Case Study: Xi Engineering Consultants Ltd achieves wind turbine tonal-noise reduction and major cost savings with COMSOL Multiphysics

Xi Engineering Consultants Ltd - Customer Case Study

Xi Engineering Consultants Ltd, an Edinburgh–based vibration specialist, was engaged to find the source of an annoying tonal noise (800–830 Hz) from a megawatt wind turbine where gearbox meshing (~820 impacts/s) was suspected. Previous remedial work (including lifting a 15‑ton gearbox and changing rubber buffers) had failed and full redesign or blanket interior coating of the 80 m towers looked prohibitively expensive. Xi used Comsol’s COMSOL Multiphysics to investigate the problem virtually and isolate the vibration path.

Using Comsol, Xi built acoustic–structural interaction and eigenfrequency models of the gearbox, nacelle, tower and surrounding air, located resonant hotspots on the tower skin, and virtually tested anti‑vibration coatings. The modeling showed that only 20 m^2 of specialist material per tower (not 100–600 m^2) was required to attenuate the tone to acceptable levels; a prototype confirmed the result. By applying Comsol simulation, Xi avoided costly on‑site trial‑and‑error (noted to be >30× the cost of additional simulation) and delivered a low‑cost, passive retrofit that satisfied the client.

Xi Engineering Consultants Ltd

Brett Marmo

Senior Consultant