The standard of living throughout the world has increased dramatically over the last 30 years and is projected to continue to rise. This growth leads to an increased demand on conventional energy sources, such as fossil fuels. However, these are finite resources. Thus, there is an increasing demand for alternative energy sources, such as wind energy. Much of current wind turbine research focuses on large-scale (>1 MW), technologically-complex wind turbines installed in areas of high average wind speed (>20 mph). An alternative approach is to focus on small-scale (1–10kW), technologically-simple wind turbines built to produce power in low wind regions. While these turbines may not be as efficient as the large-scale systems, they require less industrial support and a less complicated electrical grid since the power can be generated at the consumer’s location. To pursue this approach, a design methodology for small-scale wind turbines must be developed and validated. This paper addresses one element of this methodology, airfoil performance prediction. In the traditional design process, an airfoil is selected and published lift and drag curves are used to optimize the blade twist and predict performance. These published curves are typically generated using either experimental testing or a numeric code, such as PROFIL (the Eppler Airfoil Design and Analysis Code) or XFOIL. However, the published curves often represent performance over a different range of Reynolds numbers than the actual design conditions. Wind turbines are typically designed from 2-D airfoil data, so having accurate airfoil data for the design conditions is critical. This is particularly crucial for small-scale, fixed-pitched wind turbines, which typically operate at low Reynolds numbers (<500,000) where airfoil performance can change significantly with Reynolds number. From a simple 2-D approach, the ideal operating condition for an airfoil to produce torque is the angle of attack at which lift is maximized and drag is minimized, so prediction of this angle will be compared using experimental and simulated data. Theoretical simulations in XFOIL of the E387 airfoil, designed for low Reynolds numbers, suggest that this optimum angle for design is Reynolds number dependent, predicting a difference of 2.25° over a Reynolds number range of 460,000 to 60,000. Published experimental data for the E387 airfoil demonstrate a difference of 2.0° over this same Reynolds number range. Data taken in the Baylor University Subsonic Wind Tunnel for the S823 airfoil shows a similar trend. This paper examines data for the E387 and S823 airfoils at low Reynolds numbers (75,000, 150,000, and 200,000 for the S823) and compares the experimental data with XFOIL predictions and published PROFIL predictions.

When studied in large wind turbines, roughness on wind turbine blades has been shown to decrease wind turbine performance by up to 50%. However, during wind turbine testing in the Baylor University Subsonic Wind Tunnel, roughness effects that were an artifact of the blade manufacturing process led to a significant power increase over smooth blades at the design wind speed of 10 mph. These results have led to an investigation of the effects of roughness on wind turbine performance under a flow condition with local Reynolds numbers ranging from 14,200 to 58,800. It was found that under these flow conditions the roughness can improve measured power output by up to 126% when compared with a smooth blade. This paper examines the conditions where roughness can positively affect the operation of a wind turbine by testing a 500 mm diameter, horizontal axis, three blade, fixed pitch wind turbine system in a wind tunnel. The experiments have been carried out on a single direct-drive wind turbine model and a single blade design using the NREL designed S818 airfoil. The design point for the blades tested is 10 miles per hour, with a tip speed ratio of 7. Roughness can be an effective treatment when used at or near the stall speed of the wind turbine blade for lower Reynolds number conditions. The roughness elements tested were both perpendicular to and along the flow lines. These blades were then compared to a blade configuration without roughness elements.

Wind turbines have become a significant part of the world’s energy equation and are expected to become even more important in the years to come. A much-neglected area within wind turbine research is small-scale, fixed-pitch wind turbines with typical power outputs in the 1–10 kW range. This size wind system would be ideal for residential and small commercial applications. The adoption of these systems could reduce dependence on the aging U.S. power grid. It is possible to optimize a small-scale system to operate more efficiently at lower wind speeds, which will make wind generation possible in areas where current wind technology is not feasible. This investigation examines the use of the S818 airfoil, a typical blade root airfoil designed by the National Renewable Energy Laboratory (NREL), as a basis for the design of low Reynolds number (less than 200,000) systems. The literature shows that many of the airfoils proposed for wind turbine applications, including the S818, only have lift and drag data generated by numerical simulations. In previous research at Baylor, 2-D simulations published by NREL have been shown to predict an optimal design angle of attack (which is the angle at which L/D is maximized) up to 2.25° different from actual wind tunnel data. In this study, the lift and drag generated by the S818 airfoil has been measured experimentally at a Reynolds number of approximately 150,000 and compared with NREL simulation data, showing a discrepancy of 1.0°. Using the S818 airfoil, a set of wind turbine blades has been designed to collect wind turbine power data in wind tunnel testing. Design parameters investigated include the effect of design tip speed ratios (TSR) (1, 3, and 7) and the influence of the number of blades (2, 3 and 4) on power generated. At the low Reynolds numbers tested (ranging from 14,000–43,200 along the blade for a design TSR of 3 and a wind speed of 10 mph), the effect of roughness was explored as a performance enhancing technique and was seen to increase power output by delaying separation. Under these low Reynolds number conditions, separation typically occurs on smooth blades. However, the roughness acted as a passive flow control, keeping the flow attached and increasing power output. Preliminary data suggest that as much as a 50% improvement can be realized with the addition of roughness elements for a TSR of 3. Additionally, the increase in power output due to roughness is comparable with the increase in power due to adding another smooth blade.

The importance of renewable and alternative energy is rapidly gaining attention. A national goal of replacing 20% of the United States electricity generation with wind power by 2030 has been proposed but such an ambitious goal is dependent on many parameters. Improved aerodynamic performance of wind turbine blades is one parameter necessary to achieve this goal. Blade testing is traditionally done using 2D airfoils in a laboratory wind tunnel, developing the lift and drag coefficients, and then using this data to predict wind turbine blade performance. Dimensional analysis has been used successfully in design of rotating machinery such as pumps, developing a series of dimensionless pump parameters with which to scale a particular pump design to a larger or small size. These parameters lead to similarity or affinity laws which relate any two homologous states for two pumps that are geometrically and dynamically similar. Affinity laws could be applied to wind turbines however the conditions tested in the wind tunnel do not match what would be expected in a full scale wind machine. As with pumps, the laws would apply only if the model and full scale wind turbine would operate at identical Reynolds numbers and are exactly similar (i.e. relative surface roughness and tip conditions). Reynolds numbers in the model tests are smaller than those achieved by the actual wind turbines while the surface roughness of the model is generally larger. This leads to the need for empirical equations to predict performance. This paper examines current wind tunnel testing and the problems with scaling wind turbine blades. It also outlines a methodology to test 3-D model wind turbine blades in a wind tunnel. Blades are designed and manufactured according to existing criteria, mounted to a generator, and their performance is then tested in the wind tunnel. Challenges with wind tunnel testing as well as extrapolation of the wind tunnel data to actual applications will be addressed.

Wind power is a reliable form of energy, and increases in wind turbine efficiency have helped to provide cost-effective power to an ever-growing portion of the world. However, there are physical limits to the amount of energy that can be removed from an airstream using a single wind turbine system. This paper explores the possibility of increasing power production using two counter-rotating sets of wind turbine blades. A review of design characteristics, such as number of blades, blade angle of twist, chord length, and generator efficiencies, resulted in the design of a counter-rotating wind turbine using three different National Renewable Energy Laboratory (NREL) cross-sectional blade profiles for the blades. A three-blade front system and two three-blade rear systems were studied. The blade prototypes were modeled in SolidWorks ® , produced using a Dimension ® 3D printer, and then tested using two Parallax™ four-pole stepper motors as generators in a model 406B ELD wind tunnel. Initial testing showed a power increase of 101.4% at 25 mph. This power increase can be attributed to the addition of the second generator and a rear-blade system that was a mirror image of the front system. Testing was performed between 15 mph and 40 mph in 5-mph increments. The counter-rotating system reached its optimum operating efficiency at 25 mph, at which 12.6% of the energy in the air was converted into usable power. This outcome compares to a 6.25% power conversion for the frontblade system. Preliminary results indicate that a counter-rotating assembly is promising for increasing energy extraction from a column of air. Additional testing should focus on system efficiency based on blade angle of twist, chord length, and generator efficiencies. A power increase of 101.4% with the addition of the rear-blade system indicates that the front-system efficiency has not been maximized. The next logical step is designing blade systems for maximum total system efficiency at specified wind speeds. Additionally, it would be valuable to determine if counter-rotating systems could expand the range of possible turbine locations by lowering the required average wind speed.