Mechanical Design and Experimental Study of a Small-Scale Wind Turbine Model

Abstract

The advancement of onshore and offshore wind turbines depends on the experimental validation of new technologies, novel component designs, and innovative concepts. However, full-scale models are typically very expensive, have limited functionality, and are difficult to adapt to diverse research needs. To address this shortcoming, this article presents the design of a low-cost, modular 3D-printed small prototype of a wind turbine. It includes a multi-hollow platform for marine environments configuration and stabilization, the turbine tower, and three blades with active pitch control, not always included in wind turbine prototypes. The modular tower design allows for easy height extensions, while the rotor incorporates custom blades optimized for the prototype geometry and experimental setup. Tests were conducted to evaluate the system’s operational response and verify the proper functioning of the assembled components at various wind speeds and blade pitch angles. The results confirm that the rotor speed with the prototype’s onshore configuration is highly pitch-dependent, reaching a maximum efficiency of approximately 5°. The tower displacement, measured with an IMU, remained within a narrow range, oscillating around 2° and reaching up to 4° at higher wind speeds due to elastic deflections of the PLA structure. These results, consistent with the prototype scale, validate its usefulness in capturing essential aerodynamic and structural behaviors of the wind turbine. They also demonstrate its relevance as a new tool for experimental studies of wind turbines and open up new research, validation, and control possibilities not considered in previous developments by incorporating blade pitch control.