An aerodynamic digital twin of real-world leading edge erosion: Acquisition, Generation and 3D CFD

Wind turbine blades face extremely challenging environmental conditions over their operating life-time, that can easily exceed 2 decades. Airborne particles (insects, sand, rain, hail, ice, sea spray etc.) strike the blade leading edge (LE) first and erode or attach to it, roughening its surface. Leading edge roughness (LER) can critically alter the aerodynamic performance of blades, as its aerodynamic impact is strongly coupled to its height with respect to the local boundary layer thickness, which is thinnest around the LE. The actual, detailed topographic manifestation of LER on in-service blades—needed to accurately assess its aerodynamic impact—is highly probabilistic, as it depends on the interaction of multiple stochastic parameters, like the environmental conditions, material composition and production process. Yet little high-resolution topographic LER data of this kind is currently available. This paper details how such data is collected from blades of different turbine manufacturers and processed consistently to build digital twins of the measured LER, that can be analysed aerodynamically using 3D CFD or wind tunnels. Here a special focus lies on how to reconstruct the LER topography and build the computational mesh such that the correct aerodynamic response is observed. For this purpose multiresolution signal decomposition is used to process the topographies and a special meshing procedure established.