RENEWABLES
EOS
TURBOWIND
Design and industrialisation
of an innovative wind turbine
CLIENT
Developer of wind energy solutions, focused on compact vertical-axis systems
CHALLENGE
Take an innovative turbine from initial design through prototype and testing to industrialisation and certification
RESULT
10% lighter rotating parts, 30% better aerodynamic performance, 50% less structural vibration
01
CHALLENGE
Developing a vertical-axis wind turbine brings several design difficulties together at once: variable and cyclic aerodynamic loads, the interaction between different rotor types, vibration and resonance, and the need to optimise weight, cost and performance simultaneously rather than one at a time.
Then the step from prototype to industrial product demands careful integration of design, experimental testing and regulatory constraints — three things that usually pull in different directions.
The client needed complete engineering support to reduce the risk and accelerate the development of the product.
02
SOLUTION
We worked across every phase of the turbine’s development rather than a slice of it.
First the performance requirements were defined and numerical models developed to compute the loads on the blades and the structural components, which is what allows the system to be sized correctly rather than conservatively.
Then the optimal configuration was designed — material selection, CAD model, and support for the dialogue with the suppliers who would build the prototype.
Once built, the prototype went through a campaign of wind tunnel tests, with post-processing tools written alongside to analyse the data and evaluate performance. The design was then optimised through targeted iterations aimed at aerodynamic efficiency, lower vibration and compatibility with industrial production.
Finally we studied the applicable standards in depth, with the safety analysis and the design modifications needed for certification.
03
RESULTS
The work improved both the performance and the reliability of the turbine. The weight of the rotating elements came down by 10%, improving the dynamics of the system, while aerodynamic optimisation of the rotor raised the power generated by 30%.
Structural vibration was reduced by 50%, which lengthens the life of the machine and makes it safer.
The project also left the client with something that outlasts the turbine: calculation models and test procedures of their own for controlling performance, which is what made the move from prototype to industrialisation manageable.
