Wind Turbine Design

AE4-W09 5 ECTS 27-1-20102010

Prof. Dr. Ir. G.A.M van Kuik, Gijs and many other DUWIND experts

Delft University of Technology

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General Course Information

All communication through Blackboard. All sheets and material are available at Blackboard There is no hard-copy binder The course has a little overlap with:
1. AE4-W012: Rotor Aerodynamics (now running) 2. 27-1-2010 AE4-W013: Wind and Site Conditions, first semester so here only: the use of , and no detailed background

AE3W02: Introduction to wind energy, is mandatory as preceding course. Testing of this knowledge is done by homework assignments.
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Set-up of the course

Lectures, homework and group assignment Attendance of lectures not mandatory but strongly advised. Examination is by the group assignment Admission to group assignment requires satisfactory 27-1-2010 execution of the homework assignments Feed-back on course is highly appreciated

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The planning

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Background Material for this hour

Volume 1: Turbine Technology, from Wind Energy, the Facts Available at Blackboard and 27-1-2010 http://www.ewea.org/index.php?id=91

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The design process, starting fresh

Many classifications and/ or terminology exist. Here:
Conceptual design

27-1-2010 Preliminary design

Detailed design

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The design process

All choices depend on each other Turbine concept (e.g. const/var. , number of blades, gearbox or not, ) Main parameters (e.g. diameter, hub height, wind class, eigenfrequencies) Main operational aspects (e.g. safety, control, maintenance, grid aspects) Main materials (tower & blade material, casted or welded bedplate)

Conceptual design

27-1-2010 Preliminary design

Detailed design

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Targeted weights, annual yield, exfactory costs Each solution/param. to be detailed independent of others

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The design process

Main component/system is detailed to subcomponent level Rotor: blade geometry and construction, specs of pitch bearing Nacelle: dimensions, weights, specs of axes, bearings, couplings, gear box, yaw drives, bedplate, housing Tower: wall thickness, access, elevator, installation process Electric: specs of generator, power electronics, trafo Control: soft- & hardware Subcomponents to be detailed independent of others

Conceptual design

27-1-2010 Preliminary design

Detailed design

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The design process

Conceptual design

All components are detailed to sufficient level Rotor: sheet lay-out, resin distribution, curing times, details of hub, actuators, bearings, battery and control back-up equipment Nacelle: drawings and detailed specs of axes, bearings, couplings, gear box, yaw drives, bedplate, housing Etcetera

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Detailed design All is ready for manufacturing or ordering

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The design process

Driven by market developments, accumulated experience, manufacturing capabilities, new applications e.g. deep water offshore. Usually: careful upscaling of previous version Here the research & engineering knowledge is used to full extend. This design phase is the area of this course, with some excursions to conceptual design

Conceptual design

27-1-2010 Preliminary design

Detailed design

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Concept development: scaling effects

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Rated Power Diameter2.155

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Concept development: scaling effects

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Hub height Diameter-0.3

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Concept development: scaling effects

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Rotor mass Diameter2.6

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Concept development: scaling effects

All trends show an exponent < 3 which would follow from straightforward upscaling (square cube law) Due to increased hub height
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higher wind speeds

improved technology

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Scaling effects in case of unchanged design

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Enercon main shaft mass follows square cube law

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Main pin (it is stationairy)

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Some abandoned concepts

Darrieus turbine - Lower Cp - Guy wires

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Revival for use in built environment:

BUT:

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Some abandoned concepts

Single bladed Turbine - High tip loss 27-1-2010 - High noise level

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Some abandoned concepts

Flexible, passively controlled (downwind) 27-1-2010 turbines - Difficult technology - Most suited for 2bladers
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Modern turbines are common in:

Number of blades: 3 Collective pitch control Variable speed operation
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and differ in:

Gearbox or direct drive or mixed Rotor support (main bearing / axis) Nacelle frame
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Schematic
Example: soil stiffness / foundation results in wrong support structure frequency Conceptual
DI SA ST ER !
turbine

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tower

Detailed

soil

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Schematic
Example: many gearbox problems, control problems Conceptual
jo r m Ma ble pro
gearbox turbine

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Detailed

bearing

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The design process, starting from previous experience

Conceptual design Preceding, usually smaller, turbine measurements

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Detailed design

prototype

Series production

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Design is part of prototype development

Concept, wind class, grid

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Survey of simplifying design assumptions (1)

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Survey of simplifying design assumptions (2)

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