**Foreword:**
At the 13th World Wind Energy Conference held from April 7 to 9, senior experts provided valuable insights that helped refine the design of the device prototype. This article is a revised and updated version of the presentation delivered at the conference, incorporating the latest improvements and feedback.
**Expected Economic Benefits:**
The total investment in wind power generation is expected to increase by 3%. The blades can be deformed within the wind farm, allowing for a 20% increase in wind power output. The return on investment is projected to be completed within one year, and the after-tax profit from the deformed device is double the cost of implementation.
**1. Project Background**
In recent years, various innovative blade designs have emerged to improve wind energy utilization. These include folding blades (with different patent applications from Guodian United Power Co., Ltd. and Tsinghua University), vertical stretching blades (which expand at low and medium wind speeds and contract at high wind speeds), and transverse telescopic blades (designed with central lateral expansion). Huarui Wind Power has patented blade root expansion and contraction technology, while Xi’an Jiaotong University holds a patent for transverse telescoping blades.
**2. Technical Advancements of the Project**
The patented horizontal-axis wind turbine deformation blade (referred to as a “deformation bladeâ€) is a large or medium-sized blade consisting of a main blade and a secondary blade. These two components can move relative to each other, changing the overall surface area of the blade. The secondary blades are connected via ropes that pass through fixed pulleys, allowing them to slide along the main blade. They may also consist of thin plate collars surrounding the main blade’s body section, with deicing snow blades on either side of the front edge.
Compared to existing folding or telescoping blades, this deformation blade offers six key advantages:
1. At low and medium wind speeds, the increased tip area significantly enhances the wind energy utilization coefficient.
2. The additional costs and risks are minimal, as the system requires only minor modifications without affecting critical areas.
3. It enables rapid on-site deformation of old blades in large and medium-sized wind farms.
4. The safety factor remains nearly the same as the original blade, preserving the core benefits of current horizontal-axis turbines.
5. In winter, it effectively removes snow and ice from the blade’s front edge, reducing wind resistance.
6. It can increase annual wind power output by approximately 20%, making it a promising innovation in renewable energy. The technology has passed national inspections and holds a utility model patent in China, with multinational patents pending.
**3. First Prototype Design**
The CAD model, manufacturing process, and installation design of the deformation device (for an 80-meter diameter, 1500 kW rated wind speed of 13 m/s horizontal-axis wind turbine blade) have been largely completed. The prototype is expected to be finished within three months, followed by testing and field trials. The deformation device consists of five key components:
1. Blade pairs
2. Blade lifting drive systems
3. Blade positioning and limit systems
4. Ice and snow removal systems
5. Electrical control systems
**3.1 Secondary Blades**
These are thin steel plate rings that surround a section of the main blade, measuring about 8 meters in length and expanding to a maximum width of 3.15 meters when deployed. They add 10.8 square meters of windward area at the blade tip and are made of 0.6 mm thick stainless steel. They can be divided into 8 sections and are connected using riveted joints.
**3.2 Blade Lifting Drive System**
This system includes a winch, steel cables, and fixed pulley devices. The winch frame is bolted to the root of the main blade. The steel cable combines 11 mm and 6 mm wires, and the pulleys are positioned near the tip of the main blade to minimize aerodynamic impact. The cables are mounted along the leading edge of the blade, and the pull-back cable is routed along the winch frame to reduce torque.
**3.3 Blade Limit and Positioning System**
This system ensures the stability of the secondary blades during deployment and retraction. It includes slide rails, limit plates, positioning plates, and radial lock cards. These components work together to prevent unwanted movement and maintain the blade’s shape and alignment.
**3.4 Deicing and Snow Removal System**
A blade-mounted knife removes most of the ice and snow along the leading and trailing edges of the blade. A slow-moving motor in the blade root helps prevent ice buildup in the gaps between the cable and its sleeve, ensuring smooth operation.
**3.5 Electrical Control System**
The system automatically controls the winch, lock card, and slow-moving motor. Temperature sensors trigger the slow-moving motor when temperatures drop below zero. Centrifugal switches and time relays manage the operation based on wind speed, ensuring optimal performance and energy efficiency.
**3.6 Additional Features**
- Lightning protection is integrated into the system, with the secondary blade safely grounding through the steel wire.
- Battery options are available, depending on the setup.
- A total of 200 M6 screws and 16 M16 bolts are used, with minimal impact on the blade’s structural integrity due to careful installation techniques.
- The total weight of the deformation device is around 510 kg, which is less than 9% of the main blade’s weight, ensuring no significant reduction in safety margins.
**4. Project Benefits**
**4.1 Manufacturer Benefits**
For a 1.5 MW three-blade deformation device, the total manufacturing and on-site installation cost is about 200,000 yuan. The selling price is 300,000 yuan, yielding a post-tax profit of 90,000 yuan per unit. This translates to a profit of about 60,000 yuan per megawatt.
**4.2 Power Generation Enterprise Benefits**
The prototype increases the windward area by about 11 square meters near the blade tip, doubling the effective area of that section. This contributes to a 28% increase in power generation at an average wind speed of 6 m/s. Using the Guangxi Zixian County Jin Zishan Wind Power Project as an example, the project could see a 18.4% increase in annual power output, with a potential 20% increase after accounting for snow and ice removal. With 0.25 billion kilowatts of wind capacity converted annually, the economic benefit could reach 5.28 billion yuan per year.
**5. Project Implementation**
A cooperation agreement has been signed with Guangxi Guiguan Power Investment Co., Ltd., a subsidiary of Datang Power. The project also welcomes support from wind power companies and investors interested in R&D. The goal is to transform old wind turbines into the world’s first deformation blade wind power prototype. Cooperation methods are flexible, and patent benefits will be shared among all participants.
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