Blade Workshop Turbine Characteristics Number of Blades Airfoil Rated Torque (kN-m) Rated Power (MW) Rotor Direction 2 SNL100-03 FB 115 13.2 Down Wind Avg. Out of Plane Blade Root Mom. (kN-m) Wind Velocity (m/s) Wind Velocity (m/s) Avg. In Plane Blade Root Mom. (kN-m)
- 20. Advanced Control Methods for Reducing Loads • Power & speed regulation • Oscillations • Blade loads • Incoming wind measurement 20 Baseline Controller Rotor Params. DT & Tower Damper Indiv. Pitch Control Feedforward Control Actuators Lidar 9/19/16 2016 Sandia Blade Workshop
- 21. Control Challenge: Modelling 21 Hub Drivetrain Blades Hinges • Rotor layout • Degrees of freedom, states • Control inputs • Disturbances Rotor speed Tip deflection Gen. torqueWind Blade pitch Flap angle 9/19/16 2016 Sandia Blade Workshop
- 22. Control Challenges: Wind Resource • Shear – Uneven rotor loading – Shear effects should increase with rotor diameter • Turbulence – Turbulent length scale ~ blade length • Normally assumed to be much larger • Introduces uncorrelated loading along blade 22 𝝎 Loads Deflections 9/19/16 2016 Sandia Blade Workshop
- 23. Control Opportunity: Equations of Motion • 𝑥̇ = 𝑓 𝑥, 𝑢, 𝑑 → 𝑥̇ = 𝐴𝑥 + 𝐵𝑢 + 𝐸𝑑 • 𝑦 = ℎ 𝑥, 𝑢, 𝑑 → 𝑦 = 𝐶𝑥 + 𝐷𝑢 + 𝐹𝑑 • Stability • Controllability – Can you change the state using the inputs (and which ones)? • Observability – Can you determine the state by viewing the output (and which ones)? 23 Blades: 𝑀K 𝑥̈K + 𝐷K 𝑥̇K + 𝐾K 𝑥K = 𝑓N (𝜃, 𝜆) Tower (not shown): 𝑀N 𝑥̈N + 𝐷N 𝑥̇N + 𝐾N 𝑥N = 𝑓N 𝜃, 𝜆 Drivetrain & Control: 𝜔 = R S 𝜏U − 𝜏W 𝜃 = 𝐾X 𝜔 − 𝜔Y + 𝐾Z∫ 𝜔 − 𝜔Y 𝑑𝑡 𝑥K 𝜔 𝜃 𝜃 9/19/16 2016 Sandia Blade Workshop 𝑥N
- 24. Control Challenges: Structures • Loads – Mass reduction → increased deflection – Coning & size increase → increase in-plane loads • Actuators – What are the demands (e.g. time delays) and can they be met with current tech.? • Larger blades require more powerful pitch actuators • Implementation of a pitch/coning actuator system 249/19/16 2016 Sandia Blade Workshop
- 25. Control Opportunity: Smart Rotor Control • Control surfaces – Partial pitch, flaps, microtabs, vortex generators, etc. • Actuators – Faster bandwidths to dampen aerodynamic disturbances & structural vibrations • Sensors – For inflow velocities, pressures, accelerations, deflections and strains • Control – Centralized → Distributed 259/19/16 2016 Sandia Blade Workshop
- 26. Project Timeline 26 • Initial design • Goal: 25% rotor mass reduction CONR-13 • Optimize design based on experience from SUMR-13i • Goal: 25% LCOE reduction SUMR-13i Apply lessons from previous rotors to design of 50 MW rotor SUMR-50 Design, fabricate, configure and execute a NREL field test SUMR-D April 2016 April 2017 April 2018 April 2019 We are here 9/19/16 2016 Sandia Blade Workshop
- 29. Advanced Control - LPV Linear Parameter Varying (LPV) Control is a control method which utilizes Linearized State Space Matrices around several Operating Points contained within the plant operation envelope in order to schedule control gains. 29 Operating Points 𝑥̇ = 𝑨(𝑣_)𝑥 + 𝑩(𝑣_)𝑢 y= 𝑪(𝑣_)𝑥 + 𝑫(𝑣_)𝑢 9/19/16 2016 Sandia Blade Workshop
- 30. Performance Metric Summary • These operating limits are defined by the wind turbine designer… 30 *Source: IEC 61400-1 Turbine Parameters Electrical Mechanical • Generator Power § RMS Power § Frequency above rated § Maximum Threshold • Turbine Component Loads § Ultimate Loads § Fatigue Loads • Turbine Component Displacements § Tower fore-aft § Tower side-side § Blade in plane and out-of-plane 9/19/16 2016 Sandia Blade Workshop
- 32. Control Opportunities • Different model/control synthesis techniques – Here we might talk about SS models for wind turbines & how they are changed when size increases and weight is reduced – Also, controller synthesis: LPV, MPC – Still learning what challenges exist 329/19/16 2016 Sandia Blade Workshop
- 34. Incorporating Coning - Method • A pivotal topic of research is how to implement the coning. – Aero-elastic deflection or – Active coning actuated by an active hinge • Single point of coning • Multiple points along blade 34 *Source: “A morphing downwind-aligned rotor concept based on a 13-MW wind turbine” 9/19/16 2016 Sandia Blade Workshop
- 35. Incorporating Coning - Schedule • The coning schedule is designed to decrease average root blade bending moments and protect turbine blades during hurricane force winds 35 *Source: “A morphing downwind-aligned rotor concept based on a 13-MW wind turbine” 9/19/16 2016 Sandia Blade Workshop
- 36. 0 5 10 15 20 25 0 0.5 1 1.5 2 2.5 3 Wind Speed (m/s) Power(MW) Example Power Curves for 2.5 MW Wind Turbine Region 1 Operating Regions • Region 1: Low wind speed (below 6 m/s = 21.6 km/h) – Wind turbines not run, because power available in wind is low compared to losses in turbine system • Region 2: Medium wind speeds (6 m/s to 11.7 m/s) – Variable-speed turbines vary speed to maximize aerodynamic efficiency v Region 3: High wind speeds (above 11.7 m/s = 42.1 km/h) § Variable-pitch turbines vary the pitch of blades to limit power to avoid exceeding safe electrical and mechanical load limits Wind Power Available Max Power Coeff » 0.50 Region 2 Region 3 Lucy Pao August 2016 Expected Turbine Power 9/19/16 2016 Sandia Blade Workshop 36
- 37. 0 5 10 15 20 25 0 0.5 1 1.5 2 2.5 3 Wind Speed (m/s) Power(MW) Example Power Curves for 2.5 MW Wind Turbine Region 1 Operating Regions • Region 1: Low wind speed (below 6 m/s) – Wind turbines not run, because power available in wind is low compared to losses in turbine system • Region 2: Medium wind speeds (6 m/s to 11.7 m/s) – Variable-speed turbines vary speed to maximize aerodynamic efficiency v Region 3: High wind speeds (above 11.7 m/s) § Variable-pitch turbines vary the pitch of blades to limit power to avoid exceeding safe electrical and mechanical load limits Wind Power Available Region 3 De-rated Turbine Power Lucy Pao August 2016 Max Power Coeff » 0.50 Region 2 Expected Turbine Power 9/19/16 2016 Sandia Blade Workshop 37
- 38. 50 MW Segmented Ultralight Morphing Rotors (SUMR) for Wind Energy 2016 – 2019 [ E. Loth, D. T. Griffith, K. Johnson, P. Moriarty, L. Pao, M. Selig ] Lucy Pao August 2016 wind 9/19/16 2016 Sandia Blade Workshop