process simulation and optimization in the wind energy
TRANSCRIPT
Process Simulation & Optimization
Process Simulation and Optimization in the Wind Energy Industry
High performance
product requirements
Concept and design
Numerical simulation Optimization
Physical prototyping
Process Integration in Product Development
Manufacturing
Process Simulation and the Optimization Process
Process simulation enable checking of the product quality before industrialization phase
Internal stress resulting from manufacturing processes can be taken into account in further simulations
Optimization process coupled with virtual prototyping increase product performance and minimize costs
Advantage Gained with Process Simulation and Optimization
- Reduced number of
prototypes
- Deep understanding of the inner
quality of the product
- Find the best parameters for the
casting process
- Reduced residual stresses
• Minimizing cost
• Minimizing
residual stress
• Maximizing
reliability
• Minimizing time
Process simulation
and optimization
ModeFrontier
The whole process, from the DOE generation to the Pareto FRONTIER identification, is carried out in an efficient and automated fashion by modeFRONTIER.
Initial configurations in the design space through DOE
Pareto Frontier: the curve representing the optimal designs
Process Simulation & Optimization
Process Simulation and Optimization in Wind Energy
www.ozeninc.com/[email protected]
Process Simulation and Optimization
In what component will process simulation be crucial for a good product?
Rotor hub
Torque converter (4475 lb)
Planet carrier (1760 lb)Spindle
Process Simulation and Optimization
Numerical simulation to analyse the filling process of the melt flow into the mold
Temperature
[°C]
Optimization to find the parameters that lead to the best filling process
Process Simulation and Optimization
Numerical simulation to evaluate which melt flows through which ingate
0
5000
10000
15000
20000
25000
30000
0 10 20 30 40 50 60 70
Time [s]
Flu
x [
cm
³/s]
Ingate / 1
Ingate / 2
Ingate / 3
Optimization to maximize the ingate performance
Process Simulation and Optimization
Numerical simulations allow to see what is almost impossible to predict accurately, like the solidification process...
Optimization to find the parameters setting that determine the best solidification process (reduce the residual
internal stress)
Fraction
liquid
[%]
Process Simulation and Optimization
....and porosity
Find the best parameters setting to minimize the porosity
Temperature in the casting
Temperature in the
mold
Tem
pe
ratu
re [°
C]
Time [s]
Process Simulation and Optimization
Numerical simulations are a useful tool to evaluate the casting mechanical properties
Ferrite board [micron] Ferrite [%]
Elongation [%]
Elongation [%]
Optimization to maximize the final mechanical performance
Conclusion
• Growth in the wind power market combined with the lowered cost of entry into energy markets mean:
– Increase in competition low costs, implant efficiency and material/product quality
– Fewer“low-hangingfruit”opportunities
• The increased demands on the design and analysis of wind power projects
can be addressed by the use of engineering simulations.
– Proven techniques used widely in other high-tech areas: aerospace, automotive, etc.
– Effective way to optimize design and reduce engineering risk
– Manufacturing simulation to improve the quality and the performance of the parts
• New wind power projects need to be more competitive to guarantee ROI:
– More accurate estimation of energy production potential for sites and installation types
– Improved predictability: higher market value of produced energy, reduce fines
– More stringent engineering margins local material properties and residual stress/strain
Thank You For Your Attention
For further information, please contact:
OZEN ENGINEERING, INC.1210 E. ARQUES AVE. SUITE: 207SUNNYVALE, CA 94085(408) 732-4665
[email protected] www.ozeninc.com
• Please let us know if you have any questions on specific topics
We would like to help you achieve your goals