Wind Turbine Typology

Technische Universität München

Filippo Campagnolo
Technische Universität München
Wind Energy Institute

April 2020
 Wind Turbine Typology

Different models of turbines exist to for different purposes

• Windmills are used to mill grain or pump water 𝑩𝑨𝒃

Rotor solidity: 𝝈 =
𝝅𝑹𝟐
- Goal: maximize torque

- Low rotational speed, high rotor solidity

Wind Turbine Typologies

• Wind turbines are used to produce electricity (50~60Hz)

- Goal: maximize power capture

- Generally higher rotational speed and less solidity

Wind turbine configuration dependent upon control mechanisms

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 A Bit of History
Mechanical power
(grinding grain, water
pumping, powering tools)

Early Persian
(7th century)
Europe (invented before 1180)
Wind Turbine Typologies

Brush 1888

Jacobs1928
Smith-Putnam
late 1930s
One bladed
Ge Haliade-X Riva Calzoni & MBB
Farm windmills
12MW water pumps

Electricity generation
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 In the Beginning …
Simple vertical
axis turbine

First recorded wind mill:

• Afghanistan/Persia (ca. 945 AD)
• Similar mills developed in China to
irrigate rice fields (~1045 AD)
• Precursor to Savonius Rotors
Wind Turbine Typologies

(source: Hau Windkraftanlage, ~945–2013 AD)

Tower used to limit drag

on the blade return

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Modern Savonius rotor
(source: Wikipedia)
(source: BWE)
 In the Beginning…

(source: Hau Windkraftanlage)

Europe ~1500 AD
Specific for milling grain or
pumping water
Precursor: modern wind turbines
Horizontal
axis
Wind Turbine Typologies

Yaw control

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 In the Beginning…

(source: Historic American Engineering Record, National Park Service)

Wind mills: US mill from 1820
Gearing could be cast iron or wood
Wind Turbine Typologies

Semi-active yaw
control (tail fan)

Governor (overspeed
control, lower/raises
runner stones)

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 Ongoing: Wind Mills and Water Pumps

(source: Wikimedia P. Bolduan)

Wind Turbine Typologies

• Thousands of American style windmills (wind pumps) still in use

• Simple, robust, with passive control systems

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 Modern Wind Turbines
Design goal: cheapest cost of
energy possible
Almost every component has been
removed from various designs

General overview:
• Blades
Wind Turbine Typologies

• Spinner
• Pitch mechanism
• Main bearing(s) for rotor shaft
• Gearbox
• Brake
• Generator
• Control/Power Electronics
• Yaw motor

(source: Hau Windkraftanlage)

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 Modern Wind Turbines

(source: Hau Windkraftanlage)

General overview cont.:
• Tower
• Foundation
• Electrical Transformer
• Network connection
Wind Turbine Typologies

Almost every component has been

(source: Enercon)
removed from various designs:
• Example: Direct drive – no gearbox

• Example: Kite turbines – no tower

(source: ecochunk.com)
• Example: Delft EWICON – no blades …
(charged water droplets moved against electric field by wind)

“Value engineering”: get rid of the unnecessary

(source: mecanoo.nl)
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 Modern Wind Turbines: How Many
Blades?
Ω𝑅
Tip Speed ratio (TSR) 𝜆=
𝑉

Example:
• Rotor Speed
Wind Turbine Typologies

• Radius 𝜆=𝟓
• Wind Speed

(source: Burton, Wind Energy Handbook, 2001)

(source: Hau, Wind Turbines, 2006)

Three blades:
• Highest performance
• More aesthetic
• Less noise

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 Efficiency and Torque

𝑸 𝑪𝑷
𝑪𝑸 = =
𝟏ൗ 𝝔𝑨𝑹𝑽𝟐 𝝀
𝟐
Wind Turbine Typologies

𝐶𝑄
(source: Burton, Wind Energy Handbook, 2001)

• Clear trade off between efficiency (Power Coefficient) and torque

• Different applications require different characteristics

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 Modern Wind Turbines: Upwind or
Downwind?
Wind Turbine Typologies

Upwind:
• Active yaw is needed
• Quite stiff blades are needed (tower clearance)

Downwind:
• Very-flexible blades are possible
• Self-realignment to varying wind direction (untwist tower cable?)
• Strong tower shadow: power fluctuations and fatigue issue

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 Modern Wind Turbines

Modern wind turbines:

• 3 blades
• Upwind
• Pitch control
• Various typologies depending on generator
type, location of main bearings, gearbox,
Wind Turbine Typologies

brake

(source: Hau Windkraftanlage)

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 Modern Wind Turbines

(source: Pierre Tchakoua et al.)

Wind Turbine Typologies

• For modern commercial turbines the layout varies slightly

• This depends on the carrying frame, gearbox/generator and bearing location

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 Modern Wind Turbines: Gearbox
Wind Turbine Typologies

(sources: reuk.co.uk, geograph.org.uk, coriolis-energy.com)

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 Modern Wind Turbines: Gearbox

(source: Enercon)
Wind Turbine Typologies

Direct coupling of generator to the rotor

Remove gearbox (and associated problems) and use generator with multiple poles
(Current frequency = rotation * pole pairs)
Need to increase generator size (e.g.: E126 – 12m diameter generator)
Generator rotation speed = rotor rotation speed
Note tower location and mass imbalance

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 Modern Wind Turbines: Gearbox
Hybrid concepts:
Wind Turbine Typologies

(sources: wind-energy-the-facts.org, eetweb.com, machinedesign.com)

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 Modern Wind Turbines: Drive Train
HSS brake Gearbox Aft bearing Front bearing

Generator

Front bearing
Wind Turbine Typologies

(source: Hart et al, 2019)

(source: Nordex)
Aft bearing

• Rotor produces large bending moments due to gravity and aerodynamics

• A main bearing along the rotor shaft is used react this load (location is
different on various design layouts)

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 Modern Wind Turbines: Drive Train

(source: Ecotecnica)
Shaft bearings

Gearbox

Shaft bearings
Wind Turbine Typologies

Turbine bedplate (source: Hart et al, 2019)

• Other models decouple support structure and drivetrain

• Gearbox has to absorb some of the off-axis rotor loading

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 Modern Wind Turbines: Brake
HSS brake
Wind Turbine Typologies

(source: USDOE)
(source: geograph.org.uk)

Rotor energy is too large for mechanical braking

Brakes are for parking and slowing, most braking performed aerodynamically
Brake can be forward of gearbox (low speed shaft LSS) – very high torque
or aft of gearbox (high speed shaft HSS) - high speed, lower torque

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 Modern Wind Turbines: Nacelle
Wind Turbine Typologies

(source: Wikimedia)

Nacelle: container on top of the tower

First impressions and acceptance are
key issues for wind energy
GE 3.6MW at Arklow Bank
Aesthetically pleasing design is a plus

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 Modern Wind Turbines: Nacelle

(source: Vestas)
Wind Turbine Typologies

Vestas 3MW:
• Move all hardware forward, remove second bearing
• Lightweight, compact

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 Modern Wind Turbines: Layout
Wind Turbine Typologies

(sources: wind-energy-the-facts.org, scruss.com, windpowerengineering.com, inhabitat.com, leitwind.com)

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 Modern Wind Turbines: Pitch Systems
Hydraulic pitch actuators:
• Linear drivers to force rotation
(pitch)
• Accumulator as back-up
(pressurized fluid)
• Rotating frame hydraulic
actuators (rotor) require energy
Wind Turbine Typologies

supplied by a power unit

placed in the nacelle (non
rotating): slip ring needed
• Inherent individual blade pitch
capability
(source: windpowerengineering) (source: Hydratech)

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 Modern Wind Turbines: Pitch Systems

(source: Leitwind)
Electric pitch motors:
• Gear wheel on inside of bearing
(tooth wheel) used to rotate blade
(pitch)
• Battery or capacitors as back-up
during emergencies (need pitch
Wind Turbine Typologies

to brake rotor)
• Rotating frame (rotor) slip rings
necessary to power motors

(source: altenergy.mag)
(source: SSB Wind Systems)

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 Wind Turbines: Yaw System

(source: wwindea.org)
Wind Turbine Typologies

Yaw drives (electric or hydraulic):

• Control orientation of the rotor to the wind
• Unwind power cable
Upwind necessary, downwind?

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 Wind Turbines: Towers

(source: NREL)
Most towers are steel construction
Bolted together on-site
Wind Turbine Typologies

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 Wind Turbines: Towers
Hybrid towers:
• Segmented concrete towers
• Manufactured and shipped to location (source: abo-wind.com)

• Top of tower is steel

Wind Turbine Typologies

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 Modern Wind Turbines: 2 Blades Upwind
(source: Flowind)
• Two bladed turbines are not yet a
commercial success
• Dynamics/resonance issues and
aesthetics
• Only known ongoing commercial
concern: Flowind 500, NZ, UK
• Teeter relieves root bending
Wind Turbine Typologies

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 Modern Wind Turbines: 3 Blades
Downwind

Three bladed downwind:

• Lower yaw demand
• Built to withstand typhoon wind
storms
• Hitachi/Fuji design 2MW
Wind Turbine Typologies

(source: Hitachii.com)

Japans 1st offshore wind park

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 Wind Turbines: Other Concepts
Canadian 4+MW Darrieus Rotor and Museum

Vertical axis turbines:

• Typically lower efficiency than
horizontal axis turbines
• Renewed interest for offshore
floating applications
(source: Hau – Windkraftanlagen)
Wind Turbine Typologies

Helical blades reduce

pulsations and ease start-up ▶

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(source: quietrevolution) (source: http://www.windpower.ltd.uk/)