wind turbine flap technology development from laboratory to … · 2018-09-26 · dtu wind energy,...
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Wind Turbine Flap Technology Development
– from laboratory to full scale
H Aa Madsen [email protected]
In cooperation with
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DTU Wind Energy, Technical University of Denmark
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Flap or morphing airfoil
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Morphing trailing edge counteract disturbances from turbulent inflow
Flaps add a third control option to the traditional rotor speed and pitch control
Sandia Blade Workshop 2018 Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Ideally flap control can be very efficient and counteract most of the inflow disturbances
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Sandia Blade Workshop 2018 Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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But limitations in the real world
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bandwidth of the flap actuation
amplitude limits
non-optimal control inputs
cost of the technology
robustness
Sandia Blade Workshop 2018 Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Example of a flap system used in a steady position
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The negative flap deflection decreases most extreme loads and reduces blade tip deflection - SWT-4.0-130 turbine
Ref. Alejandro 2018
Sandia Blade Workshop 2018 Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Example of a flap system used in a dynamic control
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Ref. Barlas 2016
Case: - DTU 10MW rotor stretched 5% in radius
- Increase in AEP of 3.4%
- Flap system included to reduce the increase in loads
- 30% of the blade length, starting from the tip, with 10% chordwise length, flap angles range between -15/+15 degrees.
Sandia Blade Workshop 2018 Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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The flap technology
Sandia Blade Workshop 2018 Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Use flap technology from aircraft ?
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Too complex
Sandia Blade Workshop 2018 Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Strong requirements from the wind turbine industry to the technology
robust and reliable (25 years lifetime)
no metal parts
no electronics
no mechanical parts
scalable to large blade sizes (+100m)
piezzo electric actuators in
wind tunnel exp. 2007
9 Sandia Blade Workshop 2018
Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Basic flap design that full-fills these requirements
a flap in an elastic material
pneumatically activated
two main concepts
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internal voids
full morphing TE separate hose add/on flap
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DTU Wind Energy, Technical University of Denmark
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The development stages
CAD version
FEM simulations
Design iterations – FSI based optimization
Lab model – simplified manufacturing
Lab testing – performance - fatigue
Wind tunnel tests (typical leading to new design iteration)
Lightning testing
Final prototype manufacturing – co-extrusion
Testing functionality and performance on an outdoor rotating test rig in atmospheric flow
Full scale testing
11 Sandia Blade Workshop 2018
Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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FEM – FSI optimization
• Design variables: voids position/size
• Response: Cl, Cd, safety factor
• Optimization with Multi-Objective Genetic Algorithm (max(Cl), min(Cd), SF≥1.5
12 Sandia Blade Workshop 2018
Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Lab models – simplified testing
13 Sandia Blade Workshop 2018
Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Wind tunnel tests – CFD computations
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Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Final prototype manufacturing - co-extrusion
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Allows designs with optimal combination of soft and stiff material
Solve gluing problems with Santoprene as the surface can be covered with a layer suited for gluing
Sandia Blade Workshop 2018 Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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One flap system tested for lightning damage
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The Santoprene flap material showed a higher withstand voltage in tracking tests than GFRP
Sandia Blade Workshop 2018 Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Pitch actuator
Pressure measurements
Sketch of the rotating test rig
- Intended to close the gap between wind tunnel and full scale testing
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Test rig based on a 100 kW turbine. Rotation of a 10m long boom with an airfoil section of 2x1m
Sandia Blade Workshop 2018 Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Blade section for rotating test rig
Blade section mounted on the 10m long boom in the workshop - instrumentation
2x1 m blade section + end caps
Pressure taps in chordwise and spanwise direction
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Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Flap testing on the rotating rig
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Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Flap design from the Innwind.EU project
Example of measured flap performance on the rotating rig
ΔCL @ 8o
Case +ΔCL -ΔCL
CFD +0.21 -0.25
Wind tunnel* +0.18 -0.24
Rotating rig +0.18 -0.20
* Poul La Cour wind
tunnel - DTU (!) 20
Sandia Blade Workshop 2018 Helge Aagaard Madsen DTU, Denmark
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DTU Wind Energy, Technical University of Denmark
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Full-scale tests
• Testing on a multi-MW turbine in Denmark since Dec 2017
• Test and validation under real weather conditions
• Testing planned until end of 2018
• For further information: http://www.induflap.dk/
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DTU Wind Energy, Technical University of Denmark
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Conclusions
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a complete development line for flap technology from prototype to full scale has been developed in cooperation with two industrial partners
A considerable amount of testing in wind tunnels and on a rotating rig has been conducted
Full scale testing of first prototypes initiated and will contribute with new important information about a possible commercialization of the technology
Sandia Blade Workshop 2018 Helge Aagaard Madsen DTU, Denmark
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23 Sandia Blade Workshop 2018
Helge Aagaard Madsen DTU, Denmark
Thank you
for your attention