Coupled computational fluid dynamics/multibody dynamics method for wind turbine aero-servo-elastic simulation including drivetrain dynamics

A high-fidelity simulation framework is presented to investigate wind turbine aero-servo-elastic behavior, coupling dynamic overset computational fluid dynamics (CFD) and multibody dynamics (MBD) approaches. The Gearbox Reliability Collaborative (GRC) project gearbox was up-scaled in size and installed in the NREL 5-MW offshore wind turbine to demonstrate drivetrain dynamics. Generator torque and blade pitch controllers were implemented to simulate operational conditions of commercial wind turbines. Interactions between wind turbulence, rotor aerodynamics, elastic blades, drivetrain dynamics at the gear-level and servo-control dynamics were studied. Results show that gear contact causes dynamic transmission error within the drivetrain, and results in a decreased turbine thrust and rotational speed. The generator torque controller optimizes efficiency below rated wind speed, while the blade pitch controller properly regulates the turbine near rated power and generator speed at higher than rated wind speed under both uniform and turbulent winds. The pitch controller effectively reduces turbine thrust, blade tip deflections, and velocity deficit of the wake, benefiting both stand-alone turbines and wind farms. The tool and methodology developed show promise to study complex aerodynamic/mechanic systems, being the first time a complete wind turbine simulation includes CFD of the rotor/tower aerodynamics, wind turbulence, elastic blades, gearbox dynamics and feedback control.