This invention relates generally to the field of wind turbine generators, and more specifically to an apparatus for reducing the accretion of foreign objects on a wind turbine blade.
As is known in the art, wind kinetic energy is converted to electrical energy with a wind turbine generator (WTG). The wind turbine generator comprises rotor blades for converting wind energy to rotational energy for driving a shaft connected to a gearbox. The gearbox converts low speed rotation to high speed rotation as required for driving a generator that generates electricity. Certain WTGs lack the gearbox and instead the generator is driven directly from the shaft. The wind turbine generator also includes various control components (for example to change a blade pitch), a structural support, such as a tower, and a rotor yawing system for orienting the rotor plane perpendicular to the oncoming wind.
The WTG converts wind energy to rotational energy by efficiently slowing down incoming wind, reducing its kinetic energy and transferring that kinetic to rotational energy to rotate a generator for generating electricity. The efficiency of this process depends on the blade area within a rotor plane and on the aerodynamic performance of the blades. Rotor blade design considers power generated, noise emissions, structural integrity and loading limits.
Axial induction is a measure of the amount by which the incoming wind is slowed down, i.e., a ratio of the wind speed after impinging the rotor blades to the incoming wind speed.
An airfoil is a cross-sectional slice of a lift-producing body, such as a WTG blade. An airfoil angle of attack is the angle between an airfoil chord and a vector parallel to the incoming air flow. Blade performance is represented by force fields in the flow stream. Lift and drag vector components (both functions of the angle of attack) are vectorially added to produce an aerodynamic force vector.
Lift of an airfoil is primarily generated from a pressure difference between an upper and lower side of an airfoil. Airfoils are designed to accelerate flow around a leading edge of the airfoil thereby lowering pressure at that edge. WTG blade airfoils are designed to produce more acceleration over an upper or suction side of the airfoil blade than over a lower or pressure side during normal operation at any power level below the WTG rated power. At very high wind speeds (e.g., greater than about 25 m/second) the blades are pitched to a low angle of attack that in certain areas of the blade may result in greater acceleration over the pressure airfoil side.
Wind turbine blade soiling is specifically a leading edge surface contamination problem characterized by impingement of foreign objects on the leading edge during blade rotation. These foreign objects, e.g., dust, mud, dead insects, salt and other airborne objects, then accumulate on the blade surfaces.
Severe soiling environments are characterized by large flying insect populations, low humidity, intermittent rain and farming activities that loosen top soil.
The severity of the soiling also depends on geographical location, weather patterns, and seasonal variations. In the United States, blade soiling is an acute problem in particular in the Midwest.
This accretion of foreign objects on or near the leading edge of a wind turbine blade degrades blade performance, reduces annual energy production from the WTG and increases noise emitted by the WTG. Soiling may also lead to permanent roughing of the blade leading edge.
Specifically, soiling disturbs a flow boundary layer along the blade thereby increasing kinetic energy losses in a near-wall air flow stream. Decreasing kinetic energy directly decreases the rotational blade energy, and since the WTG generates electricity by converting kinetic energy to rotational energy, the amount of electricity generated also decreases.
Soiling can also create a fully turbulent air flow over the entire blade airfoil. This phenomenon reduces aerodynamic efficiency throughout the blade, negatively influencing both power production and noise emissions.
Blade soiling can also generate more warranty claims due to the decreased output power of the WTG. Other effects of soiling include additional costs associated with removal of the accreted material, engineering hours devoted to on-site trouble shooting, and engineering hours devoted to mitigating blade soiling.
When blade soiling increases noise emissions, serrated or chevrous-shaped strips, also known as DinoTails, can be affixed to the trailing edge of a WTG blade to reduce the noise emissions.
Knowledge of airfoil dynamics under soiled blade conditions must be considered when designing blades. Blades can be designed with an aerodynamic efficiency that not only maximizes annual energy power output under clean blade conditions, but also lowers sensitivity to blade soiling. To reduce the sensitivity to blade soiling, certain compromises can be made during deign of the WTG blades. These decisions may result in sacrificing some “clean blade surface” energy production, resulting in turbines with reduced annual energy production and reduced capacity factors.
Periodic blade cleaning is a straightforward solution to the blade soiling problem and one that can be easily implemented by the WTG owner. But it is difficult to determine a level of blade soiling that justifies blade cleaning. Also, cleaning the blades is a time consuming and expensive operation, requiring the use of special equipment (e.g., cranes) and of course shutting down the WTG.
In one prior art technique for reducing soiling, vortex generators are installed (as an add-on solution after commissioning of the WTG) on outboard sections of the wind turbine blades. The outboard section is generally defined as that segment of the blade between a mid-span chord and the blade tip.
Vortex generators with right scalene triangle shapes are typically installed in same-size pairs along an outboard surface of a blade. Several differently shaped vortex generators are installed along the blade length. The vortex generators create an air vortex that travels downstream along the blade surface, i.e., from the leading edge to the trailing edge or along the blade airfoil chord, entraining kinetic energy from the free-stream flow into a near-wall flow. Each vortex generator pair generates counter-rotating vortices that operate effectively to reduce blade soiling. The additional energy transferred to the near-wall flow also aids in reducing the negative effects of soiling by delaying flow separation along the blade airfoil. Flow separation has a negative effect on WTG efficiency. The familiar airfoil stall phenomenon is an example of air flow separation.
The invention is explained in the following description in view of the drawings that show:
Given the problems associated with wind turbine blade soiling as described above, there is a need to reduce blade soiling to improve wind turbine generator performance.
Each blade airfoil 22 extends radially from an inboard end or root end 24 to a tip end 28. The root end 24, attached to a hub 26, is relatively thick to withstand flapwise loads imposed normal to a chord of the blade airfoil. Generally, the inboard blade section is defined as a segment of the blade between the root end 24 and a mid-span chord 41, and the outboard section is defined as a segment between the mid-span chord 41 and the tip end 28.
Transverse cross-sectional profiles of the blade gradually transition from a circular shape at the root end 24 to an airfoil shape at and beyond (i.e., radially outwardly) of a shoulder region 47. Generally the shoulder region 47 is defined as proximate the chord having the longest blade chord length.
Continuing with reference to
As the transverse cross-sectional profiles of the chord change along the blade's length between the hub end 24 and the tip end 28 a chord length changes. Also, the chord 96 is considered the line of demarcation between a pressure side 38 and a suction side 40 of the blade airfoil.
Typically, the blade airfoil dimensions are given as a percent of a local chord length, where the local chord length is defined as the chord in the immediate vicinity of interest. For example, 0% of chord length is defined as a leading edge point of the blade airfoil, e.g., at the leading edge point 54 in
The loss of lift (i.e., a lower lift coefficient) due to blade soiling lowers the local axial induction factor with a consequent drop in WTG output power. Blade soiling causes earlier separation of the airflow from the surface of the blade due to the loss of momentum or kinetic energy in the airflow.
When flow separation occurs (i.e., separation of the airflow from the blade airfoil) the drag coefficient increases rapidly. Noise emissions also increase when the drag coefficient increases. Thus
As shown in
Although not specifically shown in
The shield 80 is generally not considered an aerodynamic component of the blade airfoil 22 or of the WTG. As known by those skilled in the art, an aerodynamic component is one that affects the motion of air streams and influences the motion of bodies in the air streams, i.e., a body creating lift or drag forces. But in fact, every body, whether or not characterized as an aerodynamic body, can create lift and drag. An aerodynamic body then is defined as one that has been designed to create lift and drag, e.g., one that is more slender than, for example, a circle or an ellipse in cross-section.
Because the shield of the present invention is not designed or shaped to produce meaningful lift, it is generally not considered an aerodynamic body as described above. The shield is aligned with the local air flow around the shape of the blade and does not create any meaningful adverse or beneficial effects from an aerodynamic point of view, i.e., it does not create any meaningful lift or drag forces during normal operation of the WTG. Normal operation of the WTG is considered operation at or below rated power production at angles of attack between about 0° and 10°. The shield 80 does not create more than about 10% of a total lift component when the WTG is operating within its normal operating range, i.e., when the blade angle of attack is between about 0° and 10°.
Also the shield 80 does not disturb the airflow (e.g., induce any flow separation points) at any operational angles of attack, i.e., angles of attack between about 0° and 10° when the WTG is producing power at or below the rated power of the WTG.
Continuing with
The angle of attack α is also illustrated. The angle of attack (also referred to as the blade airfoil pitch) is the angle between the chord 96 and a direction of the incoming airflow, which direction is indicated by air flow vectors 98.
In
Similarly, a line 104 extends from the point 80A to a perpendicular intersection with a surface of the blade airfoil 22 at a point 22A. From the point 22A a line 112 extends to a perpendicular intersection with the chord 96 at a point NPA.
DA is defined as a distance between the points 54 and NPA along the chord 96. DB is defined as a distance between the points 54 and NPB along the chord 96. Both DA and DB are between about 0% and 10% of the length of the chord 96. In
Given that the distances DA and DB are both generally expressed in ranges, in different embodiments the shield 80 may extend over different segments of the leading edge of the blade airfoil 22, such as the embodiments illustrated in
In the
In an embodiment of
In an embodiment of
Preferably, each distance DC and DD is between about 2 and 20 cm. At a distance less than about 2 cm. the shield 80 has an adverse effect on the airflow streams and the aerodynamic properties of the blade airfoil 22. At a distance greater than about 20 cm. the shield will not be effective to stop insects, debris, etc. from reaching the surface of the blade airfoil 22. Preferably, the distances DC and DD should be within about ±5 cm of each other.
The ranges associated with the distances DA, DB, DC, and DD offer several degrees of freedom in positioning and orienting the shield to accommodate different blade airfoil designs, leading edge shapes and prevalent wind directions at the WTG site.
In
In
In yet another embodiment of
In
Preferably the air flow stagnates on the blade 22 and the air flow is not significantly disturbed by the presence of the shield 80. Since the most forward point of the blade airfoil changes with the angle of attack, the blade and shield are designed and located relative to each other such that for the most common operating conditions (based on the most common wind direction and velocity at the site of the WTG and a site-specific most common angle of attack at or below the rated output power) the stagnation point on the blade airfoil is not blocked by the shield 80.
In
As the blades are pitched responsive to changes in wind direction the stagnation point moves. During WTG operation below rated power, the WTG controller and actuators change both the pitch and the RPMs of the rotor in response to changes in air flow direction and speed to maintain the same angle of attack (and therefore the same stagnation point).
However above rated power, the rotational speed of the rotor is not typically changed, but the pitch is changed as the wind speed increases in such a way that the angle of attack changes and becomes negative. The blades are pitched under these conditions to reduce wind loads on the blades. Of course in this scenario the stagnation point definitely moves as the blades are pitched away from their normal angle of attack (i.e., where the normal angle of attack is considered that angle of attack when the WTG is operating at or below its rated power).
In one embodiment the soiling shield 80 has a constant thickness along its radial length between the blade tip and the blade root. For example, the shield thickness is about 5 mm.
According to another embodiment the thickness of the soiling shield 80 varies along its radial length. The thickness varies between about 5% and about 12% of the blade's local chord length at any transverse cross-section.
As used herein the reference to constant thickness excludes the shield endpoints 80A and 80B, which may be rounded, pointed, serrated or chevrous (e.g., with flexible vortex generators attached) for aerodynamic efficiency.
In one embodiment a shape of the shield is concave (from the perspective of the blade airfoil) as illustrated in the various figures. The shield may also be planar as illustrated in
In yet another embodiment the shape of the shield 80 follows the contour of the leading edge of the blade airfoil 22. According to this embodiment the shield is shaped and located so that its contour is aligned with the airflow streams, i.e., the contour follows the curvature of the airflow streams, where the curvature of the airflow streams follows the contour of the leading edge of the blade airfoil. With this shape, the shield 80 does not substantially interact with the airflow streams during normal WTG operation. It is not an aerodynamic component and therefore does not provide any meaningful additional lift or drag during normal operation of the WTG.
A length of the soiling shield along the shield surface between the endpoints 80A and 80B is between about 1% and about 20% of the local chord length.
The soiling shield 80 can be made from any material that does not attract lightning. For example, the shield 80 can be formed from the same material(s), e.g., a plastic or a fiber material as other blade add-on components (e.g., vortex generators as described elsewhere herein).
In one embodiment the shield 80 may be constructed of a deformable material that deforms in situ to a profile of the airflow streams that flow over the blade airfoil. Such a shield minimizes disruption of the airflow streams after it has assumed a shape of those airflow streams.
Components for attaching the shield 80 to the blade airfoil 22 are dependent on the lift and drag forces exerted on the shield.
A lightly loaded shield is preferred, i.e., where the shield is designed and configured with respect to the blade 22 to carry only light loads and not intended to withstand significant lift and drag loads.
With reference to
In certain embodiments the plate 164, the adhesive material 166 and the fasteners 168 are not utilized and instead the end 160B is directly attached to the blade airfoil 22, again using fasteners or an adhesive material.
Generally, the blade airfoil comprises a skin surface and radially-extending internal spars with transverse ribs connected to the spars. As illustrated in
The struts 160 and 179 are spaced radially along a length of the blade with a distance between spars dependent on the loads exerted on the airfoil. For example the struts may be placed at about 2 meter intervals.
In one embodiment the struts 160 and 179 comprise a core of visco-elastic material 190 (see
Vortex generators 200 affixed to a base 201, as illustrated in
The shield can extend radially from blade tip to blade root, or along any segment of the blade. In one embodiment the shield is positioned only along the outboard segment of the blade.
Since in one embodiment the shield 80 is affixed to the blade airfoil 22, the shield is also pitched with the blade, i.e., the orientation of the shield remains fixed relative to the orientation of the blade.
But in another embodiment the shield is moveable relative to the blade. The shield 80 may be pivotable about the struts 160/179 for positioning the shield as wind inflow conditions change. The position of the shield relative to the blade can be manually controlled or controlled remotely by the WTG control system.
In one embodiment a moveable shield serves a dual purpose of preventing debris and insects from spoiling the blade and of disrupting the airflow as a spoiler/slat. In this latter embodiment a gap between the soiling shield and the blade airfoil is regulated to control the airflow disruption.
Returning to
As used herein, the terms axial and radial with reference to the blade airfoil and the soiling shield are used interchangeably to refer to a direction from a blade tip to a blade root or vice versa.
While various embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only. Numerous variations, changes and substitutions may be made without departing from the invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.