Damage detection in wind turbine blades by using operational modal analysis

Modal analysis has developed into a major technology for the study of structural dynamics in the past several decades. Through it, complex structural dynamics phenomena can be represented in terms of structural invariants, i.e., the modal parameters: natural frequencies, damping ratios and mode shapes. Operational Modal Analysis (OMA) deals with the estimation of modal parameters on vibration data measured for operational conditions, when the excitation on the structure is not measured. In this work, OMA is performed on a wind turbine blade undergoing wind tunnel testing. These tests included different wind speeds, pitch angles and also different health conditions of the blade, where masses of different magnitude were fixed to the blade on different locations to emulate damage conditions. In order to monitor the modal parameters across multiple days of varied tests in the wind tunnel, the Polymax modal parameter estimator was implemented, coupled with an Automated Modal Analysis methodology. This methodology included an automatic modal parameter selection technique, using a Machine Learning (ML) clustering algorithm, coupled with a modal tracking procedure which applied statistical thresholds on the modal parameters’ values. The tracking procedure searches for modes similar to the ones calculated for healthy conditions. The results show how the modal parameters of the wind turbine blade vary with the different measured conditions in the wind tunnel. Moreover, a damage detection methodology is implemented to differentiate between the healthy and damaged conditions on the blade, by leveraging an anomaly detection algorithm using the Multivariate Gaussian Distribution (MGD). This algorithm takes as input the modal parameters calculated by the previous Automated Modal Analysis methodology and detects statistical deviations among them which could indicate the presence of damage. All steps of this work contribute to developing an automatic framework able to detect damages on a wind turbine blade, and therefore perform Structural Health Monitoring (SHM) for different operational conditions.

One of the most critical components of wind turbines is the blades. As blades are constantly exposed to weather and high loads, they can wear and become damaged. Performing in-situ continuous monitoring can help detect sudden damages and prevent further degradation, which is imperative to avoid economic losses and fatal accidents. However, monitoring a rotating rotor blade presents some challenges. One challenge is the consideration of lightning protection. Hence, a non-conductor measurement system must be used. Another challenge is system identification and modal tracking considering environmental and operational conditions (EOCs). Furthermore, vibration-based monitoring results from actual and operational rotor blades are scarce in the existing literature. This study centres on operational modal analysis (OMA) using covariance- driven stochastic subspace identification (SSI-COV) of an offshore wind turbine blade in operation employing eight months of data from fibre optic accelerometers (FOA) and fibre Bragg grating (FBG) strain gauges. The identification focuses on the first two bending modes in flapwise and edgewise directions and the first torsional mode. The study aims to determine which fibre optic sensor delivers better results. Furthermore, it addresses the effect of EOCs on the modal parameters, where system identification and modal tracking are discussed. It was found that tracked modes showed similar trends with respect to time, and a high connection was observed between wind speed, rotor speed, and pitch angle with frequency and damping. Additionally, acceleration and strain measurements deliver the same frequency and damping values. FBG better identified the first flapwise mode. On the other hand, FOA was superior in almost all other modes. This study points towards employing FOA for vibration-based monitoring of wind turbine blades using modal parameters.

Continuous wavelet transform-based method for enhancing estimation of wind turbine blade natural frequencies and damping for machine learning purposes

Wind-induced operational variability is one of the major challenges for structural health monitoring of slender engineering structures like aircraft wings or wind turbine blades. Damage sensitive features often show an even bigger sensitivity to operational variability. In this study a composite cantilever was subjected to multiple mass configurations, velocities and angles of attack in a controlled wind tunnel environment. A small-scale impact damage was introduced to the specimen and the structural response measurements were repeated. The proposed damage detection methodology is based on automated operational modal analysis. A novel baseline preparation procedure is described that reduces the amount of user interaction to the provision of a single consistency threshold. The procedure starts with an indeterminate number of operational modal analysis identifications from a large number of datasets and returns a complete baseline matrix of natural frequencies and damping ratios that is suitable for subsequent anomaly detection. Mahalanobis distance-based anomaly detection is then applied to successfully detect the damage under varying severities of operational variability and with various degrees of knowledge about the present operational conditions. The damage detection capabilities of the proposed methodology were found to be excellent under varying velocities and angles of attack. Damage detection was less successful under joint mass and wind variability but could be significantly improved through the provision of the currently encountered operational conditions.

Operational modal analysis (OMA) is a procedure that allows the modal parameters of a structure to be extracted from the measured response to an unknown excitation generated during operation. Nonlinearity is inevitably and frequently encountered in OMA. The problem: The traditional OMA method based on linear modal theory cannot be applied to a nonlinear oscillation system. The solution: This paper aims to propose a nonlinear OMA method for nonlinear oscillation systems. The new OMA method is based on the following: (1) a self-excitation phenomenon is caused by nonlinear components; (2) the nonlinear normal modes (NNMs) of the system appear under a single-frequency harmonic excitation; and (3) using forced response data, the symbolic regression method (SR) can be used to automatically search for the NNMs of the system, whose modal parameters are implicit in the expression structure expressing each NNM. The simulation result of a three-degree-of-freedom (3-DOF) nonlinear system verifies the correctness of the proposed OMA method. Then, a disc-rod rotor model is considered, and the proposed OMA method’s capability is further evaluated.

Rotating machines are key components in energy generation processes, and faults can lead to shutdowns or catastrophes encompassing economic and social losses. Structural Health Monitoring (SHM) of structures in operation is successfully performed via Operational Modal Analysis (OMA), which has advantages over traditional methods. In OMA, white noise inputs lead to the accurate extraction of modal parameters without taking the system out of operation. However, this excitation condition is not easy to attain for rotating machines used in power generation, and OMA can provide inaccurate information. This research investigates the applicability of machine learning as a pre-stage of OMA to differentiate adequate from inadequate excitations and prevent inaccurate extraction of modal parameters. Data from a rotor system was collected under different conditions and OMA was applied. In a training stage, measurements were characterized by statistical features and K-means was used to determine which features provided information about the excitation condition, that is, which excitation was adequate to extract the rotor’s modal parameters via OMA. In a testing stage, data were successfully classified as adequate or not adequate for OMA, achieving 100% accuracy and revealing the technique’s potential to support SHM of rotating machines. The technique is extendable to other monitoring systems based on OMA.

<div class="htmlview paragraph">Operational Modal Analysis also known as Output Only Modal Analysis has in the recent years been used for extracting modal parameters of civil engineering structures and is now becoming popular for mechanical structures. The advantage of the method is that no artificial excitation needs to be applied to the structure or force signals to be measured. All the parameter estimation is based upon the response signals, thereby minimising the work of preparation for the test. This test case is a controlled lab set-up enabling different parameter estimation methods techniques to be used and compared to the Operational Modal Analysis. For Operational Modal Analysis two different estimation techniques are used: a non-parametric technique based on Frequency Domain Decomposition (FDD), and a parametric technique working on the raw data in time domain, a data driven Stochastic Subspace Identification (SSI) algorithm. These are compared to other methods such as traditional Modal Analysis. In the paper the method is illustrated by practical examples.</div>

A new operational modal analysis (OMA) method is developed for estimation of modal parameters (MPs) of a rotating structure (RS) subject to random excitation using a nonuniform rotating beam model, an image processing method, and an improved demodulation method. The solution to the governing equation of a nonuniform rotating beam is derived, which can be considered as the response of the beam measured by a continuously scanning laser Doppler vibrometer (CSLDV) system. A recently developed tracking CSLDV system can track and scan the RS. The image processing method determines the angular position of the RS so that the tracking CSLDV system can sweep its laser spot along a time-varying path on it. The improved demodulation method obtains undamped mode shapes (UMSs) of the RS by multiplying its measured response by sinusoids whose frequencies are its damped natural frequencies (DNFs) that are obtained from the fast Fourier transform of the measured response. Experimental investigation of the OMA method using the tracking CSLDV system is conducted, and MPs of a rotating fan blade (RFB), including DNFs and UMSs, with different constant speeds and its instantaneous MPs with a non-constant speed are estimated. Estimated first DNFs and UMSs of the stationary fan blade and RFB are compared with those from the lifting method that was previously developed by the authors.

The accuracy of modal parameter estimates from estimation methods built in the framework of experimental modal analysis (EMA) can be assessed by several methods provided the information of input loadings and output responses. However, a deeper investigation is necessary for estimation methods built in the operational modal analysis (OMA) framework to establish confidence boundaries for the modal parameter estimates. This paper aims to estimate uncertainties of the modal parameter estimates by testing the sensitivity of the damped natural frequencies, damping ratios, and mode shapes to the choice of the estimation method and data acquisition settings used in this method. The uncertainty estimates of the modal parameter estimates are tested for changes in the boundary conditions. The tests provide insights into tendencies for the accuracy of the modal parameter estimates when the boundary conditions provide a different set of “true” modal parameter values. A simple cantilever beam experimental setup is used to obtain benchmark modal parameter estimates from EMA that are used to estimate the accuracy of the modal parameter estimates from OMA. The method’s robustness in estimating uncertainties and accuracies for modal parameter estimates is tested for several independent experiments. The boundary conditions for the cantilever beam are changed to test the influence of altering modal parameter estimates on the estimated uncertainties and accuracies. The boundary conditions are changed using materials with different elastic properties and the connection pressure between the clamping device and beam. A method presented in Paulsen et al. (Proceedings of the 9th International Operational Modal Analysis Conference, IOMAC, 2022) calculates a representative modal parameter estimate from a set of modal parameter estimates based on weightings obtained from the modal assurance criterion. The method’s ability to reduce uncertainties and increase accuracies of the representative estimate is demonstrated by repeating a test setup ten times. The results present simultaneously a reduction of uncertainties and an increase of accuracies for the representative modal parameter when the weighting method is used. An evaluation of dependencies between the estimated uncertainties and accuracies finds a proportional relation for the damped natural frequency when the uncertainties are described as a relative standard deviation. The analysis presents higher accuracy for the damped natural frequency and mode shape estimates compared to the damping factor, and the accuracy of the damping factor is dependent on the actual value of the damping factor. These phenomena for accuracy are well known and indicate that the uncertainties of modal parameter estimates can be assessed through a sensitivity test of estimation methods and data acquisition parameters.

ABSTRACTThe structural stiffness of a blade changes when it is defective, which affects its modal parameters. Consequently, modal parameters can be crucial to investigating defects. Therefore, developing a model that can accurately analyze the modal parameters of healthy and defective blades is essential. This study proposes a high‐fidelity finite element (FE) model development method based on multiobjective optimization. Three 10‐kW‐class wind turbine blades were manufactured, and the modal parameter changes due to debonding damage were measured. The initial FE model was constructed using structural drawings and considering specific material properties. Subsequently, the modal analysis results were compared with the experimental results. The analysis errors of normal and abnormal blades were expressed as cost functions and multiobjective optimization was performed. Machine learning–based predictive models facilitated time‐ and cost‐effective optimization, enabling modal updating that simultaneously reflects modal parameter changes for various blade models. Because accurately predicting the dynamic characteristics of blades by various defect locations and sizes is crucial for blade damage detection, the proposed method is significant for damage detection research.

In order to identify time-varying transient modal parameters only from nonstationary vibration response measurement signals for slow linear time-varying (SLTV) structures which are weakly damped, a moving window differential evolution (DE) independent component analysis- (ICA-) based operational modal analysis (OMA) method is proposed in this paper. Firstly, in order to overcome the problems in traditional ICA-based OMA, such as easy to go into local optima and difficult-to-identify high-order modal parameters, we combine DE with ICA and propose a differential evolution independent component analysis- (DEICA-) based OMA method for linear time invariant (LTI) structures. Secondly, we combine the moving widow technique with DEICA and propose a moving window differential evolution independent component analysis- (MWDEICA-) based OMA method for SLTV structures. The MWDEICA-based OMA method has high global searching ability, robustness, and complexity of time and space. The modal identification results in a three-degree-of-freedom structure with slow time-varying mass show that this MWDEICA-based OMA method can identify transient time-varying modal parameters effectively only from nonstationary vibration response measurement signals and has better performances than moving window traditional ICA-based OMA.

Operational modal analysis is a procedure that allows the extraction of modal parameters of a structure in its operating environment. It is based on the idealized premise that input to the structure is white noise. In some cases, when free decay responses are corrupted by unmeasured random disturbances, the response data can be processed into cross-correlation functions that approximate free decay responses. Modal parameters can be computed from these functions by time domain identification methods such as the Eigenvalue Realization Algorithm (ERA). The extracted modal parameters have the same characteristics as impulse response functions of the original system. Operational modal analysis is performed on Ares I-X in-flight data. Since the dynamic system is not stationary due to propellant mass loss, modal identification is only possible by analyzing the system as a series of linearized models over short periods of time via a sliding time-window of short time intervals. A time-domain zooming technique was also employed to enhance the modal parameter extraction. Results of this study demonstrate that free-decay time domain modal identification methods can be successfully employed for in-flight launch vehicle modal extraction.

Operational modal analysis (OMA) has been widely used for large structures. However, measured signals are inevitably contaminated with noise and may not be clean enough for identifying the modal parameters with proper accuracy. The traditional methods to estimate modal parameters in noisy situation are usually absorbing the “noise modes” first, and then using the stability diagrams to distinguish the true modes from the “noise modes.” However, it is still difficult to sort out true modes because the “noise modes” will also tend to be stable as the model order increases. This study develops a noise reduction procedure for polyreference complex exponential (PRCE) modal analysis based on ambient vibration responses. In the procedure, natural excitation technique (NExT) is first applied to get free decay responses from measured (noisy) ambient vibration data, and then the noise reduction method based on solving the partially described inverse singular value problem (PDISVP) is implemented to reconstruct a filtered data matrix from the measured data matrix. In our case, the measured data matrix is block Hankel structured, which is constructed based on the free decay responses. The filtered data matrix should maintain the block Hankel structure and be lowered in rank. When the filtered data matrix is obtained, the PRCE method is applied to estimate the modal parameters. The proposed NExT-PDISVP-PRCE scheme is applied to field test of a jacket type offshore platform. Results indicate that the proposed method can improve the accuracy of OMA.

\nThis work presents a summary of the research study of operational modal analysis (OMA) application for condition monitoring of operating pipelines. Special focus is on the topicality of OMA for definition of the dynamic features of the pipeline (frequencies and mode shapes) in operation. The research was conducted using two operating laboratory models imitated a part of the operating pipeline. The results of finite-element modeling, identification of pipe natural modes and its modification under the influence of virtual failure are discussed. The work considers the results of experimental research of dynamic behavior of the operating pipe models using one of OMA techniques and comparing dynamic properties with the modeled data. The study results demonstrate sensitivity of modal shape parameters to modification of operating pipeline technical state. It is resumed about ability of operating pipeline condition monitoring by measuring dynamic deformations of the operating pipe and OMA techniques application for dynamic properties extraction.\n

Fatigue cracks in steel bridges can lead to catastrophic failure and cause significant risks to public safety. These cracks can grow, propagate, reduce the structure maximum design capacity, and ultimately lead to a sudden failure. Fatigue cracks in steel bridges are primarily induced by the cyclic loading from constant traffic loads over time. Therefore, monitoring fatigue on steel bridges is essential to ensure structural safety. Operational modal analysis (OMA) is a non-destructive testing technique that can be used to monitor fatigue-induced damage through changes in modal parameters. When the fatigue crack grows the stiffness of the beam will reduce. This study implements OMA on a simply supported steel beam with changing stiffness. The natural frequencies and mode shapes of the beam are obtained through OMA, and combined with a model to predict the stress/strains at any point of the structure. The case study shows how maximum stresses and the natural frequencies that are affected by the crack growth are varying due to changes in stiffness. The result demonstrates that by combining OMA with fatigue assessment, the risk of fatigue failure in steel bridges can be significantly reduced.