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Failures in hydraulic systems in offshore wind turbines represent an enormous challenge for manufacturers and operators, as the pitch system statistically is one of the subsystems contributing the most to the downtime of the turbines, which is the case for both electrical and hydraulic pitch systems. However, the complex failure mechanisms of the various different hydraulic components mean that, typically, the critical components of hydraulic systems must be tested to better understand the failure mechanisms. Nonetheless, conventional testing procedures are lengthy and costly. Accelerated testing plays a critical role as it can mimic hydraulic system failure mechanisms in a shorter period. However, the lack of standardized test methods and detailed knowledge about the failure-accelerating effects complicates the process. Therefore, this paper offers a comprehensive examination of approaches applicable to conducting accelerated tests on hydraulic systems. It identifies and discusses five primary component types or sub-components related to the acceleration of testing in hydraulic systems: pumps, cylinders, seals, valves, and hoses. Each section references studies that delve into accelerated testing methodologies for these individual components. Furthermore, within each component, a concise overview of the current techniques is provided, followed by a discussion and summary based on the state of the art. [ABSTRACT FROM AUTHOR]

In offshore winch drive applications, determining the required number of pistons in digital displacement motors is critical for minimizing torque ripples. Digital displacement motors have shown promise for improving energy efficiency for offshore operations, such as placing equipment on the seabed or mineral drilling. However, they are known for exhibiting significant torque ripples, which can affect load-handling precision. This paper estimates the required number of pistons for realizing a digital hydraulic winch drive based on information from a commercial winch. The proposed drive employs full-stroke displacement strategies at high speeds and partial-stroke at low speeds. By simulating steady-state operations, this study correlates torque output with position oscillations. The results show that 37 pistons are required to keep position oscillations below a benchmark threshold of 10 mm throughout the drive's operating range to avoid hindering the drive's performance. However, such a high piston count could result in high costs due to the large, expensive valves required for partial-stroke operations. Therefore, this paper suggests an alternative drive topology for future research, which could potentially reduce the number of pistons that are operated with partial strokes. [ABSTRACT FROM AUTHOR]

Danfoss Power Solutions Aps has a product line focusing on hydraulic steering units for heavy-duty machines. The focus of this paper is on the end-stop torque encountered by the operator for a new asymmetrical hydraulic steering unit, referred to as sSteer. This hydraulically asymmetric concept increases the steering responsiveness between the steering wheel input and the output. However, compared to traditional hydraulic steering units, the asymmetrical design has a drawback regarding the level of end-stop torque felt by the operator when reaching the left-side end stop. This paper investigates three different concepts for improving/increasing the end-stop torque, namely, including a bleed orifice, removing a set of suction valves, and a solution with pre-tensioned suction valves and tank line. During the investigations, these concepts were compared and benchmarked using experimental data to identify advantages and disadvantages. Based on the investigations, it is concluded that the concept with pre-tensioned suction valves and a pressurized tank line ensures the best compromise between the different design requirements and the establishment of a firm end-stop feeling for the operator. [ABSTRACT FROM AUTHOR]

Pitch systems form an essential part of today's wind turbines; they are used for power regulation and serve as part of a turbine's safety system. Hydraulic pitch systems include hydraulic accumulators, which comprise a crucial part of the safety system, as they are used to store energy for emergency shutdowns. However, accumulators may be subject to gas leakage, which is the primary failure mode. Gas leakage affects the performance of the accumulator and, in extreme cases, compromises the safety function of the pitch system. This paper deals with the development and experimental validation of an algorithm to detect gas leakage in piston-type accumulators. The innovation of the algorithm is the ability to generate estimates of the remaining amount of gas while solving the drift problem evidenced in previous research. Additionally, this method enables the ability to isolate gas leakage to a single accumulator out of a bank of accumulators. The approach is based on a State Augmented Extended Kalman Filter (SAEKF), which utilizes an extended thermal model of the accumulator, as well as temperature measurements along the accumulator surface to estimate the remaining gas in the accumulator. The method is experimentally validated and addresses the drift problem in estimating the gas leakage evidenced from previous research. Additionally, the method can identify and isolate gas leakage to a single accumulator from a bank of accumulators. [ABSTRACT FROM AUTHOR]

A new method for designing holographic optical elements is presented. The method is based on matching the grating-spacing profile of the recording light interference pattern to the desired grating-spacing profile. We show that for designing near-field holograms, in which the optical images involved are close to the hologram aperture, the grating-matching technique is superior to the well-established aberration-balancing method introduced by Latta [Appl. Opt. 10, 609 (1971)].

This article describes the development and application of a model-based scheme for detecting the early signs of coil failure in solenoid valves. Contrary to other works, the proposed method simply isolates the fault-induced change in the coil resistance from thermal effects and provides a cost-effective solution with no comprehensive equipment demand. The model-based detection method employs a simple thermal model of the solenoid and an extended Kalman filter (EKF) for generating coil current residuals. The EKF utilizes measurements of coil voltage, coil current, ambient, and fluid temperature. The CUmulative SUM of the current residual is found to be sensitive to the early signs of coil failure. An experimental setup is utilized for evaluating the robustness of the detection method in the event of changing ambient temperature, convection, and fluid flow conditions. Results show that the method is able to detect the early signs of coil failure, and robust behavior and high detection probabilities are achieved for realistic fault sizes. The realistic fault sizes and the number of fault instances before failure are determined through extensive accelerated tests, where solenoids are operated at high temperature until failure. [ABSTRACT FROM AUTHOR]

Fluid power systems are inherently nonlinear and typically suffer from very poor damping. Despite these characteristics, it is not uncommon that traditional linear type controllers are applied. This typically results in conservative adjustment of the controllers, or when more advanced controllers are applied, that they do not benefit from the possibilities for improving the damping by applying (internal) pressure feedback in the systems. In both cases, the result will be degraded performance compared with what may be obtained. Pressure feedback, also referred to as active damping, is not a new method. However, it is an often overlooked method, and when it is applied, it is not adjusted optimally to also account for model uncertainties, unmodeled system dynamics, and parameter variations. The focus of this paper is to explain various types of pressure feedback that may be applied; how these affect a given system, and how to adjust the parameters of the pressure feedback to obtain the best results. This is done for both a traditional symmetric cylinder servo system and a system with a differential cylinder using both pressure and nonpressure compensated proportional valves. Based on the presented models, the analysis yields results for how to properly adjust the parameters. [ABSTRACT FROM AUTHOR]

This study investigates the fabrication and performance of broadband and omnidirectional antireflective polymer foils, in the visible spectrum (400-800 nm), consisting of subwavelength inverted moth-eye structures. The foils are fabricated by a high throughput roll-to-roll extrusion coating process allowing structuring on both sides at a rate of 60 m min−1, with web width 45 cm. The highest average transmittance obtained in the visible spectrum is (98 ± 1) %; compared with (92 ± 1) % for the unstructured foil. The antireflective foil shows no significant difference in transmittance between normal incidence and incidence up to at least 60°. The foil performance is also investigated for different depths ( Dp) and shapes of structures. The transmittance initially increases with Dp and reaches a maximum at Dp ≈ 120 nm. For process parameters yielding greater depths, other shape factors also play a critical role in the foil's antireflective properties. [ABSTRACT FROM AUTHOR]

This paper presents a qualitative design tool for evaluation of the risk for fluid power pitch systems. The design tool is developed with special attention to industry standard failure analysis methods and is aimed at the early phase of system design. Firstly, the concept of Fault Tree Analysis is used for systematic description of fault propagation linking failure modes to system effects. The methodology is conducted solely on a circuit diagram and functional behavior. The Failure Mode and Effects Criticality Analysis is subsequently employed to determine the failure mode risk via the Risk Priority Number. The Failure Mode and Effect Criticality Analysis is based on past research concerning failure analysis of wind turbine drive trains. Guidelines are given to select the severity, occurrence and detection score that make up the risk priority number. The usability of the method is shown in a case study of a fluid power pitch system applied to wind turbines. The results show a good agreement to recent field failure data for offshore turbines where the dominating failure modes are related to valves, accumulators and leakage. The results are further used for making design improvements to lower the overall risk of the pitch system. Copyright © 2017 John Wiley & Sons, Ltd. [ABSTRACT FROM AUTHOR]

This paper describes the development and application of a signal-based fault detection method for identifying gas leakage in hydraulic accumulators used in wind turbines. The method uses Multiresolution Signal Decomposition (MSD) based on wavelets for feature extraction from a single fluid pressure measurement located close to the accumulator. Gas leakage is shown to create increased variations in this pressure signal. The Root Mean Square (RMS) of the detail coefficient Level 9 from the MSD is found as the most sensitive and robust fault indicator of gas leakage. The method is verified on an experimental setup allowing for the replication of the conditions for accumulators in wind turbines. Robustness is tested in a multi-fault environment where gas and external fluid leakage occurs simultaneously. In total, 24 experiments are performed, which show that the method is sensitive to gas leakage in the desired range and can be isolated from external fluid leakage. Additionally, the robustness to other operating conditions, such as wind speeds between rated and cut-off, turbulence intensity and ambient temperature is evaluated via simulations of a pitch system in a wind turbine using the Fatigue, Aerodynamics, Structures and Turbulence program (FAST). Simulation shows that robustness is affected at low ambient temperatures, however, detection is permitted in the range of 22-60 °C. [ABSTRACT FROM AUTHOR]

Discrete fluid power systems featuring transmission lines inherently include pressure oscillations. Experimental verification of a discrete fluid power power take off system for wave energy converters has shown the cylinder pressure to oscillate as force shifts are performed. This article investigates how cylinder pressure oscillations may be reduced by shaping the valve opening trajectory without the need for closed loop pressure feedback. Furthermore the energy costs of reducing pressure oscillations are investigated. [ABSTRACT FROM AUTHOR]

This paper investigates a novel, very high throughput, roll-to-roll (R2R) process for nanostructuring of polymer foils, called R2R extrusion coating. It has the potential to accelerate the integration of nanostructured materials in consumer products for a variety of applications, including optical, technical, and functional surfaces and devices. In roll-to-roll extrusion coating, a molten polymer film is extruded through a flat die forming a melt curtain, and then laminated onto a carrier foil. The lamination occurs as the melt curtain is pressed between a cooling roller and a counter roller. By mounting a nanostructured metal shim on the surface of the cooling roller, the relief structure from the shim can be replicated onto a thermoplastic foil. Among the benefits of Poil, the process are availability of a wide range of commercial extruders, off-the-shelf extrusion grade polymers, functional additives, polymeric materials with good diffusion barrier properties, and the overall maturity of the technology [S. H. Ahn and L. J. Guo, Adv. Mater. 20, 2044 (2008)]. In this article, the authors demonstrate replication of nanopits and nanopillars with diameters between 40 and 120 nm and depth/height of 100 nm. The best replication was achieved in polypropylene, by running at high roller line-speed of 60 m/min, and high cooling roller temperature of 70 °C. Replication in other common polymers like polyethylene and polystyrene was not possible for the parameter range used for the investigation. [ABSTRACT FROM AUTHOR]

Fabrication of micro‐ and nanostructures at line‐speed of 60 m min−1 by large‐area roll‐to‐roll extrusion coating is demonstrated. Nanopillars with diameters 80 nm and heights 100 nm are replicated in polypropylene. The main limiting factor for replication on nanoscale is the retardation time for solidification of the melt. [ABSTRACT FROM AUTHOR]

Fast-switching seat valves suitable for digital hydraulic pumps and motors utilize direct electromagnetic actuators, which must exhibit superior transient performance to allow efficient operation of the fluid power pump/motor. A moving coil actuator resulting in a minimum valve switching time is designed for such valves using transient finite-element analysis of the electromagnetic circuit. The valve dynamics are coupled to the fluid restrictive forces, which significantly influence the effective actuator force. Fluid forces are modeled based on transient computational fluid dynamics models. The electromagnetic finite-element model is verified against experimental measurement, and used to design an optimum moving coil actuator for the application considering different voltage–current ratios of the power supply. Results show that the optimum design depends on the supply voltage–current ratio, however, the minimum switching time obtained is nearly independent on this voltage–current ratio. Selecting a suitable power supply based on thermal considerations yields a switching time just above one millisecond for a travel length of 3.5 mm while submerged in oil. The proposed valve has a pressure drop below 0.5 bar at 600 L/min flow rate, enabling efficient operation of digital hydraulic pumps and motors. [ABSTRACT FROM PUBLISHER]

When modeling flexible robots and structures for control purposes, most often the assumed modes (AMs) method is used to describe the deformation in combination with a floating reference frame formulation. This typically has the benefit of obtaining a low-order, but accurate model of the flexible structure, if the number of modes and AMs are properly chosen. The basis for using this method is, however, that the vibrations (deflections) are time and position independent, i.e., the expression is separable in space and time. This holds for the classic Euler-Bernoulli beam equation, but essentially does not hold for translational links. Hence, special care has to be taken when including flexible translational links. In the current paper, different methods for modeling a hydraulic loader crane with a telescopic arm are investigated and compared using both the finite segment (FS) and AMs method. The translational links are approximated by a single beam, respectively, multiple beam elements, with both one and two modes and using different mode shapes. The models are all validated against experimental data and the comparison is made for different operating scenarios. Based on the results, it is found that in most cases a single beam, low mode order approximation is sufficient to accurately model the mechanical structure and this yields similar results as the FS method. [ABSTRACT FROM AUTHOR]

Fluid stiction may significantly influence the dynamic behavior when attempting to quickly separate two plates in close contact. The liquid fluid film, filling the gap between the plates, experiences a pressure drop resulting from an increasing distance, and cavita-tion may appear if sufficient separation speed and low plate distance are present. In the case of small initial plate separation, fluid tension is known to develop and the stiction force may exceed the maximum stiction force calculated by assuming strictly positive pressures in the fluid film. In this paper, a model for simulating the time dependent fluid stiction phenomenon, including a fluid tensile strength and cavitation effects, is proposed. The model is based on Reynolds theory, and the pressure distribution in the liquid zone is solved analytically for each time step, leading to a computationally efficient model without the need for finite element/volume methods. The considered geometry is two long parallel plates submerged in liquid, as present in many valve applications. The model is compared to experimental measurements, and it is found that the model is able to predict the stiction effect with reasonable accuracy given that proper selections of liquid tensile strength and initial plate distance are made. [ABSTRACT FROM AUTHOR]

A conventional simplification of the thermal problem in fluid film lubrication analysis is performed by assuming that the main direction of heat flow is conduction through the film thickness, and thereby neglecting convection. However, in a significant amount of applications, convection is not negligible, whereby the majority of design engineers exclusively use numerical solvers. This paper presents a perturbation series expansion of the temperature field for small values of the Brinkman number. The derived perturbation solution and the more conventional analytical solution, where convection is neglected, are compared to a numerical test case. The comparison shows a significant improvement in the region where the convection term and conduction term are of the same order. [ABSTRACT FROM AUTHOR]

To comply with the increasing demands for life time and reliability of wind turbines as these grow in size, new measures needs to be taken in the design of wind turbines and components hereof. One critical point is the initial testing of the components and systems before they are implemented in an actual turbine. Full scale hardware testing is both extremely expensive and time consuming, and so the wind turbine industry moves more towards simulations when testing. In order to meet these demands it is necessary to use valid system models of in order to introduce new technologies to the wind turbine market. A hydraulic yaw system is such a new technology, and so a mathematical model of the full scale system and test rig system is derived and compared to measurements from the system. This is done in order to have a validated model, which wind turbine manufacturers may use for test in their simulation environment. The model and the test rig are tested against different design load cases and the results are compared. The experiments show that the model is valid for comparing the overall dynamics of the hydraulic yaw system. Based on the results it is concluded that the model derived is suitable for testing of the dynamic behavior in wind turbine manufacturer's full scale aero elastic code. [ABSTRACT FROM AUTHOR]

The focus of the current paper is on a hydraulic soft yaw system, designed to reduce the loading of the turbine structure, by absorbing wind guest via the hydraulic system, but which also enables the system to be used as a self-aligning yaw system. The system is analyzed with basis in the NREL 5-MW turbine, modeled in FAST, in which a new robust method for implementing Coulomb friction is utilized. Based on this model and a model of the hydraulic system, the influence of friction and wind speed is investigated in relation to the possibility to use the system as a self-aligning yaw system. Similarly the behavior of the hydraulic system is analyzed and it is concluded that the hydraulic yaw system allows self-yaw under normal operating conditions for the turbine. Self-yaw control is possible in wind speeds above 12 m/s when yaw friction is kept below 1 MNm. [ABSTRACT FROM AUTHOR]

As wind turbines increase in size and the demands for lifetime also increases, new methods of load reduction needs to be examined. One method is to make the yaw system of the turbine soft/flexible and hence dampen the loads to the system, which is the focus of the current paper. The paper first presents work previous done on this subject with focus on hydraulic yaw systems.By utilizing the HAWC2 aeroelastic code and an extended model of the NREL 5MW turbine combined with a simplified linear model of the turbine, the parameters of the soft yaw system are optimized. Results show that a significant reduction in fatigue and extreme loads to the yaw system and rotor shaft are possible, when utilizing the soft yaw drive concept compared to the original stiff yaw system. The physical demands of the hydraulic yaw system are furthermore examined for a life time of 20 years. The duty cycles, based on the extrapolated loads, show that it is possible to construct a hydraulic soft yaw system, which is able to reduce the loads on the wind turbine significantly. [ABSTRACT FROM AUTHOR]

In marine applications, a cyclic varying pitch (CVP) propeller is a propeller in which the propeller blade can be cyclic-pitched. This cyclic pitching of the propeller blades is used to adapt to the local flow conditions in the non-uniform wake field that the propeller operates in, behind the ship hull. This has the potential to improve the performance of the propulsion system relative to a propeller which has fixed pitch for each revolution. The potential performance improvements include increasing the propulsion efficiency and reducing the cavitation, pressure pulses, vibrations and noise problems. However, the CVP propeller is not on the market today, and several challenges have to be addressed before the CVP propeller may be realized. One of these challenges is how to design the individual cyclic pitch mechanism for the propeller. However, before the cyclic pitch mechanism can be designed, it is necessary to know the requirements for it, such as the required pitching power and torque. The focus of the current paper is therefore to present a model for the propeller, by which it is possible to determine the loads acting on the CVP propeller blades during the cyclic pitching, and hence the actuator force/torque and power requirements. To illustrate the usefulness of the model, an example is presented, in which the loads on a CVP propeller are determined, together with the requirements for the individual cyclic pitch mechanism. The efficiency results presented are, however, not representative of the efficiency improvement that may be obtained, as neither the propeller nor the pitch trajectory has been optimised. The results do, however, serve to show the benefit and validity of the model. [ABSTRACT FROM AUTHOR]

Wind turbines have become a significant part of the global power production and are still increasing in capacity. Pitch systems are an important part of modern wind turbines where they are used to apply aerodynamic braking for power regulation and emergency shutdowns. Studies have shown that the pitch system is responsible for up to 20% of the total down time of a wind turbine. Reducing the down time is an important factor for decreasing the total cost of energy of wind energy in order to make wind energy more competitive. Due to this, attention has come to condition monitoring and fault detection of such systems as an attempt to increase the reliability and availability, hereby the reducing the turbine downtime. Some methods for fault detection and condition monitoring of fluid power systems do exists, though not many are used in today's pitch systems. This paper gives an overview of fault detection and condition monitoring methods of fluid power systems similar to fluid power pitch systems in wind turbines and discuss their applicability in relation to pitch systems. The purpose is to give an overview of which methods that exist and to find areas where new methods need to be developed or existing need to be modified. The paper goes through the most important components of a pitch system and discuss the existing methods related to each type of component. Furthermore, it is considered if existing methods can be used for fluid power pitch systems for wind turbine. [ABSTRACT FROM AUTHOR]

We disclose a simple, optical touch screen technique based on a planar injection molded polymer waveguide, a single laser, and a small linear detector array. The solution significantly reduces the complexity and cost as compared to existing optical touch technologies. Force detection of a touching finger is also demonstrated. [ABSTRACT FROM AUTHOR]

We demonstrate an optical reader principle aimed at monitoring biologically induced deflections of microcantilevers often used in biosensor systems. The principle is based on a so-called common-path optical interferometer in which the two interfering optical beams are copropagating, which makes the system less sensitive to external disturbances. A detection limit of around 1 nm's deflection is demonstrated. [ABSTRACT FROM AUTHOR]

A planar optical waveguide configuration is proposed to monitor the buildup of thick polyelectrolyte multilayers on the surface of the waveguide in aqueous solutions. Instead of detecting the layer by the electromagnetic evanescent field the polyelectrolyte layer acts as an additional waveguiding film that is sensed by guided waves instead of evanescent waves. This leads to a considerably improved sensitivity and dynamic range. [ABSTRACT FROM AUTHOR]

The effect of the attachment and spreading of living cells on the modes of a grating coupled reverse symmetry waveguide sensor is investigated in real time. The reverse symmetry design has an increased probing depth into the sample making it well suited for the monitoring of cell morphology. As a result, significant changes in the incoupling peak height and peak shape were observed during cell attachment and spreading. It is suggested that the area under the incoupling peaks reflects the initial cell attachment process, while the mean peak position is mostly governed by the spreading of the cells. [ABSTRACT FROM AUTHOR]

An alternative transduction mechanism for planar optical waveguide sensors is reported. Based on a simple measurement of the mode intensity, the presented transduction is an interesting alternative to the conventional mode-angle transduction, because the expensive, high-precision angular rotation usually employed may be avoided. [ABSTRACT FROM AUTHOR]

A reverse symmetry waveguide is presented for evanescent wave sensing in aqueous solutions. The waveguide consists of a thin polystyrene film, supported by a thicker substrate layer of nanoporous silica on glass. The nanoporous substrate layer has a refractive index of n[sub s]=1.193, hence, with an aqueous cover refractive index of n[sub C]=1.331, a reverse symmetry (n[sub S]

A sensor design that uses a grating-coupled multimode planar optical waveguide for absolute detection of the refractive indices of liquids or gases is presented. The waveguide consists of a simple 50-microm-thick, free-standing glass plate with air beneath it and the sample to be analyzed on top of it. This design offers a simple alternative to the well-known monomode waveguides, and, owing to its so-called reverse-symmetry configuration, a large detection range can be obtained.

A grating-coupled planar optical waveguide sensor is presented for sensing of bacteria by evanescent waves. The waveguide design results in increased depth of penetration into the sample volume, which makes it suitable for detecting micrometer-sized biological objects. We tested the sensor's performance by monitoring the adhesion of Escherichia coli K12 cells to the sensor surface.