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ProfilesintheCryogenicWindTunnelCologneDNWKKK
RdigerRebstock1,JunnaiZhai2
GermanDutchWindTunnels,DNWKKK,LinderHhe,51147Kln
ruediger.rebstock@dnwgermany.aero,junnai.zhai@dnwgermany.aero
Windturbinesizehasincreasedcontinuouslyinthepasttoextractmoreenergyfromthewind.Correspondingly,
theReynoldsnumbershaveincreased.TheReynoldsnumbereffectcanthereforenolongerbeignoredindesign
andoptimizationofwindturbines.Reliableprofiletestdatashouldbeavailable.
AsuitablefacilityfortestingwindturbineprofilesathighReynoldsnumbersistheCryogenicWindTunnel
CologneDNWKKK.Bymeansofinjectionliquidnitrogenthetunnelcanbecooleddownto100Kandthe
Reynoldsnumbercanberaised.ThemaximumReynoldsnumberforthe2Dprofiletestcanreach27x10 6.The
liftisdeterminedfrompressuretapsonthemodel.Thedragismeasuredusingawakerake.Theboundarylayer
intheintersectionareasbetweenthemodelandthetunnelwallscanbecontrolledbyblowinghighpressuregas
orusingvortexgenerators.Thelaminartoturbulenttransitionlinecanbedetectedusinginfraredimagingor
temperaturesensitivepaint(TSP).
InthispaperthetestuncertaintyandtheflowqualityofDNWKKKwereanalyzed.Thensometestresultson
theReynoldsnumbereffectofthewindturbineprofileswerepresented.TheReynoldsnumbereffectisdifferent
frommodeltomodel.EspeciallyforthickprofilesandflowcontroldevicestheReynoldsnumbereffectisnot
alwayslikethedescriptioninliterature.
Anotherworkinthisareaistheaeroacoustictest.Apretest withacryogenicmicrophonearrayisalready
finished.Thedataprocessingisstillongoing.
Keywords:aerodynamicsofwindturbineprofiles;Reynoldsnumbereffect;cryogenicwindtunneltest
Nomenclature
alpha
Cd
Cl
Cm
CN
Cp
CT
cl/cd
Ma
Re
p
x
y
=
Angleofattack[]
=
dragcoefficient[]
=
liftcoefficient[]
=
pitchingmomentcoefficientreferredtothequarterofchard[]
=
normalcoefficient[]
=
pressurecoefficient[]
=
tangentialcoefficient[]
=
liftdragratio,aerodynamicefficiency[]
=
machnumber[]
=
Reynoldsnumber[]
=
pressure[Pa]
=
tunnelstaticpressure[Pa]
=
totalpressure[Pa]
=
dynamicpressure[Pa]
=
Temperature[K]
=xcoordinateofpressuretap
=ycoordinateofpressuretap
=Angleofattack[]
=standardderivation
st
pg
q
T
HeadofCryogenicWindtunnel,DNW,LinderHoehe,51147Cologne,Germany.
Projectmanager,CryogenicWindtunnel,DNW,LinderHoehe,51147Cologne,Germany.
1.Introduction
Theratedpowerofawindturbineisproportionaltothediametersquared,solargerandlargerwindturbinesare
builttoextractmoreenergyfromthewind.Theprofilesusedinthebladearespeciallydesignedtoimproveits
efficiency11.Withtheincreasingsize,theReynoldsnumberincreasesalso.A5MWwindturbinecanreacha
Reynoldsnumberof11x106and20MWcanreacheven25x106.TheeffectofReynoldsnumbershouldbetaken
intoaccountindesigntheprofiles.
There are many CFD programs available that can be used to predict the profile properties 5, 6. With these
programstheprofilecanbeoptimizedquickly.Theproblemisthatsomeproperties,suchaspoststallbehavior,
themaximumlift(Clmax)andtheminimumdrag(Cdmin)couldnotbedeterminedaccuratelyusingthestateof
artCFDprogram.ThesepropertiesdonotalwaysgetbetterwithhigherReynoldsnumbers.Forthinprofiles
Clmax increases, Cdmin decreasesandaerodynamicefficiencyincreasesathigherReynoldsnumber 8.Butfor
thickprofilesorprofileswiththicktrailingedgethetrendwillbeinversed 4,9,10,12.Thesepropertiescanonlybe
determinedaccuratelyinawindtunnelattherealReynoldsnumber.Onefacilitythatcandothesetestsisthe
CryogenicWindTunnelDNWKKK.Inthispaperthetestcapabilityofthistunnelisanalyzedandthensome
representativeresultsaresummarized.
2.TestFacility
2.1TheCryogenicWindTunnelCologneDNWKKK
TheCryogenicWindTunnelCologne(KKK)isaclosedcircuitlowspeedtunnel(Fig.1).Toachievehigh
Reynoldsnumbers,thegastemperatureinthetunnelcircuitcanbelowereddownto100Kbyinjectingliquid
nitrogen.TheReynoldsnumbercanbethusincreasedbyafactorof5.5whilethedrivepowerandMachnumber
remainconstant.Duetothepossibilityofindependentvariationofthegastemperatureandflowvelocity,the
influenceoftheMachnumberandReynoldsnumberontheaerodynamiccharacteristicscanbeinvestigated
separately13.
Fig.1TunnelcircuitofDNWKKK
Thetestsectionareaconsistsofthetestsectionitself,themodelaccesslockandthemodelconditioningroom.
Thetestsectionis2.4mx2.4m.Bothsidewallsofthetestsectionareequippedwitheightwindowsintworows.
Eachwindowenablesapplicationofflowvisualizationandopticalmeasurementtechniques.Theaccesslockand
themodelconditioningroomarelocatedunderneaththetestsection.Theyallowmodelchangesatambient
temperature while the tunnel is maintained at cryogenic temperature. In this way highproductivity can be
achieved.
Fig.2Setupfor2Dprofiletest
Fig.3Awindturbineprofilemodelofthefamily
DUWintheDNWKKK
Thewindtunnel'sdegreeofturbulence(Tu'=(u'2/U2))wasdeterminedusingheatedwirearrays.Dependent
onMachandReynoldsnumbers,itliesbetween0.04%und0.1%for0.1<Ma<0.3and100k<T<300K.
Forthe2DprofiletestthesetupasshowninFig.2canbeused 14.Themodelisspannedfromtunnelfloortothe
ceiling.Bothturntablesintheupperandlowertunnelwallsaresynchronizedtominimizethedeformationofthe
model,sothattheflowaroundthemodelistwodimensional.Inaddition,tangentialblowingthroughslotsonthe
turntablesinfrontoftheairfoilfurtherimprovesthetwodimensionalityoftheflow.
Fig.3showsawindturbineprofilemodeltestedinDNWKKK.Themodelismanufacturedfromaluminum
alloy.Itschordis0.5m,instrumentedwith62pressuretaps. Themodel ispaintedwithTSP todetect the
transition7.
2.2Estimationoftestuncertainty
Theliftandmomentaredeterminedfromthepressuredistributiononthemodel.Theliftcoefficientis
calculatedusingEq.1:
Cl CNcosCTsin
(1)
Thenormalandtangentialcoefficientsareintegralofpressurecoefficientsoverthemodelsurface:
N
CN 2 (Cpi Cpi1)dxi
i1
N
(p
2i
pi1)dxi
(2)
12 (pi pi1)dyi
q
(3)
i1
1
CT 12(Cpi Cpi1)dyi
i1
i1
Thepressurecoefficientsaredefinedas:
P P
pi
i stat
(4)
IfweassumethatthestandarddeviationsoftheNmodelpressuresareequal,thestandarddeviationofCNcanbe
estimatedas:
N
2
CN
C2
p2
dxi2
q2 i1 2
q
(C N q)
(5)
Similarly,thestandarddeviationofCT
N
CT
p2dyi2
i1
q
C2 q2
(Cq)2
T
CN
Sothestandardderivationofliftcoefficientcanbeestimatedas:
(6)
Cl
CN
(7)
CT
Similarly,thestandardderivationofmomentcoefficientcanbeestimatedusing
N
Cm
1 2
2
2
2
2
2
2
2(p pst q (Cp ,iCp ,i1)/2)(dxi dyi )
i1
(8)
0.0010
0.0009
0.0008
0.0007
0.0006
0.0005
0.0004
0.0003
0.0002
0.0001
0.0000
0.000310
0.000305
Sigma Cm
Sigma Cl
DNWKKKusesapressuremeasuringsystemthathasanaccuracyof10.3Pa.Toimprovetheaccuracy,128
valuesareaveraged.Sofortheevaluationthestandardderivationofmodelpressurereaches0.9Pa.Thedynamic
pressureiscalculatedfromthedifferencebetweenthetunneltotalpressureandthestaticpressureatthetest
section.Thestandardderivationofthedynamicpressureis1.8Pa.Theerrorofangleofattackisverysmall,
about 0.01.Tohaveafeelingoftheliftcoeffici entaccuracy,thestandardderivationofliftandmoment
coefficientofatypicalwindturbineprofiletestwasestimatedusingEq.7.TheresultsareillustratedinFig.The
maximalderivationofliftcoefficientisabout0.0009,i.e.0.09liftcount.Themaximalderivationofmoment
coefficientis0.0003.
0.000300
0.000295
0.000290
0.000285
0.000280
-5
10
15
20
-5
Alpha []
10
15
20
Alpha []
Fig.4EstimatedstandardderivationofliftandmomentcoefficientatMa=0.20
Thedragoftheprofileismeasuredusingawakerake.Toestimatethederivationofthedragcoefficient,we
usethesimplifieddragcalculationequation
Cd2 ( C Cg)dy(
g
g,i
Cg,i
C
g,i1
g,i1
)dy
Thestandardderivationofdragcoefficientcanbeestimatedas
cd2(
Cg2 ,i
4C
Cg2
,i
g,i
Cg2 ,i1
4C
Cg2 ,i1)dyi
(9)
(10)
g,i1
Becausethetubesinthewakerakeareusuallyequallyspaced,eq.9canbesimplifiedas:
2
cd2( Cg ,i 2Cg2 ,i)y2
2C
(11)
g,i
Thestandardderivationofpressurecoefficientcanbeestimatedusing:
Cg,i
1 (2 2 C22)
q2 p
pst
g,iq
(12)
Fortheattachedflow,14tubesoftherakearetypicallylocatedinthewakedepressionarea.Thestandard
derivationofdragcoefficientisusuallyunder0.00005,i.e.,0.5dragcount.Toimprovetheaccuracyfurther,the
wakedepressioncanberecordedtwice.Inthesecondmeasurementtherakeisdisplacedabouty/2inthe
directionperpendiculartothemodelcord.Thestandardderivationcanthusbereducedto0.35dragcount.
2.3Testqualityfor2Dprofile
Thewakerakeismountedonatraversemechanism;itisthereforepossibletoassesstheoveralltestqualityby
meansofscanningthewakeinthespandirection.Fig.5showsthemeasureddragasafunctionofrakeposition
in span direction. The zero position is defined at the middle of the model. The data were taken at three
temperatures:290K,250Kand230K.TheMachnumberandtheangleofattackwerethesameforthe3cases.It
iscleartoseethatthe3curveshavetheidenticalcharacteristic:inthemidsection(Rz=0)wherethepressuretaps
arelocatedthefluctuationindragislarge;intheregion350mmupthemiddlelinethesecondfluctuationoccurs;
andthethirdfluctuationappearsintheregion700mmupthemiddleline.Thelattertwoarecausedbysome
imperfectionsinthemodel.Themodeliscomposedof4parts,andtheyareassembledtogetherusingscrews.In
thesetworegionsthescrewtopsarenotfittedperfectlywiththecontour.Vortexwasgeneratedinthewake.
Outsidethesedisturbedregionsthedragvalueisverystable.Thefluctuationofdraginthis900mmspansection
issmallerthan0.5dragcount.Thisproofsthattheflowaroundthemodelistwodimensional.Fortheproductive
testtherakeisplacedinthestableregion.
0.0105
0.0100
0.0095
0.0090
Cd
0.0085
0.0080
0.0075
T=290K Ma=0.2 Re=1.40E6 Alpha=3
0.0070
0.0065
0.0060
-200
200
400
600
800
Rz [mm]
Fig.5Traverseofthewakeinthespandirection
2.3Setupfortransitiondetection
Thedetectionoftransitionisimportantbothforthetunneloperatorandprofiledesigner.Itallowsthetunnel
operatorstomakesurethatthetunnelisfreeofdustsandhastheprescribeddegreeofturbulence.Themodel
surfacehastherequiredquality.FortheprofiledesignerthepositionoftransitionisrequiredformanyCFD
programs.Thetransitionlocationdeterminestoagreatextenttheprofiledrag.Asaruleofthumbthedragis
reducedby10%whenthetransitionpointmoves10%tothetrailingedge 2.Becauseturbulentboundarylayeris
lesssusceptibletodusts,ice,insectsetc,itisalsoveryimporttoknowthetransitionpositionforthedesignofa
robustprofile.
ThetransitiondetectionmethodsusedinDNWKKKarebasedontheReynoldsanalogy,inwhichthereexistsa
linearrelationshipbetweentheheatconvectivecoefficientandsurfaceshearstresscoefficient.Thesurfaceshear
stressinaturbulentboundarylayerisofanorderofmagnitudegreaterthanthatinthelaminarboundarylayer.If
thereisatemperaturedifferencebetweentheflowandthemodel,theturbulentboundarylayerreachestheflow
temperaturemorequicklythanthelaminarboundarylayer.Atasuitabletimethetemperaturedifferenceinthe
twoboundarylayerscanbeobserved.Internalheatconductioninthemodeltendstoreducethistemperaturestep.
Aninsulationcoatof80misthusneededforthemodelmadeofaluminiumalloy.
Weusethreemethodstointroduceatemperaturedifferencebetweentheflowandthemodelactively:
Heatingthemodel.Heatingfoilsorstabscanbeintegratedintothemodel.Themodelshouldbemade
ofheatconductivematerial.Itshouldbeconsideredduringthemodeldesignphase.Lateradaptionis
difficult.Anotherwayofheatingmodelistouseinfraredheatlamp.
Coolingthetunnel.AfterupgradeoftheliquidnitrogensystemofDNWKKKitisnowpossibletocool
downthetunnelquicklytogetrequiredtemperaturestep.
Heatingupthetunnel.ItworkswellforMa>0.25.Duetothegoodinsulationofthetunnelwalls,the
tunneltemperaturerisesathighMachnumberiftheliquidnitrogensystemisturnedoff.
ThetemperatureonthemodelsurfacecanbescannedusinginfraredthermographorTSP.
Infraredthermographcanbeusedintherangefromambienttemperaturetoabout230K.Atlowertemperature
theradiationistooweaktobedetected.TheinfraredcamerausedinDNWKKKiscooledwithliquidnitrogen.
Ithas256x207pixels.ThethermalsensitivityNETDis50mK.Thecameraisplacedinfrontofagermanium
glasswindow,whichistransparentintheinfraredspectrum.Thincopperleafsareadheredonthemodelsurface
asmarkerstoidentifythelocationofthetransition.Morethan8imagesareaveragedtogetonehighquality
image.
Todetecttransitionatcryogenicconditionstemperaturesensitivepaint(TSP)developedbyDLR 3canbeused.
TSPisathinpaintlayercontainingluminescentmaterial(luminophore)withinabinder.Whentheluminophore
isexcitedbyalightsource,itemitslightatlongerwavelengths.Theradiationintensityistemperaturedependent
andthisphenomenonisknownastemperaturequenching.InthecaseofcryogenicTSP,aRutheniumcomplexis
usedasluminophore.Itexhibitshightemperaturesensitivityintherangeof100Kto230K.Theluminescent
intensitydecreaseswithanincreaseintemperature.Thewavelengthrangesofexcitationandemissionofthe
luminophoreare425<exc<525nmand580<em<680nm,respectively.
InDNWKKKablueLEDlampisusedasexcitationlightsource.AcooledblackwhiteOMT1024YCCD
camerawith1280x1024pixelsand12bitdynamicrangeisusedtoacquireimages.Aninterferencefilteris
mounteddirectinfrontoftheCCDchips,selectingthewavelengthof580<<680nm.
Foreachtestpoint10imagesaretakenunderstablecondition.Theaverageofthemisdefinedasreference
image.Thenatemperaturestepisstarted.Aseriesofimagesistakentocapturethetemperaturedifferenceon
themodelsurface.Theaverageoftheimagesisrationedtothereferenceimage.Theinformationconcerningthe
absolutetemperaturedistributionisnotcalculated,sincetheprimaryinterestisthelocationofthetransition.
AtwocomponentTSPwasdevelopedbyDLRinrecentyears 3.Itallowsthetransitiontobedetectedoverthe
whole temperature range, from 100k to ambient temperature. In the warm range, from 240k to ambient
temperature,UVlightisusedasexcitation.Inthecryogenicrange,from100Kto240K,thebluelightisusedas
excitation.
3.RepresentativeResults
3.1Reynoldsnumbereffectofcleanprofile
For the clean thin profile the Reynolds number effect is typical, just like the description in the classical
literature8.AsshowninFig.6and7,withincreasedReynoldsnumber,Clmaxincreases,liftcurveismorelinear,
itsslopegoesupslightly,Cdmindecreasesandthelaminarbucketbecomessmaller.
Sometimesdesignerswanttoknowthebehaviorofprofilesunderbackwind.A360polarwastakenas
showninFig.8.Becausetheprofileisnotsymmetrical,itproducesliftevenwhenitstandsperpendiculartothe
wind.From90to180itproducesdownwardsforce.From180to270itproducesupwardsforce.
Cl
Cl
Cd
Alpha
Fig.6Reynoldsnumbereffectonliftforcleanprofile
Fig.7Reynoldsnumbereffectondragforcleanprofile
Cl
-50
50
100
150
200
250
300
350
400
Alpha []
Fig.8Performanceof2Dprofileattheangleofattachrangefrom10to350
3.2Reynoldsnumbereffectofcontaminatedprofile
Tosimulatethecontaminatedprofilesurfacethroughice,impactedinsects,dustsanderosion,carborundum60
(solidgrainsof0.25mmdiameter)isstickedonthebothsidesaroundtheleadingedge.Thiscausesthetransition
oftheboundarylayeroccursattheleadingedge,andisalmostindependentofReynoldsnumber.Asexpected
thedragincreasesdramaticallycomparedtothecleanprofile.ThestallarisesalsoearlierandClmaxissmaller.
Fig.9showstheReynoldsnumbereffectontheliftcoefficient.WithincreasedReynoldsnumberstheboundary
layerbecomesthinner,butmorepowerful.Theimpactofcarborundumthusdecreases.Thestalloccursathigher
angleofattack,soClmaxincreases.Intheregionofattachedflowtheliftincreasesalsonoticeably.Thiseffect
canbeseeninFig.10.Itillustratestwopressuredistributionsatthesameangleofattack,butunderdifferent
Reynoldsnumbers.
Cp
Cl
0.0
0.2
0.4
0.6
0.8 X/L
1.0
Fig.10Theeffectofcarborundum60onthepressure
distributionattwoReynoldsnumbers
Alpha []
Fig.9Theeffectofcarborundum60ontheliftcurve
atvariousReynoldsnumbers
3.3Reynoldsnumbereffectofflowcontroldevices
TheGurneyflapisanLshapedmetalstripattachedtothelowersurfaceofthetrailingedge.Itincreasesthe
maximum lift coefficient (Clmax), decreases the angle of attack for zero lift, and increases the nosedown
pitchingmoment(Cm).Italsotypicallyincreasesthedragcoefficient(Cd).Anetbenefitinoveralllifttodrag
ratioispossibleiftheflapissizedappropriatelybasedontheboundarylayerthickness.
Fig.11and12showtheeffectofaGurneyflapattwoReynoldsnumbers.ItisclearthattheselectedGurney
flapsuitableforthelowReynoldsnumberisnotoptimalforthehighReynoldsnumber.
25
0.60
20
0.40
10
0.30
0.20
0
-5
0.10
-10
0.00
-0.10
15
d(Cl/Cd)
dCl
0.50
-15
-5
10
-20
-0.5
15
0.0
0.5
Cl
Alfa
Fig.11TheeffectofGurneyflaponthechangeoflift
referredtothecleanprofileattwoReynoldsnumbers
1.0
1.5
2.0
Fig.12TheeffectofGurneyflaponthechangeoflift
dragratioreferredtothecleanprofileattwoReynolds
numbers
Avortexgeneratorisacomplementarypairofsmalllowaspectratioairfoils.Generallymountedatopposite
angles of attack to each other and perpendicular to the aerodynamic surface they serve. Vortex generators
developliftandproduceverystrongtipvortices.Thevortexdrawsenergeticairfromoutsideintoboundarylayer
andthusdelaysflowseparationandstall.
Fig.13and14showtheeffectofvortexgeneratorsattwoReynoldsnumbers.Thevortexgeneratorswere
optimizedatambienttemperature.TheyimproveClmaxandliftdragratio.ButatthehighReynoldsnumberthe
liftdragratiodecreasesandtheincreaseinClmaxissmaller.
0.40
30
0.30
15
d(Cl/Cd)
dCl
20
0.20
0.10
10
5
0.00
0
-5
-0.10
-0.20
25
-10
-5
5
Alpha []
10
15
-15
-0.5
0.0
0.5
Cl
1.0
1.5
2.0
Fig.13Theeffectofvortexonthechangeoflift
referredtothecleanprofileattwoReynoldsnumbers
Fig.14Theeffectofvortexonthechangeofliftdrag
ratioreferredtothecleanprofileattwoReynolds
numbers
Thetwoexamplesaboveindicatethattheflowcontrol devicesshouldbeoptimizedat thesameReynolds
numberatwhichtheyaretobeused.
3.4Reeffectofthickprofile
Fortheinnerpartofthebladetheprofilehasalargevalueofthicknesstoguaranteetheneededstructural
strengthandstiffness.Oftenithasathicktrailingedge.TheReynoldseffectofsuchprofileiscontrarytothatof
thinprofiles(Fig.16and17).TheClmaxdecreaseswithReynoldsnumberandthedragincreases.
1.5
1.5
1.0
Re=2.04E6 T=180K
Re=2.04E6 T=180K
Re=4.95E6 T=111K
1.0
0.5
Cl
Cl
0.5
Re=4.95E6 T=111K
0.0
0.0
-0.5
-0.5
-1.0
-30
-20
-10
0
Alpha []
10
20
30
Fig.15Reynoldsnumbereffectonliftforthickprofile
-1.0
0.00
0.05
0.10
0.15
0.20
Cd
0.30
0.35
Fig.16Reynoldsnumbereffectondragforthick
profile
0.25
0.40
3.5ReEffectonthetransitionposition
Fig. 17 shows the transition line detected using infrared thermograph. The laminar boundary layer length
changesfrom53%to9%whentheangleofattacksweptfrom8to16.
Fig.17TransitiondetectioninfraredthermographbyT=230K,Ma=0.30
Fig.18showsthetransitionlinedetectedusingTSP.Thelaminarboundarylayerlengthchangesfrom37%to
23%whentheangleofattacksweptfrom0to12.
0,37%4,32%8,28%10,26%12,23%Fig.18TransitiondetectionusingTSPby
T=245K,Ma=0.25
4.SummaryandOutlook
Toguaranteetheperformanceofalargewindturbine,theprofilesusedinthebladeshouldetestedatthereal
Reynoldsnumbers.ThecryogenicwindtunnelDNWKKKisasuitablefacilitytodosuchtests.Ithasthe
requiredmeasuringaccuracyandflowquality.
Noisebecomesanimportantfactorindesignawindturbine.Itcanbereducedthroughoptimizedprofileshape
andtrailingedgeserrations.BecausethisnoiseisReynoldsnumberdependent,amicrophonearray 1 thatcan
workfromambienttocryogenicconditionswasdevelopedforDNWKKK.ApretestasshowninFig.19has
alreadyfinished.Thedataprocessingisinongoing.Themicrophonearrayismountedonthesidewall.Ithas
144microphones.
Fig.19Aeroacoustictestofawindturbineprofile
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10