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AERODYNAMIC OPTIMIZATION AND OPEN FIELD

TESTING OF A 1 KW VERTICAL-AXIS WIND


TURBINE

Gabriele Bedon, PhD Student at the Department of Industrial Engi neering, Uni versity of Padua,
Via Venezia 1, 35131 Padova, gabriel e.bedon@studenti.uni pd.it
Marco Raciti Castelli, Research Associate at the Department of Industrial Engi neering, Uni versity
of Padua, Via Venezia 1, 35131 Padova, Italy, marco.raciticastelli@unipd.it
Uwe Schmi dt Paulsen, Senior Scientist at DTU Wind Energy, Department of Wind Energy,
Frederiksborgvej 399 Buil ding 125, room S14 & 16, 4000 Roskilde, Denmark, uwpa@dtu.dk
Luca Vita, Post Doctoral Researcher at DTU Wind Energy, Department of Wind Energy,
Frederiksborgvej 399 Buildi ng 125, room S14 & 16, 4000 Roskilde, Denmark,
luca. vita@dnvkema.com
Ernesto Benini, Associate Professor at the Department of Industri al Engi neering, Uni versity of
Padua, Via Venezia 1, 35131 Padova, Italy, ernesto.benini@uni pd.it

Abstract

The design of a Darri eus wi nd turbi ne rotor is a compl ex process due to the non-stationarity of
the fl ow fi eld i nside the machi ne and the dynamic stall effects at rotor blades. The combi nation of a
genetic algorithm with a Blade Element Momentum (BE-M) code can be successfully adopted to
improve the aerodynamic design of existing wind turbi nes.
In this work, starting from the Venco Twister 1000-T vertical-axis wind turbine (VAWT),
considered as a baseline configuration, the WOMBAT (Weatherly Optimization Method for Blades
of Ai r Turbi nes) algorithm is adopted to provi de the optimal chord distribution for a SCSc rotor
characterized by the same swept area.
The optimization is performed consideri ng two objecti ves: the enhancement of the power
coefficient for a wind speed of 7 m/s - the wi nd speed that maximizes the power production
probability at the test site - and the maximization of the power coefficient for a wi nd speed of 12 m/s
- the nomi nal wi nd speed of the baseline turbi ne.
An optimized three-bl aded rotor is desi gned according to t he geometrical constrai nts imposed by
the original turbine confi guration and its aerodynamic performance is investigated at the DTU Wind
Energy test ground.

1. Introduction and Background

The purpose of this work is to increase the rot or performances i n terms of power production and
power coefficient of a real vertical axis wind turbine (the Venco Twister 1000-T) by changing the
blade aerodynamic design.
The aerodynamic design optimization of a vertical axis wind turbine is a complex process due to
the di fficulties in obt aining fast and reli abl e performance estimation. Apart from expensi ve
experimental tests, which can be conducted on the physical models, the performances of a wind
turbine can be prelimi nary estimated by means of numerical methods. The most important
numerical approaches avail abl e in the literature are:
Computational Flui d Dynamics (CFD) codes, which are based on a numerical approximation of
the Navi er-Stokes equations and can provi de a reliabl e description of the turbi ne behavior.
However the requi red computational time and effort are hi gh [1].
Codes based on the Vortex Model: this approach also all ows obtai ning a reliabl e performance


estimation [2]. Anyway it still requires a considerabl e computational time to converge,
especially at low tip speed ratios, when complex vortexes are generated [3].
Codes based on the BE-M Theory: equating the bl ade element force on the rotor to the change
in fluid momentum, a very fast prediction of the rotor performance is obtained [35]. On the
other hand, the results provided by the al gorithm do not include much additional data, incl udi ng
detailed air flow information.
These methods can be coupled with an optimization al gorithm, capabl e of evaluating the
aerodynamic performance of the rotor geometry. Genetic algorithms have been developed to find
the optimal solution in complex spaces efficiently [6,7] and are widely used for sol vi ng engineering
problems: this leads to an iterati ve loop t hat should provide an improved design configuration. This
approach was foll owed by several authors. Bourguet et al. [8] adopted a CFD code coupled wit h a
genetic algorithm to fi nd the optimal airfoil shape to increase both the nominal power production
and the aerodynamic efficiency while reducing the wei ght of the blade. The optimal blade profile
resulted to be very close to the NACA 0025 geometry. Carri gan et al. [9] matched an evoluti onary
algorithm and a bi-dimensional CFD simulation for the simulation of a H-Darrieus rot or equipped
with NACA 0015 airfoils. The optimal confi guration resulted to have an increase i n efficiency of
around 6%, achi eved with an increase of 58% i n rot or blade thickness and a reduction of 40% in
rotor soli dity.
Being the aim of this work the maximization of the rotor performance in terms of power production
and power coefficient, a simulation tool based on the BE-M Theory is selected. This all ows the
evaluation of a large number of blade geometries i n a limited computational time, widening the
investigation space considered by the al gorithm. The adopted BE-M code is devel oped by Raciti
Castelli et al. [10] and is based on the double multipl e streamt ube model devel oped by Strickland
[3] and Paraschi voiu [4,5]. Moreover, dynamic stall models based on the Gormont -Strickland and
Gormont-Berg studies [11] are i ncluded, as well as a blade finite aspect ratio correction from Viterna
and Corri gan [12]. This BE-M code is coupled with the genetic algorithm based on the studi es of
Deb [13], provided as gamultiobj function in the Matlab suite, obtaining the WOMBAT algorithm, first
presented by Bedon et al. [14].

2. Case Study and Methodology

The Venco Twister 1000-T, tested at DTU Wind Energy [15], is consi dered as a case study in
order to proceed subsequently with t he experimental acti vity on the optimized prototype. Venco
Twister 1000-T is a 2-meter hi gh turbi ne characterized by three linear twisted blades pl aced at 1
meter from the rotational axis. The three blades are connected by spokes wit h the generator,
placed in correspondence to the rot ational axis. A picture of the turbine is shown in Figure 1.
The test conducted at the DTU Wind Energy test site highlighted a maximum power coefficient for
the total conversion of around 0.20, as shown in Fi gure 2 [17].
The adopted blade geomet ric paramet ers are quite di fficult to measure. However, it can be
observed that the blade is characterized by a symmet ric profile, wi th uniform chord and thickness
along the whole length. Moreover, it is difficult to establish the influence of the spoke design (quite
wide and thick) on t he power production. The numerical simulation of the Venco rotor would
therefore require a consistent amount of work on several geometric parameters that need to be
optimized. A more simpl e baseline geometry is thus adopted, neverthel ess maint aining the same
swept area of Twister 1000-T, equal to 3.61 m.




Fig. 1: Venco Twister 1000-T VAWT [16].



Fig. 2: Venco Twister 1000-T experimental power coefficient curve [17].

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 NACA 0015
profile is chosen, since it provides one of the hi ghest performance i n combination with a vari able
chord distri bution.
The simul ation al gorithm was validat ed with turbines adopting blades of Troposkien shape [19]:
this design allows limiting blade inertial loads [20]. Finally, a vari able chord distribution is adopted,
because of the difference in blade section radi us.
The electrical generat or needed to be maintai ned i n the central position, due to the fact that the
bearings are not designed to be stressed with a bending moment. The so-call ed cut SCS (SCSc)
variant [21] is therefore adopted as optimization geometry. This solution is realized by cutting a 20%
in SCS hei ght, 10% at the top and 10% at the bottom extremities. In order to have a fair
comparison, the same swept area is maintai ned, by increasing the maximum radi us.
A comparison between the original SCS and the SCSc midline geometri es is shown in Figure 3.




Fig. 3: Comparison bet ween the classical SCS geometry (bl ue line) and the proposed SCSc (red
line) one.

The SCSc shape requi res connecting arms at bot h top and lower sections. Connecting arms are
anyway provi ded in the ori ginal Venco configuration. The same swept area of Twister 1000-T, 3.61
m
2
, is maintained. The main geometrical parameters of the optimized rotor confi guration are
reported in Tabl e 1.

H [m] 1.96
R [m] 1.18
N 3
Blade Shape SCSc
Table 1: Mai n geometrical features of the optimized rotor confi guration

The rotor is mount ed on a permanent magnet generator equipped wit h eddy current brakes. The
maximum rot ational speed without their acti vation 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 i ndi viduals are evaluated and evol ved for 100 generations. The number of genes n
g

provided by the genetic algorithm is equal to hal f of the number of vertical di visi ons. The genes are
considered as control point coordi nates for a spli ne curve (n
g
/2 abscissas and n
g
/2 ordi nates) that
describe the trend of the chord.
The gamultiobj al gorit hm tends to a solution that mini mizes the fit ness val ue. The fitness of t he
profile is thus calculated consideri ng the foll owi ng expressions:




where:
is the indi vidual 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
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 WOMBAT algorithm provides a Pareto front containing several optimum indi viduals. The
Pareto front is reported i n Figure 4.


Fig. 4: Pareto front from the WOMBAT optimization algorithm. The red cross is the indi vidual
chosen for the analysis.

The indi vidual represented by the red cross is chosen for the following considerations. In fact,
indi vi duals characterized by higher power coefficients present a sensibly lower power production,
due to the curve decreasing slope. On the other side, indi vi duals with a slightly higher power
production present a sensibly decrease in power coefficients.
The chosen configuration presents the chord distribution shown i n Figure 5.


Fig. 5: Chord distribution for the chosen indi vidual.

The optimal chord distribution, considering a fixed airfoil thickness/chord rati o, is therefore not
uni form. 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 successi ve chord
reduction represents a compromise between the increase of the aerodynamic load and the
decrease of the interference factor, that would reduce the flow vel ocity across the rotor section.
A complete simulation of the optimal indi vidual is conducted, in order to have a complete
overview of the rotor performance. The rotor power coefficient and the power production for
different rotati onal speeds are shown i n Figures 6 and 7 as a function of the free-stream wind
speed.


Fig. 6: Rotor power coefficient for several angular vel ocities, as a function of the unperturbed
wind speed.


Fig. 7: Rotor power production for several angular vel ocities, 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 conversi on performed by the el ectrical generator, the rectifi er and the
inverter.



4. Rotor Prototype

The rotor prototype is obtained by assembling several parts, designed i n order to fit the origi nal
generator geometry and preserve the bl ade optimized shape.
In t he ori ginal configuration, the spoke connections are shi fted azimut hally, in order to connect
the twisted bl ades, as can be seen i n Figure 8. On the other side, the prototype confi guration
provides a blade whose medium line is entirely contained in a pl ane. A disk, presenting the spoke
links in the correct position, is therefore designed and installed on top of the el ectrical 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. Thei r width is varyi ng between 105 mm at
the generator side and 80 mm at the bl ade 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 i n-
blades, are designed i n 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 Fi gure 9, are obtained from a 8 mm steel plate and
manufactured by laser-cut.


Fig. 9: Connection component between the bl ade and the spoke (In-blade).



The in-blade components present one rectangular and two circular hol es. In the rectangul ar
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 each circul ar hol e, four 1-mm di ameter steel wires, provi ding
strength to the whol e assembly, are inserted.
Rotor blades are manufactured adopting the rapi d prototyping technique. They are made of
Proto-pl us [25], a material with a density of 0. 59 g/cm
3
and a tensile strength of 40 MPa. Every
blade is subdi vi ded into three portions, in order to make thei r manufacturi ng 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 hol es bet ween the
steel and the blade parts, provi ding additional consistence.


Fig. 10: Connection assembly of the in-blade components and bl ade 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, install ed on t he 11-meter hi gh tower at Ris - DTU Wind Energy, test site is
shown in Figure 11.




Fig. 11: Installati on at Ris - DTU Wind Energy test site.

5. Conclusions

The aerodynamic desi gn of a commercial vertical axis wind turbine is improved by adopting an
optimization al gorithm combined with a Blade Element - Momentum simulation code. Two target
wind speeds are selected, in order to provi de an optimized confi guration suitabl e for the same
worki ng condition as the baseline confi guration.
The optimized rotor configuration results to be characterized by a vari abl e chord distribution,
obtained i n order to maximize the energy conversion at two design wi nd speeds. A complete
simulation campai gn is conducted, showi ng t hat rotor performances are highly increased with
respect to the baseline confi guration. However, an experimental test is needed in order to confirm
the predictions and to estimate the aerodynamic and el ectrical losses, not included in the simulation
model. For this reason, a prototype obtained with t he rapid prototyping techni que is realized and
installed on an 11-meter tower at the test site of DTU Wind Energy. Further work is requi red in order
to complete the experimental campaign of measurements on the prot otype.

Nomenclature

c [m] airfoil chord
C
P
[-] power coefficient
h [m] blade element hei ght
H [m] rotor height
N [-] blade number
n
g
[-] number of genes
P [W] power production
R [m] rotor maximum radius
U

[m/s] free-stream mean ai r velocity









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