Krummendeich - where the dyke to the Elbe is not straight but curved. Population: 390. A flat landscape where wind is part of daily life. Since summer 2023, the rotor blades of OPUS 1 and 2 at the WiValdi Wind Energy Research Farm have been spinning here. When a rotor blade stands vertical, its tip reaches 150 metres above the ground. What isn't visible from afar: the wind turbines and measuring masts are equipped with 1500 sensors, from the base to the tip rotors, which collect and record data around the clock. And if you look closely, you will notice that the two turbines are arranged one behind the other in the main wind direction – an absolute no-go for commercial wind farms, because the rear turbine sits in the turbulence of the first. Both features are intentional. WiValdi is a research facility and is not designed to generate as much electricity as possible, but to gain as much scientific knowledge as possible. Lukas Firmhofer, Kevin Gnebner and Julia Menken have all stood 90 metres up on the large nacelle and felt the strong headwind. This series introduces the people behind the project.
"No one knows these turbines like we do," says Lukas Firmhofer from the DLR Wind Energy Experiments facility. The 31-year-old oversaw the construction of the first two wind turbines and is currently managing the assembly of a third, smaller experimental turbine: OPUS 3. Much of what Firmhofer has been working on at his desk over the past few years is now moving from the planning stage to reality. He was on site for the delivery of the rotor blades for the first two turbines to Krummendeich, accompanying the heavy transport at night through pouring rain. "After many years of preparation, it's finally happening – instead of a virtual file on a computer, there's suddenly something in the middle of a field," he recalls. Since then, he has stood 90 metres up on the turbine and climbed the 150-metre-high, free-standing measuring masts. Fear of heights? Definitely not. Otherwise, it would probably not have been possible – even with training and support from the Enercon team.
Problem solver for the project
In 2019, Lukas Firmhofer joined DLR after studying mechanical engineering in Allgäu and wind energy technology in Flensburg. He has since moved to the DLR Wind Energy Experiments facility in Augsburg to oversee the construction of the third turbine. "Project management means switching on your computer in the morning and finding an inbox full of challenges to address," he says. Delivery delays, a shortage of skilled workers or even a pandemic like COVID-19 are unpredictable, even with the best project planning. "You have to be able to deal with that and adapt." The right mindset is: "We will tackle all these challenges."
DLR WiValdi Wind Energy Research Farm
The wind energy research farm comprises several wind turbines and measuring masts.
In the future, more wind turbines will need to be built in smaller areas. But this will only be possible if the turbines are placed closer together, which will lead to turbulence that will place significantly higher loads on the turbines in the second or third row: "They will be shaken around quite a bit, reducing their lifespan." In addition, in the past, the goal was to get as much electricity as possible from a single turbine, whereas now it's about maximising electricity output with an entire wind farm consisting of many turbines. This also involves reducing the power generation from individual turbines to protect them or extend maintenance intervals. With the WiValdi Wind Energy Research Farm, DLR is providing an infrastructure that allows DLR, as well as partners from research and industry, to address a wide range of wind energy challenges. "It's a huge playground for wind energy researchers," says Firmhofer. The wind energy team at DLR is aware that such a 'playground' tends to be met with mixed reactions from the residents of Krummendeich. "Communication is incredibly important," he says, which is why this is also part of his work in the project team. Public information events and regular entries in an online construction site diary help keep everyone informed and ensure the necessary transparency.
There, you can also find out what is currently taking up all the project manager's time: the OPUS 3 wind turbine. This new turbine is being developed and built by DLR as a classic test rig, where each individual component can be replaced and tested. "If you have an idea for a new rotor blade design, for example, you sketch it out with pen and paper. Next, you create a CAD model and a simulation. Then you test a scale model in the wind tunnel – and after that, it's ready to be taken to the experimental facility in the field for testing." While the pile foundations are underway in Krummendeich, preliminary assembly of the nacelle began at the DLR site in Augsburg. Installation of the experimental facility at the wind farm in northern Germany is planned for later this year. Firmhofer will then most likely be back in the field, overseeing the construction on site and seeing the results of years of planning and project work first-hand.
He is certain that wind energy research will always remain dynamic. "Turbines have to be better, more efficient, quieter, more environmentally friendly and more cost-effective."
