Aerodynamic Optimization and Open Field Testing of A 1 KW Vertical-Axis Wind Turbine
Aerodynamic Optimization and Open Field Testing of A 1 KW Vertical-Axis Wind Turbine
Aerodynamic Optimization and Open Field Testing of A 1 KW Vertical-Axis Wind Turbine
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Rotor Prototype
Fig. 1: Venco Twister 1000-T. Fig. 2: Twister 1000-T experimental CP curve. The rotor prototype is obtained by assembling several parts, designed in order to fit the
original generator geometry and preserve the blade optimized shape.
In the optimized configuration, a fixed thickness to chord ratio is maintained along the Rotor blades are manufactured adopting the rapid prototyping technique. They are
blade span, whereas the chord distribution is free to be optimized. The NACA 0015 made of ”Proto-plus”, a material with a density of 0.59 g/cm3 and a tensile strength of
profile is chosen, since it provides one of the highest performance in combination with a 40 MPa. Every blade is subdivided into three portions, in order to make their
variable chord distribution. The electrical generator needs to be maintained in the central manufacturing and final assembly easy. As can be seen from Figure 9, rotor blades are
position, due to the fact that the bearings are not designed to be stressed with a bending assembled with the metal reinforcement bars; epoxy resin is then sucked up from the
moment. The so-called ”cut SCS” (SCSc) variant is therefore adopted as optimization bottom to the top, in order to fill the holes between the steel and the blade parts,
geometry, shown in red in Figure 3. providing additional consistence.
The prototype, installed on the 11-meter high tower at Risø - DTU Wind Energy, test site
is shown in Figure 10.
Abstract
The design of a Darrieus wind turbine rotor is a complex process due to the non-stationarity of
the flow field inside the machine and the dynamic stall effects at rotor blades. The combination of a
genetic algorithm with a Blade Element – Momentum (BE-M) code can be successfully adopted to
improve the aerodynamic design of existing wind turbines.
In this work, starting from the Venco Twister 1000-T vertical-axis wind turbine (VAW T),
considered as a baseline c onfiguration, the WOMBA T (W eatherly Optimization Method for Blades
of Air Turbines) algorithm is adopted to provide the optimal chord distribution for a SCSc rotor
characterized by the same swept area.
The optimization is performed considering two objectives: the enhancement of the power
coefficient for a wind speed of 7 m/s - the wind speed that maximizes the power production
probability at the test site - and the maximization of the power coefficient for a wind speed of 12 m/s
- the nominal wind speed of the baseline turbine.
An optimized three-bladed rotor is designed according to t he geometric al c onstraints imposed by
the original turbine configuration and its aerodynamic performanc e is investigated at the DTU Wind
Energy test ground.
A fixed thickness to chord ratio is maintained along the blade span, whereas the chord
distribution is free t o be optimized. Considering the results obtained by Bedon [18], the NA CA 0015
profile is chosen, sinc e it provides one of the highest performance in combination with a variable
chord distribution.
The simulation algorithm was validat ed with turbines adopting blades of Troposkien shape [19]:
this design allows limiting blade inertial loads [20]. Finally, a variable chord distribution is adopted,
because of the difference in blade section radius.
The electrical generat or needed to be maintained in the central position, due to the fact that the
bearings are not designed to be stressed with a bending moment. The so-called ”cut S CS” (SCSc)
variant [21] is therefore adopted as optimization geometry. This solution is realized by cutting a 20%
in SCS height, 10% at the top and 10% at the bottom extremities. In order to have a fair
comparis on, the same swept area is maintained, by increasing the maximum radius.
A comparison between the original SCS and the SCSc midline geometries is shown in Figure 3.
Fig. 3: Comparison bet ween the classical SCS geometry (blue line) and the proposed S CSc (red
line) one.
The S CSc shape requires connecting arms at bot h top and lower sections. Connecting arms are
anyway provided in the original Venco configuration. The same s wept area of Twister 1000-T, 3.61
2
m , is maintained. The main geometrical parameters of the optimized rotor configuration are
reported in Table 1.
H [m] 1.96
R [m] 1.18
N 3
Blade Shape SCSc
Table 1: Main geometric al features of the optimized rotor configuration
The rotor is mount ed on a permanent magnet generator equipped wit h eddy current brakes. The
maximum rot ational speed without their activation is 270 rpm [22]. The optimization procedure will
therefore consider the range between 0 and 270 rpm to find the best performance.
A total of 50 individuals are evaluated and evolved for 100 generations. The number of genes ng
provided by the genetic algorithm is equal to half of the number of vertical divisions. The genes are
considered as control point coordinates for a spline curve (ng/2 abscissas and ng/2 ordinates) that
describe the trend of the chord.
The gamultiobj algorit hm tends to a solution that minimizes the fit ness value. The fitness of t he
profile is thus calculated considering the following expressions:
where:
is the individual power coefficient at a wind speed equal to 7 m/s, considered as a
design wind speed. In fact, for this wind speed, the energy production probability for the Ris ø
test site is maximized [23,24].
is the power production at 12 m/s, considered as the maximum production. This value
is the same declared by Venco for the original Twister 1000-T turbine configuration [15].
3. Optimization Results
The WOMBA T algorithm provides a Pareto front containing several optimum individuals. The
Pareto front is reported in Figure 4.
Fig. 4: Pareto front from the WOMBA T optimization algorithm. The red cross is the individual
chosen for the analysis.
The individual represented by the red cross is chosen for the following considerations. In fact,
individuals characterized by higher power c oefficients present a sensibly lower power production,
due to the curve dec reasing slope. On the other side, individuals with a slightly higher power
production present a sensibly decrease in power coefficients.
The chosen configuration presents the chord distribution shown in Figure 5.
The optimal chord distribution, considering a fixed airfoil thickness/chord ratio, is therefore not
uniform. The minimum value of t he chord at the rotor top and bottom leads to a lower aerodynamic
resistance of the blade sections where the power production is very low. An increase of the chord
length is registered towards the centre of the rotor, in order t o maximize the aerodynamic load
where the radius is increasing, thus enhancing the power production. The successive chord
reduction represents a compromise between the increase of the aerodynamic load and the
decrease of the interference factor, that would reduce the flow velocity across the rotor section.
A complete simulation of the optimal individual is conducted, in order to have a complete
overview of the rotor perform ance. The rotor power coefficient and the power production for
different rotational speeds are shown in Figures 6 and 7 as a function of the free-stream wind
speed.
Fig. 6: Rotor power coefficient for several angular velocities, as a function of the unperturbed
wind speed.
Fig. 7: Rotor power production for several angular velocities, as a function of the free-stream wind
speed.
These curves represent the estimation of t he rotor performance, obt ained from the BE-M
algorithm. The real performance is however reduced by the presence of the spokes and by the
efficiency of the energy conversion performed by the electrical generator, the rectifier and the
inverter.
4. Rotor Prototype
The rotor prototype is obtained by assembling several parts , designed in order to fit the original
generator geometry and preserve the blade optimized shape.
In t he original configuration, the spoke connections are shifted azimut hally, in order to connect
the twisted blades, as can be seen in Figure 8. On the other side, the prototype configuration
provides a blade whose medium line is entirely contained in a plane. A disk, presenting the spoke
links in the correct position, is therefore designed and installed on top of the electrical generator,
using the existing bolts. With reference to Figure 8, the disk is represented in red, whereas the
generator is reproduced in whit e color.
Fig. 8: Connecting disk (red) installed on the original Venco generat or (white).
Six spokes, obtained from a 10 mm steel plate and manufactured by laser-cut in order to obtain
the desired geometry, are connected to the correct links. Their width is varying between 105 mm at
the generator side and 80 mm at the blade side, for a total length of 900 mm.
Spokes are intended not to be in contact with the blades: six metal components, the so-called ”in-
blades”, are designed in order to be fixed on t he terminal portion of the spoke, as well as to be part
of the blade. These components, represented in Figure 9, are obtained from a 8 mm steel plate and
manufactured by laser-c ut.
Fig. 9: Connection component between the blade and the spoke (”In-blade”).
The in-blade components present one rectangular and two circular holes. In the rectangular
opening, t wo 1-mm thick steel plates are inserted. These plates permit to lock the orientation of the
blade with respect to the spoke. In eac h circular hole, four 1-mm diameter steel wires, providing
strength to the whole assembly, are inserted.
Rotor blades are manufactured adopting the rapid prototyping technique. They are made of
3
”Proto-plus” [25], a material with a density of 0. 59 g/cm and a tensile strength of 40 MP a. E very
blade is subdivided into three portions, in order to make their manufacturing and final assembly
easy. As can be seen from Figure 10, rotor blades are assembled with the metal reinforcement
bars; epoxy resin is then sucked up from the bottom to the top, in order to fill the holes bet ween the
steel and the blade parts, providing additional consistence.
Fig. 10: Connection assembly of the in-blade components and blade sections, inserting the steel
reinforcements.
Steel strings are added in order to reduce the blade deformation and ensure an operational
stability. Such strings have a diameter of 2 mm and do not compromise t he aerodynamic efficiency
excessively.
The prototype, installed on t he 11-meter high tower at Risø - DTU Wind Energy, test site is
shown in Figure 11.
Fig. 11: Installation at Ris ø - DTU Wind Energy test site.
5. Conclusions
The aerodynamic design of a commercial vertical axis wind turbine is improved by adopting an
optimization algorithm combined with a Blade Element - Momentum simulation code. Two target
wind speeds are selected, in order to provide an optimized configuration suitable for the same
working condition as the baseline configuration.
The optimized rotor configuration res ults to be characterized by a variable chord distribution,
obtained in order to maximize the energy conversion at two design wind speeds. A complete
simulation campaign is conducted, showing t hat rotor performances are highly increased with
respect to the baseline configuration. However, an experimental test is needed in order to confirm
the predictions and to estimate the aerodynamic and electrical losses, not included in the simulation
model. For this reason, a prototype obtained with t he rapid prototyping technique is realized and
installed on an 11-meter tower at the test site of DTU Wind Energy. Further work is required in order
to complete the experimental campaign of measurements on the prot otype.
Nomenclature
c [m] airfoil chord
CP [-] power coefficient
h [m] blade element height
H [m] rotor height
N [-] blade number
ng [-] number of genes
P [W] power production
R [m] rotor maximum radius
U∞ [m/s] free-stream mean air velocity
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