In general, standard aerodynamic design is divided into two paths—numerical analysis and empirical tests. It is crucial to efficiently combine both approaches in order to entirely fulfill the requirements of the design process as well as the final product. An effective use of computational analysis is a challenge, however it can significantly improve understanding, exploring and confining the search for optimal product solutions. The article focuses on a rapid prototyping and testing procedure proposed and employed at the Institute of Turbomachinery, Lodz University of Technology (IMP TUL). This so called Fast Track approach combines preparation of numerical models of a wind turbine rotor, manufacturing of its geometry by means of a 3D printing method and testing it in an in-house wind tunnel. The idea is to perform the entire procedure in 24 h. The proposed process allows one to determine the most auspicious sets of rotor blades within a short time. Owing to this, it significantly reduces the amount of individual subsequent examinations. Having fixed the initial procedure, it is possible to expand research on the singled-out geometries. The abovementioned observations and the presented overview of the literature on uses of 3D printing in aerodynamic testing prove rapid prototyping as an innovative and widely-applicable method, significantly changing our approach to experimental aerodynamics.

An increase in the efficiency of Small Wind Turbines (SWTs) by aerodynamic optimisation of the blade geometry is limited (low Reynolds number influence). Solutions such as the Diffuser-Augmented Wind Turbine (DAWT) and the twin-rotor systems are of increasing interest. A diffuser promotes an increase in the wind mass flow rate through the turbine, whereas an auxiliary rotor enables extraction of the wind kinetic energy in the wake.

Purpose A solution to increase the energy production rate of the wind turbine is proposed by forcing more air to move through the turbine working section. This can be achieved by equipping the rotor with a diffusing channel ended with a brim (diffuser augmented wind turbine – DAWT). The purpose of this paper is to design an experimental stand and perform the measurements of velocity vector fields through the diffuser and power characteristic of the wind turbine. Design/methodology/approach The experiments were carried out in a small subsonic wind tunnel at the Institute of Turbomachinery, Lodz University of Technology. An experimental stand design process as well as measurement results are presented. Model size sensitivity study was performed at the beginning. The experimental campaign consisted of velocity measurements by means of particle image velocimetry (PIV) and pneumatic pitot probe as well as torque and rotational velocity measurements. Findings Characteristics (power coefficient vs tip speed ratio) of the bare and shrouded wind turbine were obtained. The results show an increase in the wind turbine power up to 70-75 per cent by shrouding the rotor with a diffuser. The mechanisms responsible for such a power increase were well explained by the PIV and pneumatic measurement results revealing the nature of the flow through the diffuser. Research limitations/implications Experimental stand for wind turbine rotor testing is of a preliminary character. Most optimal methodology for obtaining power characteristic should be determined now. Presented results can serve as good input for choice of stable and reliable control system of wind turbine operational parameters. Practical implications A 3 kW DAWT is being developed at the Institute of Turbomachinery, Lodz University of Technology. Aim of the study is to design a compact and smart wind turbine optimised for low wind speed conditions. Developed wind turbine has a potential to be used as an effective element within a net of distributed generation, e.g. for domestic use. Originality/value Research carried out is the continuation of theoretical study began in 1970s. It was also inspired by practical solutions proposed by Japanese researchers few years ago. Presented paper is the summary of work devoted to optimisation of the DAWT for wind conditions in the region. Original solution has been applied, e.g. for experimental stand design (3D printing application).

While the vast majority of the wind energy market is dominated by megawatt-size wind turbines, the increasing importance of distributed electricity generation gives way to small, personal-size installations. Due to their situation at relatively low heights and above-ground levels, they are forced to operate in a low energy-density environment, hence the important role of rotor optimization and flow studies. In addition, the small wind turbine operation close to human habitats emphasizes the need to ensure the maximum reliability of the system. The present article summarizes a case study of a small wind turbine (rated power 350 W @ 8.4 m/s) from the point of view of aerodynamic performance (efficiency, flow around blades). The structural strength analysis of the blades milled for the prototype was performed in the form of a one-way Fluid–Structure Interaction (FSI). Blade deformations and stresses were examined, showing that only minor deformations may be expected, with no significant influence on rotor aerodynamics. The study of an unorthodox material (PA66 MO polyamide) and application of FSI to examine both structural strength and blade deformation under different operating conditions are an approach rarely employed in small wind turbine design.

Purpose This paper aims to discuss the results of the performance study of wind turbine blades equipped with winglets. An investigation focusses on small wind turbines (SWTs), where the winglets are recalled as one of the most promising concepts in terms of turbine efficiency increase. Design/methodology/approach To investigate a contribution of winglets to SWT aerodynamic efficiency, a wind tunnel experiment was performed at Lodz University of Technology. In parallel, computational fluid dynamics (CFD) simulations campaign was conducted with the ANSYS CFX software to investigate appearing flow structures in greater detail. Findings The research indicates the potential behind the application of winglets in low Reynolds flow conditions, while the CFD study enables the identification of crucial regions influencing the flow structure in the most significant degree. Research limitations/implications As the global effect on a whole rotor is a result of a small-scale geometrical feature, it is important to localise unveiled phenomena and the mechanisms behind their generation. Practical implications Even the slightest efficiency improvement in a distributed generation installation can promote such a solution amongst energy prosumers and increase their independence from limited natural resources. Originality/value The winglet-equipped blades of SWTs provide an opportunity to increase the device performance with relatively low cost and ease of implementation.