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Reliability Testing Tools and Methods for Wind Turbine Drive Trains

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.

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Reliability Testing Tools and Methods for Wind Turbine Drive Trains

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  1. Reliability Testing Tools and Methods for Wind Turbine Drive Trains Robert Orange, Systems Engineer MTS Systems Corporation

  2. MTS: Mechanical Test & Simulation Solution Supplier • Ground Vehicles • Aero Structures • Materials & Structures • Includes Wind Applications • Sensors

  3. Presentation Outline • Review the Mechanical Testing Rationale & Requirements • Highlight Some Characteristics of Reliability Testing • Review Aero Structural & Ground Vehicle Testing • Introduce Additional Test Methods

  4. Reliability Review - Loads vs. Susceptibility

  5. Development & Testing Loads Definition Subsystem Testing

  6. 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 Loads >> Service Loads  Max Service

  7. 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

  8. 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)

  9. 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/orproxy 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)

  10. 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

  11. Tools/Methods • Time Compression • Load Replication • RPC (Remote Parameter Control) • Hybrid Simulation

  12. Edit time history data based on regions selected from the damage time history Damage time history shows where damaging cycles occur in the data Fatigue-based Editing

  13. 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

  14. RPC Iterations Test Rig Nacelle Drive Response + Drive Correction FRF-1 Response Error - Desired Response Continue until response error  0

  15. 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

  16. Test Rig Nacelle & WTC Controller Rig Commands Hub Forces & Moments WTC Pitch & Yaw Cmds Wind Anemometer Blade Model Pitch & Yaw Models 11/15/2014 Page 16

  17. Hybrid Simulation • Benefits • Most accurate replicationof 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

  18. 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

  19. Thank You! Photos courtesy of: • Cessna Aircraft Corporation • University of Minnesota • Airbus Military • Fraunhofer Institute LBF

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