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Wakes, blades and airfoils

an entangled trilogy
Gerard van Bussel
Oldenburg, 10-October 2012

Delft
University of
Technology
Torque from Wind 2012
Wind Energy Chair
Content
•  Evolution of rotor blade design

•  Airfoils and rotor control

•  Flat back airfoils

•  Airfoil design validation

•  (Static) stall and 3D effects


•  Rotor experiments

•  The largest blade so far

•  Conclusions

Delft
University of
Technology
Torque from Wind 2012 2
Wind Energy Chair
Rotor design: evolution in time

Delft
University of
Technology
Torque from Wind 2012 3
Wind Energy Chair
Airfoil Design considerations
Airfoil parameters

Thickness-to-chord ratio (1990) .24 - .21 .21 - .18 .18-.12

High maximum lift-to-drag ratio

Aerodynamic
Low max. and benign post stall
Insensitivity to roughness
Low noise
Geometric compatibility
Structural demands

Delft
University of
Technology
Torque from Wind 2012 4
Wind Energy Chair
Airfoils and Rotor Control

• In the 90ties wind turbine rotors were stall controlled

• Stall control demands dedicated airfoils

• And rotor blades with tuned planforms

Delft
University of
Technology
Torque from Wind 2012 5
Wind Energy Chair
The DU airfoil series (DU xx-W-yyy)
TU Delft designed airfoils for use on
wind turbine rotor blades
Airfoil Design considerations
Airfoil parameters

Thickness-to-chord ratio (1990) .24 - .21 .21 - .18 .18-.12

DU 91-W2-250 High maximum lift-to-drag ratio

Aerodynamic
Low max. and benign post stall

Insensitivity to roughness
Low noise
Geometric compatibility

Structural demands

Del ft
Uni ve rsi ty of
Te ch no lo g y
DUWIND Rotor aerodyn am ic s 6
Wind E ne rg y C h air

DU 93-W-210

DU 96-W-180
Delft
University of
Technology
Torque from Wind 2012 6
Wind Energy Chair
The DU airfoil series (DU xx-W-yyy)
TU Delft designed airfoils for use on
wind turbine rotor blades

DU 96-W-180

DU 93-W-210

DU 91-W2-250

DU 97-W-300

Delft
University of
Technology
Torque from Wind 2012 7
Wind Energy Chair
Airfoils and Rotor Control

• In the 90ties wind turbine rotors were stall controlled

• Stall control demands dedicated airfoils

• And rotor blades with tuned planforms

• Low drag over a large range of α ‘s

• No lift overshoot at high(er angles) => low Clmax

• Benign stall behaviour

Delft
University of
Technology
Torque from Wind 2012 8
Wind Energy Chair
Airfoils and Rotor Control II
• Ten years later: variable pitch variable speed control
getting mainstream

• Airfoils better tuned to single point of operation

• High l/d in a low drag pocket (limited range of α ‘s)

• More optimised blade planforms

• Towards much larger diameters

Delft
University of
Technology
Torque from Wind 2012 9
Wind Energy Chair
Airfoil Design considerations
Airfoil parameters

Thickness-to-chord ratio (1990) .24 - .21 .21 - .18 .18-.12

High maximum lift-to-drag ratio

Aerodynamic
Low max. and benign post stall
Insensitivity to roughness
Low noise
Geometric compatibility
Structural demands

Delft
University of
Technology
Torque from Wind 2012 10
Wind Energy Chair
Airfoil Design considerations
Airfoil parameters

Thickness-to-chord ratio (1990) .24 - .21 .21 - .18 .18-.12


Thickness-to-chord ratio (2010) > .32 .32 - .24 .24-.18
High maximum lift-to-drag ratio

Aerodynamic
Increased
Low design
max. and lift post stall
benign
Insensitivity to roughness
Low noise
Geometric compatibility
Structural demands

Delft
University of
Technology
Torque from Wind 2012 11
Wind Energy Chair
The DU airfoil series (DU xx-W-yyy)
TU Delft designed airfoils for use on
wind turbine rotor blades

DU 96-W-180

DU 93-W-210

DU 91-W2-250

DU 97-W-300

Delft
University of
Technology
Torque from Wind 2012 12
Wind Energy Chair
The DU airfoil series (DU xx-W-yyy)
TU Delft designed airfoils for use on
wind turbine rotor blades DU 00-W-212

DU 96-W-180
DU 00-W2-350

DU 93-W-210
DU 00-W2-401

DU 91-W2-250

DU 08-W-180
DU 97-W-300

Delft
University of
Technology
Torque from Wind 2012 13
Wind Energy Chair
Airfoils and Rotor Control II
• Ten years later: variable pitch variable speed control
getting main stream

• Airfoils better tuned to single point of operation

• High l/d in a low drag pocket (limited range of α ‘s)

• More optimised blade planforms

• Towards much larger diameters


BUT
• Big issue for upscaling: square cube law!!

Delft
University of
Technology
Torque from Wind 2012 14
Wind Energy Chair
Rotors (so far) did not follow
the square cube law!!
Molly,Gasch M ~ R3
Garrad Hassan M ~ R2.6
Jamieson M ~ R2.4
Ashuri (2012) M ~ R2.1

PhD Turaj Ashuri 2012

Delft
University of
Technology
Torque from Wind 2012 15
Wind Energy Chair
Escapes from R2-R3 law through:

• Thicker airfoils

• Higher cl design

• More optimised planforms (thicker stem, slender tips)

• Design for slightly lower induction factors

BUT
• Drawback: more pronounced (abrupt) stall behaviour

Delft
University of
Technology
Torque from Wind 2012 16
Wind Energy Chair
Relation between CP-λ and CP-λ curve
1.2

T 1
CT = 3 2
1
2 ρU π R
0.8
Cp, Ct [-]

0.6

P 0.4
CP = 3 2
1
2 ρU πR
0.2

0
2 4 6 8 10 12 14
ΩR
tip speed ratio [-] TSR = λ =
U

Delft
University of
Technology
Torque from Wind 2012 17
Wind Energy Chair
More recent airfoil developments

Measurements in Delft
•  increase of Reynolds number to 5.0 x 106
(via increase in chord and wind speed)
…… and in Göttingen (op to Re 12 x 106)

DU 08-W-180 compared to DU 96-W-180


•  5% increased max lift-to-drag
•  20% higher (design) lift

Suite of Flat back DU airfoils


(designed using RFOIL calculations)
•  aerodynamic shaping of the “root”
based upon DU97-W-300
Delft
University of
Technology
Torque from Wind 2012 18
Wind Energy Chair
Flatback airfoils to brigde the gap

•  Transition between root airfoil and circular hub connection

•  Based upon DU97-W-300

•  And even thicker dedicated


“airfoils” up to 0.6t/c (60%)

•  Challenge: generate “stable” lift DU-A 400-050

against limited drag (pres. Papadakis) DU-A 501-100

DU-A 600-180

Delft
University of
Technology
Torque from Wind 2012 19
Wind Energy Chair
Root solutions may vary

•  Flat back airfoils


DU-A 400-050

DU-A 501-100

DU-A 600-180

•  Extended blade chords


(fitted on the erection spot)

•  Huge circular cross sections


(with some hidden features)

•  Multi element airfoils (slats/flaps)


(poster Zahle)

Delft
University of
Technology
Torque from Wind 2012 20
Wind Energy Chair
But…..
We don’t know how to validate airfoil
designs!
•  Flow around wind turbine blade is extremely complex

•  There is no location where the flow is 2 dimensional

Delft
University of
Technology
Torque from Wind 2012 21
Wind Energy Chair
We don’t know how to validate airfoil
designs!

•  ANSYS CFX calculations

•  Watch “particles: carefully

•  Look at radial displacements


(radial velocities => BEM not valid)

•  See how complex root flow is

Source: KARI Korea

Delft
University of
Technology
Torque from Wind 2012 22
Wind Energy Chair
But…..
We don’t know how to validate airfoil
designs!
•  Flow around wind turbine blade is extremely complex

•  There is no location where the flow is 2 dimensional

•  What is an angle of attack in rotor flow? (pres Guntur)

•  Strip theory (BEM theory) is not valid (pres Soerensen)

•  CFD calculations are time consuming and can be ambiguous


(turbulence modeling, transition modeling, grid issues, numerical
dissipation, etc etc)

Delft
University of
Technology
Torque from Wind 2012 23
Wind Energy Chair
CFD Model comparison NREL rotor
in NASA-Ames
wind tunnel
3D Full Navier-Stokes
Phase VI, 10 m/s
Limited Streamlines
Suction side

ANSYS/ CFX
Transition en k-ω SST

EllipSys3D
Fully turbulent
Unsteady DES
BL: k-ω SST

FLUENT
Fully turbulent
Steady k-ω SST

Delft
University of
Technology
Torque from Wind 2012 24
Wind Energy Chair
The lift coefficient across the span
NREL rotor in NASA-Ames tunnel
=> α not measured, derived with vortex wake code
=> cl and cd from α, cn and ct

Comparison with 2d:

à Near tip: d(cl)/dα reduced


lower cl-level
lower cl,max

à Near root: equal d(cl)/dα in


attached conditions
higher cl,max

Delft
University of
Technology
Torque from Wind 2012 25
Wind Energy Chair
Three-dimensional tip flow
•  Three-dimensional flow in tip region (pres Guntur)

•  Analogous to (translating) wing

Wake induction

Added local induction


due to tip vortex

•  This leads to a virtual de-camber (lower d(cl)/dα) near the tip

- - - -
Tip view
+ + + +
Front view
Delft
University of
Technology
Torque from Wind 2012 26
Wind Energy Chair
Stall delay models (semi empirical)
•  Basis: 3D (rotational) boundary layer equations
•  Engineering modelshcorrecting Cl:
⎛ c ⎞ n
cl ,3d = cl ,2 d + a ⎜ ⎟ ( cos β ) ( cl ,inv − cl ,2 d )
⎝ r ⎠
•  cl,2d : ‘true’ airfoil cl at given α (no rotation)
•  cl,inv : inviscid airfoil cl at given α (no rotation)
•  c : chord, r: radius, β : airfoil twist
•  Tuning parameters (a,n,h)=(3,0,2) Snel et al., 1993
(2.2,4,1) Chaviaropoulos & Hansen, 2000

•  Engineering modification to integral boundary layer formulation:


•  Better capture of cp-distribution
•  XFOIL (2d) à RFOIL (rotational)

Delft
University of
Technology
Torque from Wind 2012 27
Wind Energy Chair
RFOIL demonstration – results
•  Airfoil: DU91-W2-250
•  Cases:
•  Potential flow
•  Viscous with Re = 5·106, two-dimensional
•  Viscous with Re = 5·106, rotating with c/r = 0.3

Delft
University of
Technology
Torque from Wind 2012 28
Wind Energy Chair
Stall delay models need
2d input => measurements
•  2d flow beyond stall is not 2d!!
=> stall cells occur above a certain a.o.a. (pres Manolesos)

•  How good is Rfoil then??

Flow

T.E L.E DU 91-W2-250 at 12 degrees (stall angle 9.5 degrees)

Delft
University of
Technology
Torque from Wind 2012 29
Wind Energy Chair
Stall delay models need
2d input => measurements
•  2d flow beyond stall is not 2d!!

•  How good is Rfoil then??


2,0 2,0
cl cl
1,5 1,5

1,0 1,0

DU 97-W-300
0,5 Re = 3.0x106     0,5

0,0 0,0
0,000 0,015 0,030 0,045 -10 0 10 ķ (o) 20
cd
-0,5 smooth
-0,5
zztape 5% u.s. + 20% l.s.
RFOIL, 1% u.s. + 15% l.s.
-1,0 -1,0

•  Drag is under predicted


•  At heavy separation/stall Rfoil (in 2d mode) is wrong
T.E L.E •  The thicker the airfoil, the larger the problem!
Delft
University of
Technology
Torque from Wind 2012 30
Wind Energy Chair
Tweak 2d measurements around stall
e.g. through vortex generators Distance to stall power
(VG’s) (Delay of rated wind speed)

2.0
Increase
Cl in
1.5
max.
power

1.0
Rapid drop
=>
0.5 Sharp kink
in P-V curve
VG's at x/c= 0.2
0.0 VG's at x/c= 0.4
DU 93-W-250 VG's at x/c= 0.6
Re = 3.0x106 Clean
-0.5
50.0 100.0 150.0 -5.0 0.0 5.0 10.0 15.0 20.0 25.0
Cl/Cd Angle (deg.)

BUT: leads to drag increase at all α‘s


Delft
University of
Technology
Torque from Wind 2012 31
Wind Energy Chair
So what is the situation:
•  At the real root region
flow is highly 3 dimensional: no 2d equivalent at all
- 3D measurements or CFD

•  Inboard:
- use 2d measurements
- trust Rfoil for stall behaviour
- and/or tweak stall behaviour using VG’s

•  Midspan & outboard:


- design using e.g. Rfoil
- use 2d measurements

•  At the tip region: DU-A 400-050

- first determine effect of tip vortex DU-A 501-100


- design for de-cambering DU-A 600-180
- 2d measurements of de-cambered airfoil

Delft
University of
Technology
Torque from Wind 2012 32
Wind Energy Chair
Blade design through:
•  Coupling of RFoil with BEM 3D panel code
- to capture 3D effects from planform and wake

•  Coupled design of inboard, midspan and outboard


- using genetic/gradient based optimisers (pres Grasso)
- with cost functions for structure, manufacturing and costs

•  Validation of 2-3 airfoils in windtunnel

•  Check final design using CFD


DU-A 400-050
=> Experiments on real rotors needed for validation!!
DU-A 501-100

DU-A 600-180

Delft
University of
Technology
Torque from Wind 2012 33
Wind Energy Chair
Will CFD become a winner in the
end??
•  if issues regarding turbulence modeling, transition modeling,
grid issues, numerical dissipation are tackled
•  and calculation time is speeded up
•  and validation has taken place in more operational cases
•  then the answer may become yes

Validation experiments on real rotors!!

DU-A 400-050

DU-A 501-100

DU-A 600-180

Delft
University of
Technology
Torque from Wind 2012 34
Wind Energy Chair
Experiments for validation of codes
Rotor experiments in controlled conditions:
•  The NASA-Ames experiments DU 91-W2-250

•  The MEXICO experiments


Risø A1-21
(Gerard Schepers presentation Thursday afternoon)

2.25 m
NACA 64-418
•  The TU Delft OJF experiments

Mexico rotor blade

Delft
University of
Technology
Torque from Wind 2012 35
Wind Energy Chair
Root flow rotor: Chord wise SPIV experiments

2 bladed rotor, 2 m O
Chord wise measurement set-up
RPM: 0-20 Hz.
λ=7 at Vwind= 17 m/s

Laser 2 cameras

•  measurements not inside BL


•  axis-symmetric flow conditions
•  stationary laser, rotating blade
Delft
University of
Technology
Torque from Wind 2012 36
Wind Energy Chair
Stereo PIV (SPIV) results
Spanwise velocities: brown => outboard
blue => inboard

Panel code calculations

Stereo PIV experimental results


PhD research Busra Akay, Daniel Micallef

Delft
University of
Technology
Torque from Wind 2012 37
Wind Energy Chair
Comparison measurements (SPIV)
to calculations (3D panel code)

SPIV

Panel
code

Axial velocities λ=7 top: SPIV measurements


bottom: panel code calculations
PhD research Busra Akay, Daniel Micallef
Delft
University of
Technology
Torque from Wind 2012 38
Wind Energy Chair
From SPIV experimental results:

•  3D velocity field around rotor, including tip- and root flow


•  Detailed information about radial component of flow (outside BL)
•  Forces on the blade through contour integration of velocities

In plane velocities station 2 (mid span)


and force integration contours Radial velocities in root region

PhD research Busra Akay Together with Carlos Ferreira and Daniele Ragni

Delft
University of
Technology
Torque from Wind 2012 39
Wind Energy Chair
Details of the tip flow

SPIV

Panel
code

Tip vorticity from SPIV measurements


Axial velocities station at tip
PhD research Daniel Micallef

Delft
University of
Technology
Torque from Wind 2012 40
Wind Energy Chair
LM Alstom Haliade (150m O) blade

VG’s

Gurney flap
(BL fence)

Vortex generators

Ozlem Ceyhan ECN

Delft
University of
Technology
Torque from Wind 2012 41
Wind Energy Chair
Conclusions

•  2d wind tunnel measurement still


basis for major part of blade design

•  3D wake model inevitable for a.o.a.,


root flow and tip (vortex) flow

•  Stall modeling needs improvement


(stall delay + dynamic stall)

•  2d measurements +Rfoil+3D panel


code current design vehicle

•  CFD is runner up for airfoil and


for blade design
•  3D rotating experiments are key in
further understanding and validation

Delft
University of
Technology
Torque from Wind 2012 42
Wind Energy Chair

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