Aerodynamic Upgrade Solutions for Optimization of Wind Turbines
Our solutions are developed to ensure that you don't have to settle for less than maximum performance.
PowerCurve develops, manufactures and supplies blade upgrade solutions designed to unlock greater wind turbine performance. Our work is built on deep aerodynamic expertise and many years of hands-on experience with blades and optimization of turbine performance. Our solutions are designed for the turbine type in question and customized for the project including site and blade surface condition.
The result is measurable gains in annual energy production and strong financial returns allowing operators to generate more energy from the same wind resources. Don’t settle for less than maximum performance.
At PowerCurve we address two distinct aerodynamic issues on both old and new blades to optimize wind turbine performance. Operating blades are subject to wear and tear on the outer blade part causing leading edge roughness that over time results in significant AEP losses due to flow detachment on the blade.
In the inboard region of the blade, the shape is thicker to support the turbine’s structure. But this thickness creates aerodynamic challenges—specifically, flow separation or stall, where the wind no longer flows smoothly across the surface. This reduces lift and power production.
Leading edge erosion and surface wear often cost operators valuable AEP (annual energy production). Our solutions help re-energize flow in this critical region by re-attaching the flow on the blade, restoring aerodynamic stability and improving turbine performance.
Every blade has structural constraints in the root area — but that also means every blade has room for aerodynamic improvement. By energizing the boundary layer, our upgrades keep the airflow attached longer, improving lift and increasing AEP. Even though the inboard region moves slower than the tip, enhancing its aerodynamic efficiency still contributes to noticeable AEP gains across the full blade span.
Working with PowerCurve has exceeded our expectations. After installing vortex generators on a group of G87 turbines, we saw consistent AEP improvements across all units — averaging more than 2%. (...) Based on the trial outcome, we decided to install PowerCurve upgrade solutions on more turbines in our fleet.
Our DragonScale technology represents a new generation of vortex generator design, engineered to enhance aerodynamic performance on modern wind turbine blades. Developed through advanced CFD optimisation and wind tunnel validation, DragonScale moves beyond traditional plate-based designs by using a series of aerofoil-shaped fins that work together to create a controlled vortex system.
This configuration stabilises the boundary layer while maintaining low drag, delivering an effective balance of lift and aerodynamic efficiency. The result is increased rotor torque and improved annual energy production.
DragonScale is the next-generation aerodynamic blade add-on for superior AEP increase on modern turbines. It can be applied on the entire blade length to mitigate flow seperation in the inboard region on the blade from thick aerofoils and towards the outer blade part from leading edge roughness. The optimized shape and design improves aerodynamic efficiency and allows for even higher AEP increase.
Our VG panels are used to optimise flow across the entire blade surface. Wind turbine blades can experience significant amounts of stall due to both inherent design choices and blade surface degradation. VGs energise the flow, reduce stall, and increase power production.
Click here to see our CTO, Nicholas Gaudern explain how our vortex generators work.
The root region performance of all wind turbine blades is dominated by poorly-performing thick aerofoils. PowerCurve Gurney flaps boost lift where it is needed most to increase power production.
Click here to see our CTO, Nicholas Gaudern explain the gurney flap technology.
Our blade upgrade solutions are installed on more than 2000 turbines.
We have worked with more than 50 different blade models.
Every year our solutions provide added energy equal to more than the consumption of 28.000 households.
Our aerodynamic upgrades improve the blade’s ability to generate lift at lower wind speeds. By energizing the boundary layer and stabilizing airflow along the blade surface, the upgrades delay flow separation and increase aerodynamic efficiency. As a result, the turbine reaches higher power output at lower wind speeds, effectively shifting the power curve to the left before rated power is achieved.
This improvement allows the turbine to capture more energy in the sub-rated region, where turbines operate most of the time, leading to increases in annual energy production (AEP).
Since we upgraded our blades with PowerCurve’s vortex generators we experienced a gain in energy production of 3.6%.
Our blade upgrade solutions are designed to improve aerodynamic performance without introducing additional structural loads. Using advanced aeroelastic modelling, CFD optimisation, and structural analysis, our solutions ensure performance gains without compromising turbine integrity.
Our technology has been independently validated by UL in accordance with the IEC 61400 standard, confirming load-neutral behaviour. This allows turbines to benefit from improved efficiency while maintaining structural safety and long-term reliability.
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Did you know that PowerCurve also offers aerodynamic engineering consultancy services? Read more here.