Design of Wind turbines using OpenFOAM as part of the CAE ...€¦ · Copyright © ESI Group, 2013....

Copyright © ESI Group, 2013. All rights reserved. Copyright © ESI Group, 2013. All rights reserved.

Design of Wind turbines using OpenFOAM®

as part of the CAE chain– Overview

Dr. Ries Bouwman

Dipl.-Ing. Manfred R. Müller

@riesbouwman

20 March 2013

1

Copyright © ESI Group, 2013. All rights reserved.

ESI Group

2

Headquarters in Paris, France

Offices in more than 30 countries

Average Headcount: +1000 people

Over 200 Scientists

WW Revenue 2012: 130 M$

Paris, France Eschborn, Germany Pilsen, Czech Republic Farmington Hills, MI Beijing, China Tokyo, Japan

Licenses Services

EMEA

Asia Pacific

Americas


ESI Trade Solutions and Vision

3

Virtual Manufacturing

Virtual Performance

Virtual Environment

Enabled by

a common

Platform

Full Concurrent End to End

Virtual Prototyping

Conceived in the

Real World.

Experienced,

Built and Tested

in the Virtual World


OpenFOAM® is a free, open source CFD software toolbox

OpenCFD Ltd contributes software, integrates modules and generates documentation to the OpenFOAM® software

OpenFOAM Foundation is a non-profit organization which was established for the purpose of ensuring the sustainable distribution of OpenFOAM®

11 September 2012 Acquisition of OpenCFD Ltd., The leader in Open Source software in Computational Fluid Dynamics

ESI becomes owner of OpenFOAM® trademark

ESI becomes producer of OpenFOAM® software

ESI will continue to manage the development, production and maintenance of the OpenFOAM® Software, for distribution through the OpenFOAM Foundation

OpenCFD Ltd. Acquisition

4


OpenFOAM Foundation owns OpenFOAM — to be released open source ONLY

Foundation distributes OpenFOAM with source code under the GPL

GPL grants right to redistribute original or modified OpenFOAM, ONLY

with same right to redistribute

with source code

under same ownership

Redistribution under different terms damages OpenFOAM and is illegal

Breach of the terms means license termination

OpenFOAM Licensing

5

GPL = General Public License


Contribute

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Management

IT

Engineering

Open source is the unique software feature

The competitive advantage comes from control to

modify the software freely

assess code quality

know what the software is doing

deploy OpenFOAM however they wish, e.g. own hardware,

cloud, etc.

influence development priorities

manage costs, i.e. choose when and how to get something for

their money

OpenFOAM users benefit from this control

Unique Competitive Advantage

7


Enterprise

Subscription

Migration

Service

Training: public scheduled and on-site

Engineering Services: pilot projects, consultancy

Process Integration: OpenFOAM into a work-flow

Process Interface: OpenSIM, application specific

Development: OpenFOAM development projects

Advanced Support: hour-based support

Platform Support: hardware tuning, benchmarking

Code Integration: third-party code into OpenFOAM

Strategic Collaboration: roadmap reviews, planning

ESI OpenFOAM Services

8


ESI application based GUI

OpenSIM

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Example: Wind Turbine

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Vibrations/Fatigue:

VPS/Implicit

Acoustic:

VA-ONE

Composites:

PAM-RTM/FORM

Manufacturing:

SYSWELD

ProCAST

PAM-STAMP

Electromagnetism/

EMC/Lightn./Radar:

PAM-CEM

SYSMAGNA

Gear Box, drive:

PAM-MEDYSA

CFD:

ACE+

PAM-FLOW

OpenFOAM

Impact & shocks:

VPS/PAM-CRASH


Natural Wind

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Wind Characterization

Spectral Densities periodicites of stochastic processes micro-meteorological conditions of interest hourly wind intensity as frequency of gusts

Coherence forces the randomness to represent real winds

(where points nearby have similar time histories)

Mean and Gusts Profiles influence of height on mean wind intensity and on

gusts intensities

Pow

er

spectr

al

density G

(f*)

Non dimensional frequency density f*=(L*/u*) f

Davenport

Karman

Harris

DIN1055

L*= characteristic

length

U*= characteristic

velocity

Spectral Density Functions


Windmill in Natural Wind

Proof of Feasibility

POWER QUALITY

numerical generation

coupled PAM-FLOW / VPS model


Process development requirement

Large parts

Complex and new materials/processes

High performances required

Cost of trials (in time and money)

Production rate increase required

Recyclability

Composites

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Strategy 2 Strategy 1

Infusions Simulation Complex Injection Strategy

Copyright © ESI Group, 2013. All rights reserved. 15

Explicit-based solutions

PAM-CRASH Linear and non-linear materials,

large displacements

PAM-SAFE Restraint systems

PAM-MEDYSA Non-linear Dynamics

PAM-SHOCK High velocity impact

Implicit-based solutions

PAM-STATICS Linear and non-linear materials,

large displacements

PAM-NVH Eigen-mode Extraction, Harmonic

and Transient Analyses

PAM-ACOUSTICS Interior acoustics,

Porous Elastic Materials

One

Executable


Kinematics

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Time Step Run End Machine Calculation Time

0.8 10e-6 0.85 s 8 proc 4 days

Copyright © ESI Group, 2013. All rights reserved. Copyright © ESI Group, 2010. All rights reserved.

Oil Management

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Oil Flow

estimation

on each

critical parts

(Bearing,

gears, etc…)

Estimation of

the oil

dynamic

unbalance

Estimation of

the impact of

the oil

viscosity.


Velocities for barge close to floating wind turbine in waves

(demo case)

Floating wind turbine in waves


Virtual Performance:

Vibro-Acoustics

SEA BEM - FEM

Response

Frequency Log

-Transmission path:

Translational structure born noise

Torsional structure born noise

-Noise emission: Airborn noise (high frequency)

(directed/undirected)


Casting

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The Benefits

For a foundry:

Suppression/reduction of physical trials

Reduction of recovering and rejecting

causes

Enhanced understanding of process

capability

Casting/process optimization

Better fit with customer requirements

For the customer:

Effective and early design for manufacturing

The Challenge

Meet the customer’s quality standard by accurately

predicting and optimizing microstructure,

mechanical properties and porosity formation in

large cast iron wind power turbine castings.


EMC & Electromagnetismus

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Interference for Weather-Radar: 320 km/h

Rotationspeed is like a Thunderstorm for Radar (RAM:

Radar absorbing Material)

Interference for Aeronautical-Radar

Thunderlightning …

Electrical Grounding & Lightning Strike Protection (LSP)

Materials for Composite Wind Turbines

Windturbine – Fire in 130 m

(Foto: dpa)


ICIDO belongs to ESI

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ICIDO is the leading

vendor of virtual-

reality based

collaborative

decision-making

solutions. We allow

our customers to

work

collaboratively with

colleagues, suppliers

and customers in a

virtual environment

either at one location

or in a distributed

environment.

icidoteaser.wmv


11-14 March 2013, Melbourne, Australia

25-28 March 2013, Barcelona, Spain

15-18 April 2013, Paris, France

29-02 April/May 2013, Boston, MA, USA

20-23 May 2013, Munich, Germany

24-27 June 2013, San Francisco, CA, USA

01-04 July 2013, Paris, France

Public OpenFOAM Training

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OpenFOAM Webinars

Start April 2013

OpenFOAM Users Conference 2013

24-26 April 2013, Frankfurt, Germany

NAFEMS World Congress 2013

9-11 June 2013, Salzburg, Austria

Upcoming Events

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Many Thanks!

Design of Wind turbines using OpenFOAM as part of the CAE ...€¦ · Copyright © ESI Group, 2013....

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Transcript of Design of Wind turbines using OpenFOAM as part of the CAE ...€¦ · Copyright © ESI Group, 2013....