Shape optimization of wind turbine blades

This paper presents a design tool for optimizing wind turbine blades. The design model is based on an aerodynamic/aero‐elastic code that includes the structural dynamics of the blades and the Blade Element Momentum (BEM) theory. To model the main aero‐elastic behaviour of a real wind turbine, the code employs 11 basic degrees of freedom corresponding to 11 elastic structural equations. In the BEM theory, a refined tip loss correction model is used. The objective of the optimization model is to minimize the cost of energy which is calculated from the annual energy production and the cost of the rotor. The design variables used in the current study are the blade shape parameters, including chord, twist and relative thickness. To validate the implementation of the aerodynamic/aero‐elastic model, the computed aerodynamic results are compared to experimental data for the experimental rotor used in the European Commision‐sponsored project Model Experiments in Controlled Conditions, (MEXICO) and the computed aero‐elastic results are examined against the FLEX code for flow past the Tjæreborg 2 MW rotor. To illustrate the optimization technique, three wind turbine rotors of different sizes (the MEXICO 25 kW experimental rotor, the Tjæreborg 2 MW rotor and the NREL 5 MW virtual rotor) are applied. The results show that the optimization model can reduce the cost of energy of the original rotors, especially for the investigated 2 MW and 5 MW rotors. Copyright © 2009 John Wiley & Sons, Ltd.     

小型变桨距风力机的气动优化设计

基于叶素动量理论分析了小型风力机的气动性能分析模型,并提出了叶片的气动优化设计方法.结合叶片制造和应用中的实际要求,设计了10 kW小型变桨距风力机叶片的气动外形.计算结果表明,设计叶片具有良好的气动性能,验证了该设计方法有效实用.     

Overall design optimization of dedicated outboard airfoils for horizontal axis wind turbine blades

Designing the primary airfoils for the outboard part of wind turbine blades is a complicated problem of balancing structural, aerodynamic, and acoustic requirements. This paper presents an optimization method for the overall performance of outboard wind turbine airfoils. Based on the complex flow characteristics of the rotor blades and the varying requirements along the span of a blade, the design principles of outboard airfoils were investigated. The requirements for improving the structural performance and reducing the aerodynamic noise were combined with the following aerodynamic design considerations: high efficiency, low extreme loads, stability, and a wide operating region. Thus, this paper proposes a new mathematical model for overall airfoil optimization using the airfoil performance evaluation indicators. Then, an integrated optimization design platform is established for outboard airfoils. Through 2 design cases, new airfoils with desirable aerodynamic characteristics and improved overall performance were obtained. Comparisons between the new airfoils and reference airfoils based on numerical predictions indicate that the proposed method with the newly established mathematical model can effectively balance the complex requirements of the airfoil and improve its overall performance. More notably, the design cases also indicate that the established optimization design method can be used to address special designs of outboard airfoils for different blade requirements.     

基于一种新的优化方法的水平轴风力机风轮设计软件

提出了一种用于水平轴风机风轮设计的软件。该软件的主要目的是为风力机设计者提供一种灵活的集成设计环境，其核心是一个水平轴风机的气动优化过程。该过程基于一种改进的叶素理论，它采用一个有限叶片的旋涡系，因此叶片数量的影响被考虑进行并可得到更精确的气动力。     

Development of an aeroelastic code based on three‐dimensional viscous–inviscid method for wind turbine computations

Aerodynamic and structural dynamic performance analysis of modern wind turbines are routinely estimated in the wind energy field using computational tools known as aeroelastic codes. Most aeroelastic codes use the blade element momentum (BEM) technique to model the rotor aerodynamics and a modal, multi‐body or the finite‐element approach to model the turbine structural dynamics. The present work describes the development of a novel aeroelastic code that combines a three‐dimensional viscous–inviscid interactive method, method for interactive rotor aerodynamic simulations (MIRAS), with the structural dynamics model used in the aeroelastic code FLEX5. The new code, called MIRAS‐FLEX, is an improvement on standard aeroelastic codes because it uses a more advanced aerodynamic model than BEM. With the new aeroelastic code, more physical aerodynamic predictions than BEM can be obtained as BEM uses empirical relations, such as tip loss corrections, to determine the flow around a rotor. Although more costly than BEM, a small cluster is sufficient to run MIRAS‐FLEX in a fast and easy way. MIRAS‐FLEX is compared against the widely used FLEX5 and FAST, as well as the participant codes from the Offshore Code Comparison Collaboration Project. Simulation tests consist of steady wind inflow conditions with different combinations of yaw error, wind shear, tower shadow and turbine‐elastic modeling. Turbulent inflow created by using a Mann box is also considered. MIRAS‐FLEX results, such as blade tip deflections and root‐bending moments, are generally in good agreement with the other codes. Copyright © 2017 John Wiley & Sons, Ltd.     

Aeroelastic analysis of a wind turbine blade using the harmonic balance method

An aeroelastic model for wind turbine blades derived from the unsteady Navier‐Stokes equations and a mode shape–based structural dynamics model are presented. For turbulent flows, the system is closed with the Spalart‐Allmaras turbulence model. The computation times for the aerodynamic solution are significantly reduced using the harmonic balance method compared to a time‐accurate solution. This model is significantly more robust than standard aeroelastic codes that rely on blade element momentum theory to determine the aerodynamic forces. Comparisons with published results for the Caradonna‐Tung rotor in hover and the classical AGARD 445.6 flutter case are provided to validate the aerodynamic model and aeroelastic model, respectively. For wind turbines, flutter of the 1.5 MW WindPACT blade is considered. The results predict that the first flapwise and edgewise modes dominate flutter at the rotor speeds considered.     

Predictions of unsteady HAWT aerodynamics in yawing and pitching using the free vortex method

To predict the unsteady aerodynamic loads of horizontal-axis wind turbines (HAWTs) during operations under yawing and pitching conditions, an unsteady numerical simulation method is proposed. This method includes a nonlinear lifting line method to compute the aerodynamic loads on the blades and a time-accurate free-vortex method to simulate the wake. To improve the convergence property in the nonlinear lifting line method, an iterative algorithm based on the Newton–Raphson method is developed. To increase the computational efficiency and the accuracy of the calculation, a new wake vortex model consisting of the vortex core model, the vortex sheet model and the tip vortex model is used. Wind turbines with different diameters, such as NREL Phase VI, the TU Delft model turbine and the Tjæreborg wind turbine, are used to validate the method for rotors operating at given yaw and/or pitch angles and during yawing and/or pitching processes at different wind speeds. The results, including the blade loads, the rotor torque and the locations of the tip vortex cores in the wake, agree well with the measured data and the computed data. It is shown that the proposed method can be used for predictions of unsteady aerodynamic loads and rotor wakes in the operational processes of blade pitching and/or rotor yawing.     

Advanced brake state model and aerodynamic post-stall model for horizontal axis wind turbines

In scientific literature, when the aerodynamic design of a horizontal axis wind turbine is discussed, different brake state models are presented. The brake state models are implemented within a BEM code which is a 1-D numerical code, based on Glauert propeller theory, and able to predict HAWT performance. This code provides reliable results only if a proper brake state model and aerodynamic post-stall model are implemented.In this research, the authors have produced a numerical code based on BEM theory in conjunction with an aerodynamic post-stall model, indispensable for taking into account radial flow along the wind turbine blades (Himmelskamp Effect), and the brake state models by Buhl, combined with the calculation of Jonkman's tangential induction factor.In scientific literature, Shen's brake state model is commonly implemented within 1-D numerical codes, based on BEM theory. Subsequently, a comparison with Shen's brake state models was carried out. With the numerical code presented in this work, the power for an NREL wind rotor was predicted. With the numerical simulation, it was possible to notice when these different brake state model furnish results close to experimental data.     

Inverse design of horizontal axis wind turbine blades using a vortex line method

A new inverse design process for horizontal axis wind turbine blades is developed to account for three‐dimensional blade features such as non‐planar wing tip. The multidimensional Newton iteration method combined with a vortex line method is used to provide blade geometry parameters given desired aerodynamic behaviors such as lift coefficient and axial induction. The Jacobian matrix is visualized to show the effect of the change of the blade twist and chord on the change of the aerodynamic behaviors. The method is validated for a canonical straight blade with uniform lift coefficient and axial induction distributions. The results show an excellent agreement with those obtained by PROPID, which is a blade element momentum theory‐based inverse design code. The National Renewable Energy Laboratory Phase VI blade is used to validate the method for a straight blade with non‐uniform distributions of the lift coefficient and axial induction. The method is also applied successfully to a non‐straight blade design with a non‐planar wing tip. A noticeable change in the twist and chord for this non‐straight blade is seen compared with a straight blade. Finally, the inverse design code is used to make a large rotor blade, and the power output generated by this blade is computed. Copyright © 2014 John Wiley & Sons, Ltd.     

Combined analytical/FEA-based coupled aero structure simulation of a wind turbine with bend–twist adaptive blades

The simulation of wind turbines with bend–twist adaptive blades is a coupled aero-structure (CAS) procedure. The blade twist due to elastic coupling is a required parameter for wind turbine performance evaluation and can be predicted through a finite element (FE) structural analyser. FEA-based codes are far too slow to be useful in the aerodynamic design/optimisation of a blade. This paper presents a combined analytical/FEA-based method for CAS simulation of wind turbines utilising bend–twist adaptive blades. This method of simulation employs the induced twist distribution and the flap bending at the hub of the blade predicted through a FEA-based CAS simulation at a reference wind turbine run condition to determine the wind turbine performance at other wind turbine run conditions. This reduces the computational time significantly and makes the aerodynamic design/optimisation of bend–twist adaptive blades practical. Comparison of the results of a case study which applies both combined analytical/FEA-based and FEA-based CAS simulation shows that when using the combined method the required computational time for generating a power curve reduces to less than 5%, while the relative difference between the predicted powers by two methods is only about 1%.     

Assessment of a comprehensive aeroelastic tool for horizontal‐axis wind turbine rotor analysis

This paper presents the development of a computational aeroelastic tool for the analysis of performance, response and stability of horizontal‐axis wind turbines. A nonlinear beam model for blades structural dynamics is coupled with a state‐space model for unsteady sectional aerodynamic loads, including dynamic stall effects. Several computational fluid dynamics structural dynamics coupling approaches are investigated to take into account rotor wake inflow influence on downwash, all based on a Boundary Element Method for the solution of incompressible, potential, attached flows. Sectional steady aerodynamic coefficients are extended to high angles of attack in order to characterize wind turbine operations in deep stall regimes. The Galerkin method is applied to the resulting aeroelastic differential system. In this context, a novel approach for the spatial integration of additional aerodynamic states, related to wake vorticity and dynamic stall, is introduced and assessed. Steady‐periodic blade responses are evaluated by a harmonic balance approach, whilst a standard eigenproblem is solved for aeroelastic stability analyses. Drawbacks and potentialities of the proposed model are investigated through numerical and experimental comparisons, with particular attention to rotor blades unsteady aerodynamic modelling issues. Copyright © 2016 John Wiley & Sons, Ltd.     

Wind turbine aerodynamic response under atmospheric icing conditions

This article deals with the atmospheric ice accumulation on wind turbine blades and its effect on the aerodynamic performance and structural response. The role of eight atmospheric and system parameters on the ice accretion profiles was estimated using the 2D ice accumulation software lewice Twenty‐four hours of icing, with time varying wind speed and atmospheric icing conditions, was simulated on a rotor. Computational fluid dynamics code, FLUENT, was used to estimate the aerodynamic coefficients of the blade after icing. The results were also validated against wind tunnel measurements performed at LM Wind Power using a NACA64618 airfoil. The effects of changes in geometry and surface roughness are considered in the simulation. A blade element momentum code WT‐Perf is then used to quantify the degradation in performance curves. The dynamic responses of the wind turbine under normal and iced conditions were simulated with the wind turbine aeroelastic code HAWC2. The results show different behaviors below and above rated wind speeds. In below rated wind speed, for a 5 MW virtual NREL wind turbine, power loss up to 35% is observed, and the rated power is shifted from wind speed of 11 to 19 m s^?1. However, the thrust of the iced rotor in below rated wind speed is smaller than the clean rotor up to 14%, but after rated wind speed, it is up to 40% bigger than the clean rotor. Finally, it is briefly indicated how the results of this paper can be used for condition monitoring and ice detection. Copyright © 2012 John Wiley & Sons, Ltd.     

Aeroelastic multidisciplinary design optimization of a swept wind turbine blade

Mitigating loads on a wind turbine rotor can reduce the cost of energy. Sweeping blades produces a structural coupling between flapwise bending and torsion, which can be used for load alleviation purposes. A multidisciplinary design optimization (MDO) problem is formulated including the blade sweep as a design variable. A multifidelity approach is used to confront the crucial effects of structural coupling on the estimation of the loads. During the MDO, ultimate and damage equivalent loads are estimated using steady‐state and frequency‐domain–based models, respectively. The final designs are verified against time‐domain full design load basis aeroelastic simulations to ensure that they comply with the constraints. A 10‐MW wind turbine blade is optimized by minimizing a cost function that includes mass and blade root flapwise fatigue loading. The design space is subjected to constraints that represent all the necessary requirements for standard design of wind turbines. Simultaneous aerodynamic and structural optimization is performed with and without sweep as a design variable. When sweep is included in the MDO process, further minimization of the cost function can be obtained. To show this achievement, a set of optimized straight blade designs is compared to a set of optimized swept blade designs. Relative to the respective optimized straight designs, the blade mass of the swept blades is reduced of an extra 2% to 3% and the blade root flapwise fatigue damage equivalent load by a further 8%.     

Innovative design approaches for large wind turbine blades

A preliminary design study of an advanced 50 m blade for utility wind turbines is presented and discussed. The effort was part of the Department of Energy WindPACT Blade System Design Study with the goal to investigate and evaluate design and manufacturing issues for wind turbine blades in the 1–10 MW size range. Two different blade designs are considered and compared in this article. The first is a fibreglass design, while the second design selectively incorporates carbon fibre in the main structural elements. The addition of carbon results in modest cost increases and provides significant benefits, particularly with respect to blade deflection. The structural efficiency of both designs was maximized by tailoring the thickness of the blade cross‐sections to simplify the construction of the internal members. Inboard the blades incorporate thick blunt trailing edge aerofoils (flatback aerofoils), while outboard more conventional sharp trailing edge high‐lift aerofoils are used. The outboard section chord lengths were adjusted to yield the least complex and costly internal blade structure. A significant portion of blade weight is related to the root buildup and metal hardware for typical root attachment designs. The results show that increasing the number of studs has a positive effect on total weight, because it reduces the required root laminate thickness. The aerodynamic performance of the blade aerofoils was predicted using computational techniques that properly simulate blunt trailing edge flows. The performance of the rotor was predicted assuming both clean and soiled blade surface conditions. The rotor is shown to provide excellent performance at a weight significantly lower than that of current rotors of this size. Copyright © 2004 John Wiley & Sons, Ltd.     

New vortex‐lift and tangential‐force models for HAWT aerodynamic load prediction

Horizontal axis wind turbines (HAWTs) experience three‐dimensional rotational and unsteady aerodynamic phenomena at the rotor blades sections. These highly unsteady three‐dimensional effects have a dramatic impact on the aerodynamic load distributions on the blades, in particular, when they occur at high angles of attack due to stall delay and dynamic stall. Unfortunately, there is no complete understanding of the flow physics yet at these unsteady 3D flow conditions, and hence, the existing published theoretical models are often incapable of modelling the impact on the turbine response realistically. The purpose of this paper is to provide an insight on the combined influence of the stall delay and dynamic stall on the blade load history of wind turbines in controlled and uncontrolled conditions. New dynamic stall vortex and nonlinear tangential force coefficient modules, which integrally take into account the three dimensional rotational effect, are also proposed in this paper. This module along with the unsteady influence of turbulent wind speed and tower shadow is implemented in a blade element momentum (BEM) model to estimate the aerodynamic loads on a rotating blade more accurately. This work presents an important step to help modelling the combined influence of the stall delay and dynamic stall on the load history of the rotating wind turbine blades which is vital to have lighter turbine blades and improved wind turbine design systems.     

The inverse design of the wind turbine blade sections by the singularities method

The aerodynamic characteristics of wind turbines are closely related to the geometry of their blades. The innovation and the technological development of wind turbine blades can be centred on two tendencies. The first is to improve the shape of existing blades; the second is to design new shapes of blades. The aspiration in the two cases is to achieve an optimal circulation and hence enhancing some more ambitious aerodynamic characteristics. This paper presents an inverse design procedure, which can be adapted to both thin and thick wind turbine blade sections aiming to optimise the geometry for a prescribed distribution of bound vortices. A method for simulating the initial contour of the blade section is exposed, which simultaneously satisfy the aerodynamic and geometrical constraints under nominal conditions. A detailed definition of the function characterising the bound vortex distribution is presented. The inviscid velocity field and potential function distributions are obtained by the singularities method. In the design method implemented, these distributions and the circulation of bound vortices on the camber line of the blade profile, are used to rectify its camber in an iterative calculation leading to the final and optimal form of the blade section once convergence is attained. The scheme proposed has been used to design the entire blade of the wind turbine for a given span-wise distribution of bound circulation around the blade contour.     

Development of small domestic wind turbine with scoop and prediction of its annual power output

Based on an unperturbed airflow assumption and using a set of validated modelling methods, a series of activities were carried out to optimise an aerodynamic design of a small wind turbine for a built up area, where wind is significantly weaker and more turbulent than those open sites preferable for wind farms. These activities includes design of the blades using a FORTRAN code; design of the nose cones and nacelles, which then constituted the rotor along with the blades; optimisation of the rotor designs in the virtual wind tunnel developed in the first part of the study; and finally, estimation of the annual power output of this wind turbine calculated using hourly wind data of a real Scottish Weather Station. The predicted annual output of the finalised rotor was then compared with other commercial turbines and result was rather competitive.     

Downwind pre‐aligned rotors for extreme‐scale wind turbines

Downwind force angles are small for current turbines systems (1–5 MW) such that they may be readily accommodated by conventional upwind configurations. However, analysis indicates that extreme‐scale systems (10–20 MW) will have larger angles that may benefit from downwind‐aligned configurations. To examine potential rotor mass reduction, the pre‐alignment concept was investigated a two‐bladed configuration by keeping the structural and aerodynamic characteristics of each blade fixed (to avoids a complete blade re‐design). Simulations for a 13.2 MW rated rotor at steady‐state conditions show that this concept‐level two‐bladed design may yield 25% rotor mass savings while also reducing average blade stress over all wind speeds. These results employed a pre‐alignment on the basis of a wind speed of 1.25 times the rated wind speed. The downwind pre‐aligned concept may also reduce damage equivalent loads on the blades by 60% for steady rated wind conditions. Even higher mass and damage equivalent load savings (relative to conventional upwind designs) may be possible for larger systems (15–20 MW) for which load‐alignment angles become even larger. However, much more work is needed to determine whether this concept can be translated into a practical design that must meet a wide myriad of other criteria. Copyright © 2017 John Wiley & Sons, Ltd.     

Structural investigation of composite wind turbine blade considering various load cases and fatigue life

This study proposes a structural design for developing a medium scale composite wind turbine blade made of E-glass/epoxy for a 750 kW class horizontal axis wind turbine system. The design loads were determined from various load cases specified at the IEC61400-1 international specification and GL regulations for the wind energy conversion system. A specific composite structure configuration, which can effectively endure various loads such as aerodynamic loads and loads due to accumulation of ice, hygro-thermal and mechanical loads, was proposed. To evaluate the proposed composite wind turbine blade, structural analysis was performed by using the finite element method. Parametric studies were carried out to determine an acceptable blade structural design, and the most dominant design parameters were confirmed. In this study, the proposed blade structure was confirmed to be safe and stable under various load conditions, including the extreme load conditions. Moreover, the blade adapted a new blade root joint with insert bolts, and its safety was verified at design loads including fatigue loads. The fatigue life of a blade that has to endure for more than 20 years was estimated by using the well-known S–N linear damage theory, the service load spectrum, and the Spera's empirical equations. With the results obtained from all the structural design and analysis, prototype composite blades were manufactured. A specific construction process including the lay-up molding method was applied to manufacturing blades. Full-scale static structural test was performed with the simulated aerodynamic loads. From the experimental results, it was found that the designed blade had structural integrity. In addition, the measured results of deflections, strains, mass, and radial center of gravity agreed well with the analytical results. The prototype blade was successfully certified by an international certification institute, GL (Germanisher Lloyd) in Germany.     

On the use of a linear microphone array to measure wind turbine aerodynamic noise

A linear microphone array is shown to be a simple tool to locate aerodynamic sound sources on a horizontal axis wind turbine. This paper discusses the capabilities and limitations of a linear microphone array to locate sound sources and measure aerodynamic noise on the blades of a horizontal axis wind turbine rotor. Compared with a planar microphone array, a linear array requires fewer microphones to achieve the same resolution, a simpler structure to support it and a simpler signal processing algorithm. For a linear array, areas exist in the rotor plane where the sources cannot be located unambiguously. For certain applications, it is not necessary to map the whole rotor plane. This paper also shows the result of an experimental test aimed at locating and measuring aerodynamic sound sources on the three blades of a wind turbine. Each blade received a different surface treatment, with the goal of comparing their relative sound emission levels. The test was carried out with a 10.32 m linear microphone array, placed horizontally near the ground, extending parallel to the rotor plane. The results show that for all three blades, most of the noise is generated in the outer 25% of the blade span, with a maximum occurring just after the blade has passed the horizontal position going downwards. Results also show that tripped blade is the noisiest of the three, whereas the smoothest, polished blade is clearly the quietest. Copyright © 2012 John Wiley & Sons, Ltd.