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Fix SED crashes: VTK segfault and zero-inertia NaN propagation #3408

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Fix SED crashes: VTK segfault and zero-inertia NaN propagation #3408

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002e8c7
Fix segfault in SetVTKParameters when CompElast=SED with VTK enabled
andrew-platt Jul 29, 2026
3df8ed6
SED: add fatal error for zero drivetrain inertia with GenDOF enabled
andrew-platt Jul 29, 2026
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25 changes: 20 additions & 5 deletions modules/openfast-library/src/FAST_Subs.f90
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Original file line number Diff line number Diff line change
Expand Up @@ -166,6 +166,7 @@ SUBROUTINE FAST_InitializeAll( t_initial, m_Glue, p_FAST, y_FAST, m_FAST, ED, SE
logical :: CallStart

REAL(R8Ki) :: theta(3) ! angles for hub orientation matrix for aeromaps
TYPE(ED_InitOutputType) :: InitOutData_ED_Dummy ! dummy for SetVTKParameters when ED is not used

CHARACTER(*), PARAMETER :: RoutineName = 'FAST_InitializeAll'
CHARACTER(ErrMsgLen) :: ErrMsg2
Expand Down Expand Up @@ -1523,8 +1524,13 @@ SUBROUTINE FAST_InitializeAll( t_initial, m_Glue, p_FAST, y_FAST, m_FAST, ED, SE
!----------------------------------------------------------------------------

if ( p_FAST%WrVTK > VTK_None ) then
! TODO: support multiple ElastoDyns
call SetVTKParameters(p_FAST, Init%OutData_ED(1), Init%OutData_SED, Init%OutData_AD, Init%OutData_SeaSt, Init%OutData_HD, ED, SED, BD, AD, HD, ErrStat2, ErrMsg2)
! TODO: support multiple ElastoDyns -- remove InitOutData_ED_Dummy when done.
! FIXME: this solution conflicts with multirotor development. When merging, favor the multirotor approach already in dev over this.
if (allocated(Init%OutData_ED)) then
call SetVTKParameters(p_FAST, Init%OutData_ED(1), Init%OutData_SED, Init%OutData_AD, Init%OutData_SeaSt, Init%OutData_HD, ED, SED, BD, AD, HD, ErrStat2, ErrMsg2)
else
call SetVTKParameters(p_FAST, InitOutData_ED_Dummy, Init%OutData_SED, Init%OutData_AD, Init%OutData_SeaSt, Init%OutData_HD, ED, SED, BD, AD, HD, ErrStat2, ErrMsg2)
end if
call SetErrStat(ErrStat2,ErrMsg2,ErrStat,ErrMsg,RoutineName)
end if

Expand Down Expand Up @@ -3803,7 +3809,7 @@ SUBROUTINE SetVTKParameters(p_FAST, InitOutData_ED, InitOutData_SED, InitOutData
TYPE(SeaSt_InitOutputType), INTENT(INOUT) :: InitOutData_SeaSt !< The initialization output from SeaState
TYPE(HydroDyn_InitOutputType),INTENT(INOUT) :: InitOutData_HD !< The initialization output from HydroDyn
TYPE(ElastoDyn_Data), TARGET, INTENT(IN ) :: ED !< ElastoDyn data
TYPE(SED_Data), INTENT(IN ) :: SED !< Simplified-ElastoDyn data
TYPE(SED_Data), TARGET, INTENT(IN ) :: SED !< Simplified-ElastoDyn data
TYPE(BeamDyn_Data), INTENT(IN ) :: BD !< BeamDyn data
TYPE(AeroDyn_Data), INTENT(IN ) :: AD !< AeroDyn data
TYPE(HydroDyn_Data), INTENT(IN ) :: HD !< HydroDyn data
Expand Down Expand Up @@ -3862,6 +3868,9 @@ SUBROUTINE SetVTKParameters(p_FAST, InitOutData_ED, InitOutData_SED, InitOutData
if ( p_FAST%CompElast == Module_BD ) then
BladeLength = TwoNorm(BD%y(1)%BldMotion%Position(:,1) - BD%y(1)%BldMotion%Position(:,BD%y(1)%BldMotion%Nnodes))
HubRad = InitOutData_ED%HubRad
else if ( p_FAST%CompElast == Module_SED ) then
BladeLength = InitOutData_SED%BladeLength
HubRad = InitOutData_SED%HubRad
else
BladeLength = InitOutData_ED%BladeLength
HubRad = InitOutData_ED%HubRad
Expand Down Expand Up @@ -3916,7 +3925,11 @@ SUBROUTINE SetVTKParameters(p_FAST, InitOutData_ED, InitOutData_SED, InitOutData
! Create the tower surface data
!.......................
! TODO: Support multiple towers
TowerMotionMesh => ED%y(1)%TowerLn2Mesh
if (p_FAST%CompElast == Module_SED) then
TowerMotionMesh => SED%y%TowerLn2Mesh
else
TowerMotionMesh => ED%y(1)%TowerLn2Mesh
end if

CALL AllocAry(p_FAST%VTK_Surface%TowerRad,TowerMotionMesh%NNodes,'VTK_Surface%TowerRad',ErrStat2,ErrMsg2)
CALL SetErrStat(ErrStat2,ErrMsg2,ErrStat,ErrMsg,RoutineName)
Expand Down Expand Up @@ -4001,7 +4014,9 @@ SUBROUTINE SetVTKParameters(p_FAST, InitOutData_ED, InitOutData_SED, InitOutData
CALL SetErrStat(ErrStat2,ErrMsg2,ErrStat,ErrMsg,RoutineName)
IF (ErrStat >= AbortErrLev) RETURN
END DO
! ELSE IF (p_FAST%CompElast == Module_SED) THEN ! no blade surface info from SED
ELSE IF (p_FAST%CompElast == Module_SED) THEN
! SED has no blade line2 mesh; skip generic blade surface generation
call WrScr('Skipping generic blade surfaces for Simplified ElastoDyn (no blade mesh available).')
ELSE
call WrScr('Using generic blade surfaces for ElastoDyn (rectangular airfoil, constant chord). ') ! TODO make this an option
DO K=1,NumBl
Expand Down
8 changes: 8 additions & 0 deletions modules/simple-elastodyn/src/SED.f90
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Original file line number Diff line number Diff line change
Expand Up @@ -190,6 +190,14 @@ subroutine SED_SetParameters(ErrStat3,ErrMsg3)
! system inertia
p%J_DT = p%RotIner + p%GBoxRatio**2_IntKi * p%GenIner

! Check for zero inertia with GenDOF enabled (would cause division by zero in CalcContStateDeriv)
if (p%GenDOF .and. EqualRealNos(real(p%J_DT, ReKi), 0.0_ReKi)) then
ErrStat3 = ErrID_Fatal
ErrMsg3 = 'GenDOF is enabled but drivetrain inertia (RotIner + GBoxRatio^2*GenIner) is zero. '// &
'This would result in a division by zero. Set RotIner or GenIner to a non-zero value, or disable GenDOF.'
return
end if

! Set the outputs
call SetOutParam(InputFileData%OutList, p, ErrStat3, ErrMsg3 )
end subroutine SED_SetParameters
Expand Down
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