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Wind energy
During their lifetime, wind turbines must reliably withstand a wide variety of stresses and environmental conditions. In order to test their strength, their design, and also validate the manufacturing process early in the development cycle, simulation is becoming essential for manufacturers. Physical tests are time consuming indeed, expensive and only possible in limited circumstances due to the size of wind turbines. ESI offers virtual prototyping software and services helping wind energy companies address these challenges and understand the physics of the materials to manufacture wind turbines faster and in a cost efficient way.
Composites design & manufacturing
Demo: Injection of a wind blade
Wind Turbine infusion/injection and Resin Transfer Molding (RTM) processes are quickly tested and optimized with PAM-RTM, ESI’s dedicated tool for infusion simulation. PAM-RTM can compute resin flow and optimize process parameters (ports, vents and media location, injection pressure, mold design…) in a matter of hours on parts reaching dozen of meters and taking into account potential 3D aspect of the manufacturing process (such as the influence of the flow media and the flow around the inserts). Moreover, simulation allows making any small improvement in the design or modification in the material lay-up, sequence or type without compromising the manufacturing of the blade, thus reducing cost.
PAM-RTM is also available under CATIA V5
Webcast: How to Optimize Resin Infused Wind Turbine Blades
“Blades are a key element of the wind turbine and its manufacturing can be challenging, especially with their increasing sizes and complexity. Simulation is fully integrated in our development process and we chose PAM-RTM 2010 to perform our Liquid Composites Molding (LCM) process optimization because of its unique capability to accurately simulate the infusion of very large models. Using PAM-RTM helps us save time in the development process and reduce blades production costs while encouraging innovation.”
An Advanced Manufacturing Engineer from an American wind blade manufacturer
Large cast iron wind power turbine castings
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“ ...ProCAST recent developments prove to be excellent for predicting the microstructure and the basic mechanical properties of casting materials. In addition ProCAST solves the main complex phenomenon in cast iron solidification i.e. graphite expansion. Using the microstructure module, the simulation of local graphite expansion is possible with a sensitively higher accuracy for shrinkage defects prediction..." |
Frame of a wind turbine generator in cast iron |
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| Dr. Antton Meléndez Arranz, Metallurgist- Inasmet-Tecnalia | ||
Computational Fluid Dynamics calculation under realistic wind conditions
It remains a challenge to have optimum blade design to give best torque and thus power in varying wind conditions. The situation can be equally problematic whether for the industrial windmill (with horizontal shaft) or the household one (with vertical shaft). With varying wind speed, aerodynamic efficiency of windmill blades is of great importance. ESI software simulates fluid-structure interaction where the deformation of blades due to wind-loading and thus the effect on windmill efficiency can be studied with great accuracy.
Velocity field
Nacelle modeling and vibro-acoustics
Radiated noise is a major concern when planning wind turbines, including radiated noise from the nacelle. VA One offers a wide range of modeling options, such as SEA (Statistical Energy Analysis), FE (Finite Element), BEM (Boundary Element Method) and hybrid FE/SEA (Finite Element/Statistical Energy Analysis), to determine near and far field radiation from panels and openings. For example, nacelle panels can be modeled by SEA and the supporting structure with FE, to capture global vibration and at the same time get efficient radiation results by SEA for a wide frequency range analysis. In addition, the noise levels can be optimized by detailed studies of mounting locations and designs within the nacelle.
Nacelle modeling and vibro-acoustics simulation
Lightning strikes and electromagnetic impact
Typically 100 meters high and located far from other tall objects, wind turbines are targets for lightning strikes. In accordance to international regulations, a complete electromagnetic protection is required in addition to the usual mechanical, light weight, acoustic and other stiffness constraints. With their large moving blades, wind farms may also create interference with weather radar or air-traffic control systems. ESI's PAM-CEM Simulation Suite helps not only in the “electromagnetic” design of wind turbine towers but also in evaluating environmental radar effects of wind farms.
Wind turbines impact on electromagnetic waves propagation
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