SANY Heavy Energy realizes high-precision wind turbine simulation with Siemens Simcenter 3D.
Since 2016, SANY Heavy Energy’s product development team has been developing new methods for predicting dynamic loads, developing digital design methods for product platforms and supporting operation and maintenance through optimizing the mechanical performance and control strategies for existing products.
The team has established a complete, mature and efficient digital simulation process, and uses software for external wind load computation and subsequent structural strength analysis of parts. The key step in this process is prediction of the dynamic response of the complete machine. For this purpose, SANY Heavy Energy compared several technical solutions available in the market and decided to implement SimcenterTM solutions from Siemens PLM Software, including LMS Samtech SamcefTM Wind Turbines software for digital simulation modeling and the LMS Samcef solver for prediction of complete machine dynamic response.
LMS Samcef Wind Turbines is a specialized solution for development of wind turbine systems. SANY Heavy Energy uses the software to create a high-precision simulation model that supports the entire development cycle (including conceptual design, detailed design, prototype or modified model development, certification, troubleshooting, and other tasks), thereby coordinating traditionally separate design processes.
The high-precision model of the complete machine provides important value. First, it improves simulation quality by supporting in-the-loop simulation. SANY Heavy Energy can import actual wind farm loads and calculate dynamic responses quickly and precisely to help optimize wind turbine structures and control systems. In addition, the model can also be driven by control system commands that adjust relevant parameters to rapidly obtain control responses.
An added complexity in wind turbine simulation is nonlinearity. For large flexible mechanisms like wind turbines, large rotations and deformations can result in simulation inaccuracy. SANY Heavy Energy uses the LMS Samcef solver’s nonlinear multibody simulation capabilities to compute more accurate dynamic loads.
One of the key capabilities of LMS Samcef Wind Turbines is parametric modeling of turbines. Parameterized models enable designers to easily compare and verify different designs or modify existing designs without complex and time-consuming model reconstruction. The result is shorter development cycles and reduced costs. The software also includes tools that streamline wind turbine certification, enabling SANY Heavy Energy to quickly execute standard sets of calculations and reports that are required by regulatory agencies.
Digital twin and smart wind turbines
SANY Heavy Energy has also implemented intelligent controls for wind turbine operation and maintenance processes. When weather conditions deteriorate or the remote monitoring system sends real-time messages, SANY Heavy Energy’s operation and maintenance team can quickly predict the status and develop an optimal control strategy or maintenance plan, thereby improving the overall wind farm efficiency while avoiding wind turbine failures and extending power generation time. This intelligent operation and maintenance results in a significantly reduced LCOE.
SANY Heavy Energy’s use of Simcenter solutions has yielded positive results. The insights gained through leading-edge simulation have enabled the company to improve wind turbine and farm efficiency by 50 percent, and to reduce projected LCOE by more than ten percent.
“In the rapidly changing wind power industry that has many giants, the key for SANY Heavy Energy to succeed is to fully utilize smart technologies like the digital twin to improve development efficiency and product reliability, thus lowering LCOE and supporting our ultra-low wind speed product strategy,” says Wu Shengfei, CAE simulation manager at SANY Heavy Energy. “In this process, Simcenter 3D provided by Siemens PLM Software is a key value.”