Direct mechanical torque sensor for model wind turbines

A torque sensor is developed to measure the mechanical power extracted by model wind turbines. The torque is measured by mounting the model generator (a small dc motor) through ball bearings to the hub and by preventing its rotation by the deflection of a strain-gauge-instrumented plate. By multiplying the measured torque and rotor angular velocity, a direct measurement of the fluid mechanical power extracted from the flow is obtained. Such a measurement is more advantageous compared to measuring the electrical power generated by the model generator (dc motor), since the electrical power is largely affected by internal frictional, electric and magnetic losses. Calibration experiments are performed, and during testing, the torque sensor is mounted on a model wind turbine in a 3 rows x 3 columns array of wind turbines in a wind tunnel experiment. The resulting electrical and mechanical powers are quantified and compared over a range of applied loads, for three different incoming wind velocities. Also, the power coefficients are obtained as a function of the tip speed ratio. Significant differences between the electrical and mechanical powers are observed, which highlights the importance of using the direct mechanical power measurement for fluid dynamically meaningful results. A direct calibration with the measured current is also explored. The new torque sensor is expected to contribute to more accurate model wind tunnel tests which should provide added flexibility in model studies of the power that can be harvested from wind turbines and wind-turbine farms.