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There are a number of approaches that can be taken towards wind turbine
design, and there are many issues that must be considered, the key design
steps include the following:
1. Determine application
2. Review previous experience
3. Select topology
4. Preliminary loads estimate
5. Develop tentative design
6. Predict performance
7. Evaluate design
8. Estimate costs and cost of energy
9. Refine design
10. Build prototype
11. Test prototype
12. Design production machine
1. Determine application
The first step in designing a wind turbine is to determine the application.
Wind turbines for producing bulk power for supply to large utility networks,
for example, will have a different design than will turbines intended for
operation in remote communities.
The application will be a major factor in choosing the size of the turbine,
the type of generator it has, the method of control, and how it is to be
installed and operated. For example, wind turbines for utility power will
tend to be as large as practical. At the present time, such turbines have
power ratings in the range of 500 to 1500 kW, with rotor diameters in the
range of 38 m (125 ft) to 61 m (200 ft). Such machines are often installed in
clusters or wind farms, and may be able to utilize fairly developed
infrastructure for installation, operation and maintenance.
Turbines for use by utility customers, or for use in remote communities,
tend to be smaller, typically in the 10 to 200 kW range. Ease of installation
and maintenance and simplicity in construction are important design
considerations for these turbines.
2. Review previous experience
The next step in the design process should be a review of previous
experience. This review should consider, in particular, wind turbines built
for similar applications. A wide variety of wind turbines have been
conceptualized. Many have been built and tested, at least to some degree.
Lessons learned from those experiences should help guide the designer and
narrow the options.
A general lesson that has been learned from every successful project is
that the turbine must be designed in such a way that operation, maintenance,
and servicing can be done in a safe and straightforward way.
3. Select topology
There are a wide variety of possible overall layouts or topologies for a
wind turbine. Most of these relate to the rotor. The most important choices
are listed below.
Fabrication methods
Ease of maintenance
Aesthetics
Noise
The commercially available items will typically have prices that will be
lowered only slightly when bought in volume for mass production. Special
items will often be quite expensive in the prototype level, because of the
design work and the effort involved in building just one or a few of the
items. In mass production, however, the price for the component should
drop so as to be close to that of commercial items of similar material,
complexity and size.
9. Refine design
When the preliminary design has been analyzed for its ability to withstand
loads, its performance capability has been predicted, and the eventual cost of
energy has been estimated, it is normal that some areas for refinement will
have been identified. At this point iteration on the design is made. The
revised design is analyzed in a similar manner to the process summarized
above. This design, or perhaps a subsequent one if there is more iteration,
will be used in the construction of a prototype.
10. Build prototype
Once the prototype design has been completed, a prototype should be
constructed. The prototype may be used to verify the assumptions in the
design, test any new concepts, and ensure that the turbine can be fabricated,
installed, and operated as expected. Normally the turbine will be very similar
to the expected production version, although there may be provision for
testing and instrumentation options which the production machine would not
need.
11. Test prototype
After the prototype has been built and installed, it is subjected to a wide
range of field tests. Power is measured and a power curve developed to
verify the performance predictions. Strain gauges are applied to critical
components. Actual loads are measured and compared to the predicted
values.
12. Design production machine
The final step is the design of the production machine. The design of this
machine should be very close to the prototype. It may have some differences,
however. Some of these may be improvements, the need for which was
identified during testing of the prototype. Others may have to do with
lowering the cost for mass production. For example, a weld joint may be
appropriate in the prototype stage, but a casting may be a better choice for
mass production.