Small wind turbine

for grid-connected and

stand-alone operation
Fig. 1 䊳 Grid-connected and stand-alone
operation possible

䊳 Adapted for extreme climate zones

䊳 Objective of achieving a series price

of approximately 1,000 euros/kW
(without tower)

Prototype with 5 kW rated output

A
bout two billion people do not yet have a sufficient electricity In a research project sponsored by the German Federal Ministry for
supply. While this applies to many rural areas in developing the Environment, a small wind turbine has been developed, with a
countries, up to two million people in Europe live far from rated output of 5 kW, which can be implemented in stand-alone op-
supply lines, mostly on small islands, or in inaccessible mountain eration, as well as parallel to the grid. A lightweight structure, high
regions. Here, electrification often begins with individual, decentralised availability, long maintenance intervals, and optimised energy yield
stand-alone systems which depend on diesel generators. While earlier should keep the operating costs low and also enable implementation
attempts to realise a basic supply involved many small systems which in remote grids, even with unfavourable climate conditions. The
were only extendible to a limited degree, ever more stand-alone AC grids developers are aiming to achieve a series price of around €1,000/kW
with new possibilities are now being designed. Electricity generated (without tower), i.e. a sum similar to those typical of large systems
in a decentralised manner from diesel generators, photovoltaics, today. To this end, all components of the wind turbine have been
hydropower and also from wind energy, is fed into the grid at arbitrary tested for possible savings and improvements. Primarily, optimisa-
locations. The stand-alone grids can be expanded and interconnected tion possibilities are being researched for the rotor blades and the
according to demand and available finances. In recent years, intensive generator, as these are components which are often disproportion-
research has been conducted for the development of modular system ately expensive for small systems.
technology and its components, for hybrid systems such as these.
䊳 Supply and demand Project objectives
It should also be possible to implement the wind
turbine in locations with extreme climatic conditions.
It is relatively easy to identify countries account, but also the extent to which these
Thus, requirements have been defined, which go
which have an insufficient electricity sup- countries already have structures available beyond the specifications of the international
ply. However, the locations where wind- for the marketing of small wind power series of standards IEC 61400:
based decentralised energy systems have systems, and for implementation of decen- ■ Maximum survival wind speed of 65 m/s
actual market potential are determined by tralised energy supply projects.
■ Low noise emissions due to low rotor speeds
numerous factors, such as infrastructure, Many small wind turbines are available in
■ High protection degree for the housing
climate, financing, etc. The worldwide the output range of a few kilowatts, and are
against moisture and dust (IP65)
possibilities for decentralised electricity mostly manufactured in small numbers.
■ Operating temperature of -25 °C to 50 °C
supply with small autonomous systems The size-specific prices of these small
■ Suitable for different grid voltages:
have been investigated in a comprehensive systems are in some cases double, or even
400 V / 3-phase and 240 V / single-phase
market analysis. The central objective was triple, those of today's large wind power
■ Can be implemented for 50 Hz and 60 Hz
to determine which countries are suitable systems. In many cases, their electrical
■ Can be installed with human power
for implementation of the planned 5 kW equipment is not intended for direct
and few technical aids
wind turbine. It was determined that at connection to modern hybrid systems for
■ High technical and personal safety
present, the greatest market potential is in decentralised supply.
■ Easy to operate without special knowledge
the USA, India, Australia, Great Britain and
China. In this analysis, not only the popu-
■ Highly robust and reliable
lation situation, the gross domestic product, ■ Long service life and long maintenance cycles
and the wind conditions were taken into

䊳 System design: less is more

Achieving maximum reliability with mini- Fig. 2: The prototype's nacelle Well adapted – the generator
mum maintenance requirements is a partic- without housing The rotor is coupled to an asynchronous gen-
ular challenge. To this end, fault-susceptible erator by means of a single-level spur gear
mechanical functional units in the wind tur- unit. The pole-switchable generator is
bine are being reduced, or replaced with switched between two rotational speeds, ac-
electrical components. Being a self-tracking cording to the present amount of power be-
downwind machine, the system does away ing fed. On the first level, the rated output is
with active control elements for wind track- 1.5 kW, and it is 5.5 kW on the second level.
ing. With a special rotor concept, it is also On the high rotational speed level, the gen-
possible to do away with a controller which erator achieves high partial load and max-
turns the rotor out of the wind in extreme imum efficiencies of up to around 90% with
wind conditions. All system components must a power output of 3 kW (fig. 4). Also at the
have long-term protection against sand and low rotational speed, the maximum effi-
dust penetration, and against corrosion ciency is 84% with a power output of about
caused by damp air with high salt content. 1 kW. The high efficiencies when outputs are
Also, the nacelle weight should allow trans- low suit the design of a wind power system
port and installation of the system with sim- direction of impact. Thus, in extreme winds very well, as such systems' largest contribu-
ple equipment. The structure and manufac- of 65 m/s, the rotor radius decreases to tions to the energy yield result from medium
ture of all components have been examined 67%. At the same time, the bending reduces wind speeds. Somewhat lower efficiencies
for possible savings and simplifications the drag coefficient. In extreme wind con- at rated output cause a comparatively slight
with optimised efficiency. This applies espe- ditions, the combination of these two reduction of the overall energy yield.
cially to the rotor blades and generators, effects halves the wind stress on the entire The developers have gone to great lengths
as these are often disproportionately expen- system in comparison to systems with rigid to reduce the air gap between rotor and sta-
sive in small systems. blades. This allows savings on material for tor. This has a decisive influence on the gen-
the load transfer components, such as rotor erator's power factor, and thus on the gen-
Those who are cleverer give in – shaft, machine housing, vertical bearing, erator's reactive power, which must be
the rotor tower, guys and foundation, thus reducing provided by other components in the grid.
The turbine’s three rotor blades are manu- the system's manufacturing costs consider- The technically realisable reduction of the
factured economically from extruded glass ably. air gap to just 0.25 mm improved the power
fibre reinforced plastic (GRP) sections (fig. 3). factor in the partial load range by 10%.
This material has good fatigue properties, Fig. 3: Rotor blade in a wind tunnel
Simultaneously, the efficiency in the partial
high resistance to abrasion, and excellent load range also increased by about 10%.
UV-resistance. The blade sections are designed
so that the power output at high wind Flexible – the operational
speeds is limited by the stall effect. Despite management
a simple blade design, with constant depth This wind turbine is designed for different
and no twist, the rotor achieves high effi- electrical grid conditions. It can be operated
ciency (cp = 0.43). parallel to the grid, and also in a stand-alone
The wind turbine survives wind speeds of grid, in conjunction with a battery inverter.
up to 65 m/s. This equates to very heavy As well as the model with a 3-phase generator
weather conditions, far beyond hurricane (400 V / 50 Hz), a version with a single-
wind speeds. This is achieved due to the phase generator (240 V / 60 Hz) is envis-
rotor blades' low bending stiffness in the aged for operation in the USA. The opera-
2 BINE projektinfo 02/07
 Fig. 4: Efficiency of the generator at which the measurement data can be collected Fig. 5: Technical data
high rotational speed, with and/or parameters can be set. Remote mon- Generator: Asynchronous generator,
different rated voltages
itoring is possible via a telephone line or pole-switchable
100 GSM modem. Rated output
In addition, for incorporation into the (4-pole / 6-pole): 5.5 kW / 1.5 kW
Efficiency [%]

80
hybrid system, an adjustable load has been Frequency: 50 Hz (60 Hz)
60 Cut in wind speed;
developed, with which excess energy in a
rated wind speed: 3.5 m/s; 13.0 m/s
40 90 % rated voltage stand-alone grid can be discharged system-
Rated voltage (400 V) Operating temperature
20 110 % rated voltage atically. range: -25 °C to 50 °C
The operational management unit has the Rotor: 3 blades, free-yaw down
0 wind machine, passive stall
0 2,000 4,000 6,000 8,000 task of detecting all of the system's operat-
Electrical output [W] ing states, and initiating appropriate reac- Rotor diameter; weight: 5.1 m; 31 kg
tions. A chain of sensors monitor opera- Nominal rotational speed: 133/200 rpm
tional management unit is accommodated in tions to ensure that system operation is Mast, guyed: Lattice mast, tubular mast
a separate stainless steel housing with pro- secure. This safety chain comprises an over- Nacelle weight without rotor: 110 kg
tection degree IP65, and is fastened to the speed switch, a vibration sensor, and a tem-
tower below. It has a data interface, via perature sensor.

䊳 Connected to the grid, and autonomous – prototypes put to the test

Fig. 6: Prototype on the test stand stance, the start-up behaviour, automatic speeds and high turbulence on average, in
connection to (and disconnection from) the comparison to the coast.
grid, and switching between the generator The hybrid system (fig. 8), with a 2.6 kW pho-
levels were examined. The alignment of the tovoltaic system as well as the wind turbine,
nacelle in relation to the wind direction was is operated autonomously, without grid con-
also analysed. If the nacelle were to oscillate nection. A diesel generator serves as backup.
significantly, and if it were often aslant to If a large amount of electricity is being fed in
the wind, it would not be possible to utilise by the photovoltaic system and the wind pow-
a portion of the potentially available energy, er system when the battery is already charged,
The first two prototypes were initially tested and the tower could be caused to sway in an a thermal resistor can increase the consumer
on a test stand at the University of Kassel (fig. 6). undesired manner. The measurements showed power significantly. The core of the experi-
Here, the dynamics of the wind were simulat- good, stable yawing. mental hybrid system is composed of three
ed by a motor which was flanged to the gener- Based on the measurements, it was possible battery inverters (4.5 kW), which form the
ator. It was primarily the examination of volt- to significantly improve the system concept grid and monitor it in conjunction with the
ages and currents upon connection of the and the components. For instance, the analy- battery bank (60 V, 30 kWh). All other com-
generator to the stand-alone grid via the new- sis of two different rotor blade incidence an- ponents connected to the grid (3 PV con-
ly developed operational management unit gles shows how sensitively the power out- verters with 850 W each, 9 kW diesel gen-
which yielded many findings, which it was put reacts to the incidence angle (fig. 7). For erator) also feed into the stand-alone grid,
possible to incorporate into the first versions of optimisation of the first blade sections, in addition to the wind turbine.
the operational management unit. which were developed with the aid of com- The primary subject of investigation is the
puters, the intended incidence angle had to interaction between the prototype and the
Connected to the grid be corrected by just 1° in order to optimise battery inverters. Voltages, currents, and the
A prototype, optimised on the test stand, was the power output. frequency are observed in the various operat-
installed in Spring 2004, at the Windtest ing states and in particular during connection
Kaiser-Wilhelm-Koog GmbH test field. This – and autonomous to the grid, and upon switching between the
system is connected parallel to the grid, and The second prototype is being tested while two generator levels. The wind turbine itself
has been in fully automatic operation since operating with an autonomous hybrid sys- is also examined, including, for instance, the
late summer 2004. After it confirmed its gen- tem. The test field 'Alte Schanze' near Kassel, effects of the tower's shadow on the rotor
eral suitability, and achieved the envisaged Germany, is about 400 m above sea level. The torque and output, stimulation of tower oscil-
rated output at high wind speeds, compre- terrain and vegetation provide typical inland lation and blade oscillation, or the effectiveness
hensive optimisation work began. For in- wind conditions, with relatively low wind of the stall effect for limitation of output.

Fig. 7: Block circuit diagram of the experimental hybrid system Fig. 8: Measured output with 5° and 7° rotor blade incidence angles

7° Pitch 5° Pitch
Meteorological measurement mast Superordinate operational management, data acquisition 7
400 V / 50 Hz energy bus
6
Measurement of 5
energy and output
Information bus 4
kW

3
2

Operational
1
management ASM ASM
unit 0
-1
0 2 4 6 8 10 12 14 16 18 20
Battery with Wind PV generator Diese Grid Loads
grid-forming inverters generator with inverters generator connection
m/s

BINE projektinfo 02/07 3

䊳 Outlook PROJECT ORGANISATION

■ Project Funding
Federal Ministry for the Environment,
The results from the test fields 'Kaiser-Wilhelm-Koog' and 'Alte Schanze' are so encour- Nature Conservation and Nuclear Safety (BMU)
aging, that a pre-production series is to be tested in real operating conditions. At present, D-11055 Berlin
ten systems from the pre-production series are being installed at worldwide locations
which offer extreme weather conditions: high wind speeds, extreme temperature Project Management Organisation Jülich
Jochen Viehweg
differences, moisture, dust, and air with salt content. D-52425 Jülich
For the ten systems, the following locations were selected from a large number of
candidate sites after intensive testing: ■ Project Number
■ Greece, Mount Athos (operation in a stand-alone grid) 0329908A, 0329908B
■ Madagascar, Sahasifotra (operation in a stand-alone grid)
■ France, La Baume de Transit (grid-parallel operation)
■ Ireland, Cape Clear (grid-parallel operation)
■ Germany, Großschirma, Ore Mountains (operation in a stand-alone grid)
■ Germany, Göttingen (operation in a stand-alone grid) IMPRINT
■ Spain, Tenerife (grid-parallel operation)
■ ISSN
At present, it is envisaged that the test operation shall last approximately one year. 0937 – 8367
The experience gathered at these sites will be incorporated into the final system design.
■ Publisher
Under the name 'aeroSmart5', the first series-produced systems should be delivered FIZ Karlsruhe
in mid-2008. D-76344 Eggenstein-Leopoldshafen
The wind turbine's rated output is suited to the typical low power levels of generators
■ Reprint
and consumers in decentralised supply systems. If consumer power levels are somewhat Reproduction of this text is permitted provided
higher, the modular philosophy of the hybrid system enables easy integration of several the source is quoted and a complimentary copy
wind power systems in parallel. In such situations, a 10 kW wind power system would is provided to the publisher; reproduction of
the images contained in this newsletter requires
probably be considerably more economical than two 5 kW systems. Therefore, the prior approval of the copyright owner.
possibilities are to be investigated for development of a 10 kW variant, on the basis
■ Editor
of the wind turbine which is currently being tested.
Dr. Franz Meyer

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PROJECT ADDRESSES ADDITIONAL INFORMATION
▼

FIZ Karlsruhe, which is promoted

▼

by the Federal Ministry of Economics

Project management, operational Literature and Technology (BMWi).
management, electrical components, • Geipel, R.; Hahn, B.; Landau, M. u.a.:
system integration Kleine Windkraftanlage für modulare
• SMA Technologie AG Hybridsysteme. - Entwicklung und Prototy-
Hannoversche Straße 1-5 pentest -. Kasseler Symposium Energie-
D-34266 Niestetal Germany Systemtechnik 2004. Kassel, 11.-12. Nov.
2004. Institut für Solare Energieversor-
Market analysis gungstechnik (ISET) Verein an der Univer-
• microwind GmbH sität Gesamthochschule Kassel e.V., Kassel
Bonnstraße 18, D-50321 Brühl (Hrsg.). 2004. 22 S.
Internet
Mechanical construction
• aerodyn Energiesysteme GmbH • [Link]
Provianthausstraße 9 Service
D-24768 Rendsburg • Additional information such as literature,
addresses and internet links are available
KERSTIN CONRADI · Mediengestaltung, Hennef

Generator online from BINE at [Link]

• Universität Kassel, Institut für Elek- (Service/InfoPlus) in German. FIZ Karlsruhe GmbH, Büro Bonn
trische Energietechnik Elektrische
Images Kaiserstraße 185 – 197
Energie-Versorgungs-Systeme
Wilhelmshöher Allee 71 • Figures 1, 4, 7: ISET e. V. D-53113 Bonn
D-34109 Kassel (IEE-EVS) • Figures 2: SMA AG Tel.: +49 228 92379-0
• Figures 3, 6, 8: aerodyn GmbH Fax: +49 228 92379-29
Measurement and analysis
• Institut für Solare bine@[Link]
Energieversorgungstechnik (ISET) e. V.
[Link]
Königstor 59, D-34119 Kassel

4 BINE projektinfo 02/07