From Simulations to Accelerated Testing: Design of Experiments for Accelerated Load Testing of a Wind Turbine Drivetrain Based on Aeroelastic Multibody Simulation Data
The trend of increasing the power output and nominal load capacities of wind turbines (WT) over time has been driving the construction of testing facilities with increasing load capacities for testing WT drivetrain components prior to field deployment. Due to the high investment and operational cost...
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-12-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/13/1/356 |
| _version_ | 1797626303303647232 |
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| author | Baher Azzam Ralf Schelenz Martin Cardaun Georg Jacobs |
| author_facet | Baher Azzam Ralf Schelenz Martin Cardaun Georg Jacobs |
| author_sort | Baher Azzam |
| collection | DOAJ |
| description | The trend of increasing the power output and nominal load capacities of wind turbines (WT) over time has been driving the construction of testing facilities with increasing load capacities for testing WT drivetrain components prior to field deployment. Due to the high investment and operational costs of such facilities, a need exists to design accelerated tests that cover load situations corresponding to expected field conditions while maintaining high time-efficiency. This investigation addresses this need by presenting a methodology to achieve the following goals. Firstly, identifying ranges and combinations of WT 6-degree of freedom (6-DOF) rotor loads is to be expected in the field. This is achieved using aeroelastic multibody simulations (MBS) of an MBS WT model being subjected to simulated wind fields covering the design load cases outlined in the IEC 61400-1 standard and by analyzing the simulated time-series data to design accelerated tests that efficiently and realistically cover the design space of the variables, e.g., 6-DOF rotor loads, to be applied during WT drivetrain testing. The designed tests are to take place on a purpose-built test rig that allows for the application and control of the 6-DOF drivetrain input loads and rotational speed. Using the proposed method, accelerated tests were designed that efficiently cover load combinations within the realistic regions of the design space. A comparison with a full factorial design of experiments shows a significant (95+ %) reduction in total test time as well as the ability of the proposed method to help to avoid unsustainable and unrealistic load conditions within the design space that could result in costly, unintended drivetrain failures during testing. |
| first_indexed | 2024-03-11T10:08:30Z |
| format | Article |
| id | doaj.art-fe8be3502eaf40f9bb27b051b9c402b2 |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-11T10:08:30Z |
| publishDate | 2022-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-fe8be3502eaf40f9bb27b051b9c402b22023-11-16T14:55:56ZengMDPI AGApplied Sciences2076-34172022-12-0113135610.3390/app13010356From Simulations to Accelerated Testing: Design of Experiments for Accelerated Load Testing of a Wind Turbine Drivetrain Based on Aeroelastic Multibody Simulation DataBaher Azzam0Ralf Schelenz1Martin Cardaun2Georg Jacobs3Center for Wind Power Drives, RWTH Aachen University, 52074 Aachen, GermanyCenter for Wind Power Drives, RWTH Aachen University, 52074 Aachen, GermanyCenter for Wind Power Drives, RWTH Aachen University, 52074 Aachen, GermanyCenter for Wind Power Drives, RWTH Aachen University, 52074 Aachen, GermanyThe trend of increasing the power output and nominal load capacities of wind turbines (WT) over time has been driving the construction of testing facilities with increasing load capacities for testing WT drivetrain components prior to field deployment. Due to the high investment and operational costs of such facilities, a need exists to design accelerated tests that cover load situations corresponding to expected field conditions while maintaining high time-efficiency. This investigation addresses this need by presenting a methodology to achieve the following goals. Firstly, identifying ranges and combinations of WT 6-degree of freedom (6-DOF) rotor loads is to be expected in the field. This is achieved using aeroelastic multibody simulations (MBS) of an MBS WT model being subjected to simulated wind fields covering the design load cases outlined in the IEC 61400-1 standard and by analyzing the simulated time-series data to design accelerated tests that efficiently and realistically cover the design space of the variables, e.g., 6-DOF rotor loads, to be applied during WT drivetrain testing. The designed tests are to take place on a purpose-built test rig that allows for the application and control of the 6-DOF drivetrain input loads and rotational speed. Using the proposed method, accelerated tests were designed that efficiently cover load combinations within the realistic regions of the design space. A comparison with a full factorial design of experiments shows a significant (95+ %) reduction in total test time as well as the ability of the proposed method to help to avoid unsustainable and unrealistic load conditions within the design space that could result in costly, unintended drivetrain failures during testing.https://www.mdpi.com/2076-3417/13/1/356multivariate data analysiswind turbine testingdrivetrain simulationwind simulationwind energy |
| spellingShingle | Baher Azzam Ralf Schelenz Martin Cardaun Georg Jacobs From Simulations to Accelerated Testing: Design of Experiments for Accelerated Load Testing of a Wind Turbine Drivetrain Based on Aeroelastic Multibody Simulation Data Applied Sciences multivariate data analysis wind turbine testing drivetrain simulation wind simulation wind energy |
| title | From Simulations to Accelerated Testing: Design of Experiments for Accelerated Load Testing of a Wind Turbine Drivetrain Based on Aeroelastic Multibody Simulation Data |
| title_full | From Simulations to Accelerated Testing: Design of Experiments for Accelerated Load Testing of a Wind Turbine Drivetrain Based on Aeroelastic Multibody Simulation Data |
| title_fullStr | From Simulations to Accelerated Testing: Design of Experiments for Accelerated Load Testing of a Wind Turbine Drivetrain Based on Aeroelastic Multibody Simulation Data |
| title_full_unstemmed | From Simulations to Accelerated Testing: Design of Experiments for Accelerated Load Testing of a Wind Turbine Drivetrain Based on Aeroelastic Multibody Simulation Data |
| title_short | From Simulations to Accelerated Testing: Design of Experiments for Accelerated Load Testing of a Wind Turbine Drivetrain Based on Aeroelastic Multibody Simulation Data |
| title_sort | from simulations to accelerated testing design of experiments for accelerated load testing of a wind turbine drivetrain based on aeroelastic multibody simulation data |
| topic | multivariate data analysis wind turbine testing drivetrain simulation wind simulation wind energy |
| url | https://www.mdpi.com/2076-3417/13/1/356 |
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