TOpWind: Optimized wind harvesting capability by using active flow control

The continuous enlargement of wind turbines (WEA), both onshore and offshore, particularly the increase in rotor diameter, presents aerodynamic and aeroacoustic challenges. To address these challenges and improve the efficiency and economy of the plants, research and development of optimization concepts are being advanced. Here, the integration of fluidic actuators for active flow control plays a central role. This technology not only allows for better adaptation of aerodynamics but also supports the use of lighter and longer rotor blades.

The fluidic actuators, including Pulsed Jet actuators and Synthetic Jet actuators, which have mainly been studied in the aviation sector so far, offer the potential to increase rotor efficiency and thus significantly improve the energy yield of the WEA. The joint project, consisting of research institutions, university chairs, industrial companies, and SMEs, focuses on the development and integration of these actuators into the fiber-reinforced rotor blade structure. Additionally, innovative strategies for integrating other components such as electronics and sensor technology are being developed.

The research priorities include the development of technologies for optimizing blade flow, numerical and experimental analysis of these technologies, and the development of an assessment and control concept for the economic evaluation of the use of active flow control over the entire life cycle of the plants. Through these advanced technologies and close cooperation within the consortium, participants aim to achieve both economic and ecological improvements in the production and operation of WEA and enable new rotor geometries.

Main areas of research

The research focuses on the design, development and integration of fluidic actuators (synthetic jet actuators) as well as their characterization and validation. Accompanying all these steps is the economic and ecological evaluation of the overall system. The individual steps of the entire development cycle are shown in the diagram below.

Development workflow for the integration of fluidic actuators

The research topics can be structured according to the technical work packages of the project, which are divided as follows:

WP 1: Aerodynamics and aeroacoustics, investigation of rotor blades with and without AFC

The goal is to establish the basis and requirements for actuator development using numerical and experimental aerodynamic and aeroelastic analyses as well as testing the hypotheses in wind tunnel tests and comparing the results with CFD (Computational Fluid Dynamics) analyses.

 

WP 2: Actuator and actuator system development, development of integration concepts

In this work package, the development of a suitable actuator as well as sensor system based on the aerodynamic studies and experiments (from WP1) is performed. Research and construction of novel functionalized products suitable for integration into the fiber-reinforced rotor blade structure that do not compromise structural integrity.

 

WP 3: Economic and ecologic evaluation and control

Development and application of an economically (and ecologically) oriented life cycle related evaluation and control concept using validated figures from the project developments. The added value of the addressed technologies is shown. The focus is both set on the development of the overall system and on the manufacturing phase of the single components. In addition, the systematic achievement of innovation success is addressed by means of business model development and risk mitigation.

 

WP 4: Characterization of the performance, robustness and reliability of the actuators

Definition of the requirement profiles for the developments and, based on this, characterization of the performance, robustness and reliability of the actuators. All those points are with regard to the industrial requirements for specific applications.

The consortium of TOpWind consists of partners from industry and research. Participants are:

Fraunhofer participates in TOpWind with four institutes:

Fraunhofer ENAS - Projekt Coordinator

Fraunhofer Institute for Electronic Nano Systems
Technologie-Campus 3, 09126 Chemnitz, Germany

www.enas.fraunhofer.de

 

Fraunhofer IWES

Fraunhofer Institute for Wind Energy Systems
Am Seedeich 45, 27572 Bremerhaven, Germany

www.iwes.fraunhofer.de

 

Fraunhofer IWU

Fraunhofer Institute for Machine Tools and Forming Technology
Reichenhainer Straße 88, 09126 Chemnitz, Germany

www.iwu.fraunhofer.de

 

Fraunhofer LBF

Fraunhofer Institute for Structural Durability and System Reliability
Bartningstraße 47, 64289 Darmstadt, Germany

www.lbf.fraunhofer.de

ALTRAN Deutschland S.A.S & Co. KG

Karnapp 25, 21079 Hamburg, Germany

www.altran.com

Deutsches Zentrum für Luft- und Raumfahrt e. V. (DLR)

Institute of Aerodynamics and Flow Technology
Lilienthalplatz 7, 38108 Braunschweig, Germany

www.dlr.de

Siemens Gamesa Renewable Energy GmbH & Co. KG

Beim Strohhause 17-31, 20097 Hamburg, Germany

www.siemensgamesa.com

The smart system solution GmbH

Westring 72, 64711 Erbach, Germany

www.ts3gmbh.de