Sustainability Enhancement of a Turbine Vane Manufacturing Cell through Digital Simulation based Design

Modern manufacturing systems should satisfy emerging needs related to sustainable development. The design of sustainable manufacturing systems can be valuably supported by simulation, traditionally employed mainly for time and cost reduction. In this paper, a multi-purpose digital simulation approach is proposed to deal with sustainable manufacturing systems design through Discrete Event Simulation (DES) and 3D digital human modelling. DES models integrated with data on power consumption of the manufacturing equipment are utilized to simulate different scenarios with the aim to improve productivity as well as energy efficiency, avoiding resource and energy waste. 3D simulation based on digital human modelling is employed to assess human factors issues related to ergonomics and safety of manufacturing systems. The approach is implemented for the sustainability enhancement of a real manufacturing cell of the aerospace industry, automated by robotic deburring. Alternative scenarios are proposed and simulated, obtaining a significant improvement in terms of energy efficiency (−87%) for the new deburring cell, and a reduction of energy consumption around −69% for the coordinate measuring machine, with high potential annual energy cost savings and increased energy efficiency. Moreover, the simulation-based ergonomic assessment of human operator postures allows 25% improvement of the workcell ergonomic index.

Investigation of the effects of flow conditions at rotor inlet on mixed flow turbine performance for automotive applications

Current trends in the automotive industry have placed increased importance on engine downsizing for passenger vehicles. Engine downsizing often results in reduced power output and turbochargers have been relied upon to restore the power output and maintain drivability. As improved power output is required across a wide range of engine operating conditions, it is necessary for the turbocharger to operate effectively at both design and off-design conditions. One off-design condition of considerable importance for turbocharger turbines is low velocity ratio operation, which refers to the combination of high exhaust gas velocity and low turbine rotational speed. Conventional radial flow turbines are constrained to achieve peak efficiency at the relatively high velocity ratio of 0.7, due the requirement to maintain a zero inlet blade angle for structural reasons. Several methods exist to potentially shift turbine peak efficiency to lower velocity ratios. One method is to utilize a mixed flow turbine as an alternative to a radial flow turbine. In addition to radial and circumferential components, the flow entering a mixed flow turbine also has an axial component. This allows the flow to experience a non-zero inlet blade angle, potentially shifting peak efficiency to a lower velocity ratio when compared to an equivalent radial flow turbine.
This study examined the effects of varying the flow conditions at the inlet to a mixed flow turbine and evaluated the subsequent impact on performance. The primary parameters examined were average inlet flow angle, the spanwise distribution of flow angle across the inlet and inlet flow cone angle. The results have indicated that the inlet flow angle significantly influenced the degree of reaction across the rotor and the turbine efficiency. The rotor studied was a custom in-house design based on a state-of-the-art radial flow turbine design. A numerical approach was used as the basis for this investigation and the numerical model has been validated against experimental data obtained from the cold flow turbine test rig at Queen’s University Belfast. The results of the study have provided a useful insight into how the flow conditions at rotor inlet influence the performance of a mixed flow turbine.

Impianti idroelettrici per la produzione di energia

L'energia idroelettrica è una fonte di energia alternativa e rinnovabile che sfrutta il moto dell'acqua, generato grazie all'energia potenziale presente tra due bacini posti a quote diverse per convertire l'energia meccanica in elettrica attraverso un alternatore collegato a turbina. Gli impianti si classificano in: impianti ad acqua fluente, a deflusso regolato, ad accumulo tramite pompaggio. Le turbine idrauliche sono quei dispositivi meccanici in grado di convertire l'energia cinetica in energia meccanica. Fra tutte studieremo la Pelton, la Francis e la Kaplan e i loro criteri di scelta. I grandi impianti hanno un notevole impatto ambientale, ecco perché la nuova tecnologia si basa sul mini idroelettrico; quest'ultimo dal punto di vista economico è competitivo rispetto alle altre fonti rinnovabili ed ai combustibili fossili.

Microturbinas em redes de abastecimento de água

Nos dias de hoje a sociedade exige níveis qualitativos de vida cada vez mais elevados, o que torna prioritária a conceção de sistemas eficientes, não poluidores, económicos e diversificados que permitam uma gestão integrada e racionalizada de recursos tão escasso como é o da água e da energia. Em sistemas de abastecimento de água, o uso de válvulas redutoras de pressão (VRP) visa a uniformização e controlo de pressões, promovendo uma perda de carga localizada que dissipa a energia hidráulica presente através da redução dos valores de pressão a jusante. Estas são fundamentais no controlo e redução de pressão. A utilização de microturbinas é uma alternativa sustentável para o controle de pressão e, simultaneamente, para a produção de energia elétrica. Trata-se de um método de mitigação para controlar as perdas referidas convergindo no âmbito da eficiência energética. Na perspetiva de promover um aproveitamento de energia nas redes de abastecimento de água, o presente trabalho sugere a substituição de válvulas redutoras de pressão (VRP) por microturbinas. Desse modo, apresenta-se um método automático de seleção de (i) local para implementação e (ii) projeto de microturbinas para sistemas de abastecimento de água. Para a modelação do funcionamento dos sistemas hidráulicos recorre-se ao simulador hidráulico EPANET. Esta ferramenta possibilita avaliação de caudais e pressões em todos os pontos da rede durante um determinado intervalo de tempo. A metodologia desenvolvida permite selecionar o local ideal no sistema hidráulico através de uma análise de cada secção conduta-nó escolhendo-se a melhor opção baseada na produção de energia. Depois da localização procede-se à seleção do tipo de turbina (Kaplan, Francis, Pelton e Cross-flow) que vai depender das características do sistema hidráulico. Na etapa seguinte apresenta-se os resultados obtidos pela turbina nomeadamente a produção de energia elétrica anual, o investimento necessário, o tempo de retorno e a rentabilização ao final de um período de 25 anos. Na última etapa da metodologia, de forma avaliar o comportamento do sistema final, realiza-se uma nova simulação da rede mas tendo em conta a introdução da microturbina no local. Apresentam-se alguns casos de estudo que validam a ferramenta desenvolvida. A metodologia desenvolvida é comparada com um caso de estudo real. Em ambos os exemplos simulados a metodologia aplicada permite obter soluções com ganhos energéticos significativos associados ao sistema. Apenas num dos exemplos se observaram que a implementação da microturbina no sistema hidráulico não seria economicamente rentável.

Investigation expérimentale du décollement dans l’aspirateur d’une turbine bulbe

La présente thèse propose une étude expérimentale du décollement dans le diffuseur d’un modèle de turbine hydroélectrique bulbe. Le décollement se produit quand la turbine est opérée à forte charge et il réduit la section effective de récupération du diffuseur. La diminution de la performance du diffuseur à forte charge engendre une baisse brusque de l’efficacité de la turbine et de la puissance extraite. Le modèle réduit de bulbe est fidèle aux machines modernes avec un diffuseur particulièrement divergent. Les performances de la turbine sont mesurées sur une large gamme de points d’opération pour déterminer les conditions les plus intéressantes pour l’étude du décollement et pour étudier la distribution paramétrique de ce phénomène. La pression est mesurée le long de l’aspirateur par des capteurs dynamiques affleurants alors que les champs de vitesse dans la zone de décollement sont mesurés avec une méthode PIV à deux composantes. Les observations à la paroi sont pour leur part faites à l’aide de brins de laine. Pour un débit suffisant, le gradient de pression adverse induit par la géométrie du diffuseur affaiblit suffisamment la couche limite, entraînant ainsi l’éjection de fluide de la paroi le long d’une large enveloppe tridimensionelle. Le décollement instationnaire tridimensionnel se situe dans la même zone du diffuseur indépendamment du point d’opération. L’augmentation du débit provoque à la fois une extension de la zone de décollement et une augmentation de l’occurrence de ses manifestations. La position et la forme du front de décollement fluctue significativement sans périodicité. L’analyse topologique et celle des tourbillons des champs de vitesse instantanés montrent une topologie du front de décollement complexe qui diffère beaucoup d’une réalisation à l’autre. Bien que l’écoulement soit turbulent, les tourbillons associés aux foyers du front sont clairement plus gros et plus intenses que ceux de la turbulence. Cela suggère que le mécanisme d’enroulement menant aux tourbillons du décollement est clairement distinct des mécanismes de la turbulence.

Tests of the fatigue strength of steam turbine blade shapes : a report

Cover title.

Étude expérimentale de l'écoulement en entrée d'aspirateur d'une turbine bulbe

Ce mémoire présente l’étude expérimentale de l’écoulement d’entrée d’un aspirateur d’une turbine bulbe présentant une chute abrupte de performance. Des mesures par vélocimétrie laser à effet Doppler (LDV) ont été réalisées sur deux axes soit en aval des pales de la roue et en aval du moyeu de la roue. Une particularité de cette étude est la conception d’un montage permettant de mesurer la vitesse axiale proche de la paroi du cône. De plus, une méthode d’estimation de la vitesse radiale moyenne a été développée. Ces mesures ont permis de caractériser l’écoulement primaire et les écoulements secondaires et d’analyser leur évolution entre les deux axes. De plus, l’évolution de ces écoulements est analysée en fonction de la chute de performance de la turbine. Les principales particularités de l’écoulement sont la présence d’une recirculation sous le moyeu, d’une zone contrarotative, des sillages des directrices et des tourbillons de bout de pale.

Detached eddy simulation of unsteady turbulent flows in the draft tube of a bulb turbine

Les aspirateurs de turbines hydrauliques jouent un rôle crucial dans l’extraction de l’énergie disponible. Dans ce projet, les écoulements dans l’aspirateur d’une turbine de basse chute ont été simulés à l’aide de différents modèles de turbulence dont le modèle DDES, un hybride LES/RANS, qui permet de résoudre une partie du spectre turbulent. Déterminer des conditions aux limites pour ce modèle à l’entrée de l’aspirateur est un défi. Des profils d’entrée 1D axisymétriques et 2D instationnaires tenant compte des sillages et vortex induits par les aubes de la roue ont notamment été testés. Une fluctuation artificielle a également été imposée, afin d’imiter la turbulence qui existe juste après la roue. Les simulations ont été effectuées pour deux configurations d’aspirateur du projet BulbT. Pour la deuxième, plusieurs comparaisons avec des données expérimentales ont été faites pour deux conditions d’opération, à charge partielle et dans la zone de baisse rapide du rendement après le point de meilleur rendement. Cela a permis d’évaluer l’efficacité et les lacunes de la modélisation turbulente et des conditions limites à travers leurs effets sur les quantités globales et locales. Les résultats ont montrés que les structures tourbillonnaires et sillages sortant de la roue sont adéquatement résolus par les simulations DDES de l’aspirateur, en appliquant les profils instationnaires bidimensionnels et un schéma de faible dissipation pour le terme convectif. En outre, les effets de la turbulence artificielle à l’entrée de l’aspirateur ont été explorés à l’aide de l’estimation de l’intermittence du décollement, de corrélations en deux points, du spectre d’énergie et du concept de structures cohérentes lagrangiennes. Ces analyses ont montré que les détails de la dynamique de l’écoulement et de la séparation sont modifiés, ainsi que les patrons des lignes de transport à divers endroits de l’aspirateur. Cependant, les quantités globales comme le coefficient de récupération de l’aspirateur ne sont pas influencées par ces spécificités locales.

Performance assessment of a vertical axis turbine in a marine current flume tank and CFD modelling

As advances in numerical modelling techniques support the increased confidence in predictions from computer simulations, the need remains to have experimental verification built into the design process. This paper outlines the experimental investigation carried out on a shielded vertical axis turbine in a marine environment. The experiments consist of performance measurements and the use of particle image velocimetry on a small scale device in a marine current flume. The results demonstrate that the performance of the device can be modelled numerically; in particular, the results show that the numerical model used can correctly predict the increase in performance with Reynolds number.

Probabilistic design optimization of horizontal axis wind turbine rotors

Considerable interest in renewable energy has increased in recent years due to the concerns raised over the environmental impact of conventional energy sources and their price volatility. In particular, wind power has enjoyed a dramatic global growth in installed capacity over the past few decades. Nowadays, the advancement of wind turbine industry represents a challenge for several engineering areas, including materials science, computer science, aerodynamics, analytical design and analysis methods, testing and monitoring, and power electronics. In particular, the technological improvement of wind turbines is currently tied to the use of advanced design methodologies, allowing the designers to develop new and more efficient design concepts. Integrating mathematical optimization techniques into the multidisciplinary design of wind turbines constitutes a promising way to enhance the profitability of these devices. In the literature, wind turbine design optimization is typically performed deterministically. Deterministic optimizations do not consider any degree of randomness affecting the inputs of the system under consideration, and result, therefore, in an unique set of outputs. However, given the stochastic nature of the wind and the uncertainties associated, for instance, with wind turbine operating conditions or geometric tolerances, deterministically optimized designs may be inefficient. Therefore, one of the ways to further improve the design of modern wind turbines is to take into account the aforementioned sources of uncertainty in the optimization process, achieving robust configurations with minimal performance sensitivity to factors causing variability. The research work presented in this thesis deals with the development of a novel integrated multidisciplinary design framework for the robust aeroservoelastic design optimization of multi-megawatt horizontal axis wind turbine (HAWT) rotors, accounting for the stochastic variability related to the input variables. The design system is based on a multidisciplinary analysis module integrating several simulations tools needed to characterize the aeroservoelastic behavior of wind turbines, and determine their economical performance by means of the levelized cost of energy (LCOE). The reported design framework is portable and modular in that any of its analysis modules can be replaced with counterparts of user-selected fidelity. The presented technology is applied to the design of a 5-MW HAWT rotor to be used at sites of wind power density class from 3 to 7, where the mean wind speed at 50 m above the ground ranges from 6.4 to 11.9 m/s. Assuming the mean wind speed to vary stochastically in such range, the rotor design is optimized by minimizing the mean and standard deviation of the LCOE. Airfoil shapes, spanwise distributions of blade chord and twist, internal structural layup and rotor speed are optimized concurrently, subject to an extensive set of structural and aeroelastic constraints. The effectiveness of the multidisciplinary and robust design framework is demonstrated by showing that the probabilistically designed turbine achieves more favorable probabilistic performance than those of the initial baseline turbine and a turbine designed deterministically.

Characterization of sea water ageing effects on mechanical properties of carbon/epoxy composites for tidal turbine blades

In recent years, many tidal turbine projects have been developed using composites blades. Tidal turbine blades are subject to ocean forces and sea water aggressions, and the reliability of these components is crucial to the profitability of ocean energy recovery systems. The majority of tidal turbine developers have preferred carbon/epoxy blades, so there is a need to understand how prolonged immersion in the ocean affects these composites. In this study the long term behaviour of different carbon/epoxy composites has been studied using accelerated ageing tests. A significant reduction of composite strengths has been observed after saturation of water in the material. For longer immersions only small further changes in these properties occur. No significant changes have been observed for moduli nor for composite toughness. The effect of sea water ageing on damage thresholds and kinetics has been studied and modelled. After saturation, the damage threshold is modified while kinetics of damage development remain the same.

Effect of Geometric Uncertainties on the Aerodynamic Characteristic of Offshore Wind Turbine Blades

Offshore wind turbines operate in a complex unsteady flow environment which causes unsteady aerodynamic loads. The unsteady flow environment is characterized by a high degree of uncertainty. In addition, geometry variations and material imperfections also cause uncertainties in the design process. Probabilistic design methods consider these uncertainties in order to reach acceptable reliability and safety levels for offshore wind turbines. Variations of the rotor blade geometry influence the aerodynamic loads which also affect the reliability of other wind turbine components. Therefore, the present paper is dealing with geometric uncertainties of the rotor blades. These can arise from manufacturing tolerances and operational wear of the blades. First, the effect of geometry variations of wind turbine airfoils on the lift and drag coefficients are investigated using a Latin hypercube sampling. Then, the resulting effects on the performance and the blade loads of an offshore wind turbine are analyzed. The variations of the airfoil geometry lead to a significant scatter of the lift and drag coefficients which also affects the damage-equivalent flapwise bending moments. In contrast to that, the effects on the power and the annual energy production are almost negligible with regard to the assumptions made.

Wind turbine rotor blade monitoring using digital image correlation: a comparison to aeroelastic simulations of a multi-megawatt wind turbine

Optical full-field measurement methods such as Digital Image Correlation (DIC) provide a new opportunity for measuring deformations and vibrations with high spatial and temporal resolution. However, application to full-scale wind turbines is not trivial. Elaborate preparation of the experiment is vital and sophisticated post processing of the DIC results essential. In the present study, a rotor blade of a 3.2 MW wind turbine is equipped with a random black-and-white dot pattern at four different radial positions. Two cameras are located in front of the wind turbine and the response of the rotor blade is monitored using DIC for different turbine operations. In addition, a Light Detection and Ranging (LiDAR) system is used in order to measure the wind conditions. Wind fields are created based on the LiDAR measurements and used to perform aeroelastic simulations of the wind turbine by means of advanced multibody codes. The results from the optical DIC system appear plausible when checked against common and expected results. In addition, the comparison of relative out-of-plane blade deflections shows good agreement between DIC results and aeroelastic simulations.

Aerodynamic behavior of an airfoil with morphing trailing edge for wind turbine applications

The length of wind turbine rotor blades has been increased during the last decades. Higher stresses arise especially at the blade root because of the longer lever arm. One way to reduce unsteady blade-root stresses caused by turbulence, gusts, or wind shear is to actively control the lift in the blade tip region. One promising method involves airfoils with morphing trailing edges to control the lift and consequently the loads acting on the blade. In the present study, the steady and unsteady behavior of an airfoil with a morphing trailing edge is investigated. Two-dimensional Reynolds-Averaged Navier-Stokes (RANS) simulations are performed for a typical thin wind turbine airfoil with a morphing trailing edge. Steady-state simulations are used to design optimal geometry, size, and deflection angles of the morphing trailing edge. The resulting steady aerodynamic coefficients are then analyzed at different angles of attack in order to determine the effectiveness of the morphing trailing edge. In order to investigate the unsteady aerodynamic behavior of the optimal morphing trailing edge, time-resolved RANS-simulations are performed using a deformable grid. In order to analyze the phase shift between the variable trailing edge deflection and the dynamic lift coefficient, the trailing edge is deflected at four different reduced frequencies for each different angle of attack. As expected, a phase shift between the deflection and the lift occurs. While deflecting the trailing edge at angles of attack near stall, additionally an overshoot above and beyond the steady lift coefficient is observed and evaluated.