20 kW Wind Turbine Design: Innovation and Efficiency for Renewable Energy

Ecolibrì, a company based in Agrate Brianza active in the wind power market since 2015, commissioned Asotech to design a 20 kW vertical-axis wind turbine to expand its range of high-performance on-grid products. The challenge was to develop an efficient, cost-effective, easily transportable, quiet, and wind-resistant (up to 60 m/s) turbine with a reduced acoustic and environmental impact.

Our team of engineers, coordinated by Ing. Davide Mavillonio, Ing. Luigi Barile, and Ing. Riccardo Castagnoli, adopted a multidisciplinary approach integrating theoretical sizing, advanced CAD design, FEM structural analysis, and CFD fluid dynamic verification. This collaboration resulted in an innovative and high-performing turbine capable of fully meeting Ecolibrì’s needs and significantly contributing to the production of renewable energy.

Reduction
of Turbine Mass

Increased
Structural Resistance

Reduced Acoustic

and Environmental Impact

Enhanced Resistance
to Strong Winds

Initial Requirement

Ecolibrì tasked Asotech with expanding its range of vertical-axis wind turbines by designing a new 20 kW generator with superior performance. This wind turbine, intended for on-grid operation, was designed to support structures already connected to an electrical network, contributing to the supply of renewable energy.

Ecolibrì's requirements were clear and ambitious: develop a cost-effective, easily transportable, safe, and quiet turbine with minimal acoustic and environmental impact, capable of withstanding winds over 60 m/s. Avoiding destructive resonance phenomena was crucial to ensuring stable and secure operation under all conditions.

Solution

To meet these requirements, Asotech adopted a multidisciplinary approach, integrating expertise from various engineering fields. The project began with theoretical calculations, followed by detailed 2D and 3D fluid dynamics simulations using Ansys-Fluent. These analyses enabled the optimization of the airfoil profile of the three vertical-axis blades, ensuring maximum aerodynamic and structural efficiency.

Material selection played a crucial role in the project's success. Unlike previous 3 kW and 10 kW turbines, which were made of aluminum, the new 20 kW turbine features composite material blades. The fiberglass main profile, reinforced with internal carbon fiber, allowed for a reduction in turbine mass while increasing structural strength, minimizing loads on the system, and ensuring greater durability.

The turbine control system was completely redesigned to maximize operational efficiency. In low-wind conditions, the motor-generator allows the turbine to reach speeds above 50 rpm, enabling self-sustaining operation with winds as low as 2 m/s. The turbine achieves its peak performance at 12 m/s, with a braking system that modulates speed and limits it to 100 rpm, ensuring both safety and stability.

Benefits for Ecolibrì

Through its collaboration with Asotech, Ecolibrì gained a cutting-edge wind turbine, combining a lightweight and durable structure with high performance. The project successfully delivered a 20 kW turbine with competitive construction costs and compact dimensions, ideal for the on-grid market. The composite material used for the blades not only improved resistance to high winds but also reduced acoustic and environmental impact, making the turbine suitable for installations in sensitive areas.

A further advantage for Ecolibrì was having a single point of contact for a team of highly specialized engineers. This integrated approach allowed Ecolibrì to oversee all project phases—from CAD design to fluid dynamic and structural analyses—without having to coordinate with multiple parties, optimizing both time and costs.

Client

Ecolibrì srl

Category

Mechanical Design, CAE Analysis

Tags

Energy, Wind Power Solutions

Team

Riccardo Castagnoli
Riccardo Bonvicini
Marco Simonelli
Luigi Barile

Design of a 20 kW Wind Turbine for Ecolibrì