On the influence of airfoil deviations on the aerodynamic performance of wind turbine rotors

The manufacture of large wind turbine rotor blades is a difficult task that still involves a certain degree of manual labor. Due to the complexity, airfoil deviations between the design airfoils and the manufactured blade are certain to arise. Presently, the understanding of the impact of manufacturing uncertainties on the aerodynamic performance is still incomplete. The present work analyzes the influence of a series of airfoil deviations likely to occur during manufacturing by means of Computational Fluid Dynamics and the aeroelastic code FAST. The average power production of the NREL 5MW wind turbine is used to evaluate the different airfoil deviations. Analyzed deviations include: Mold tilt towards the leading and trailing edge, thick bond lines, thick bond lines with cantilever correction, backward facing steps and airfoil waviness. The most severe influences are observed for mold tilt towards the leading and thick bond lines. By applying the cantilever correction, the influence of thick bond lines is almost compensated. Airfoil waviness is very dependent on amplitude height and the location along the surface of the airfoil. Increased influence is observed for backward facing steps, once they are high enough to trigger boundary layer transition close to the leading edge. (paper)