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CrossFlow Wind Turbine Integrated Energy System (IES)

Power to ‘Off-Grid’ Locations

At the core of Crossflow Energy’s IES system is its durable wind turbine unit which incorporates a rim-mounted pulley wheel to drive a Permanent Magnet Generator (PMG) via a pulley belt. The variable AC output from the turbine PMG is rectified to DC & provides an electrical power input into the common 96VDC Busbar.

Likewise, a photovoltaic array is able to capture available solar energy & feed into the 96VDC BUS which is linked to a distribution board which can provide power to drive either AC (via an inverter) or DC loads; surplus energy can be either drawn or stored within the IES’s 96V Battery Accumulator to provide a reserve power back-up to drive the Turbine and IES control and electrical systems for cases where there is no wind/sun/diesel.

The principal power output is used to deliver a consistent source of electrical energy to meet the demand of the primary load consumer with a secondary power output available from excess power generated from solar and wind resources.

Primary Load 1 = Turbine + IES self-power
Primary Load 2 = Primary Customer
Secondary Load = Other users

  • Secure, affordable clean energy solutions for off-grid and weak-grid locations

  • Reducing dependency on fossil fuels

  • Guaranteed reliable ‘firm’ power delivery

  • Significant cost benefits achieved by integrated smart power management

  • Permanent or temporary installations, ability to deploy and re-deployed rapidly

  • Containerised (20ft standard containers) for ease of transport, access & installation in remote areas

  • Low maintenance and long life, with remote performance and condition monitoring


Crossflow Energy's Unique Wind Turbine & Integrated Energy System (IES) Offers the Following Benefits:

  • Rugged design coupled with quality of componentry, integrated lubrication system and remote condition monitoring reduces maintenance requirements and minimises system downtime
  • ‘Firm’ power output derived from wind & solar energy sources linked to a reserve battery accumulator system
  • Compact, with component parts sized to be transportable in standard 20ft / 6m shipping containers
  • Easily lowered for simplicity of periodic maintenance and in event of forecasted severe storm weather event
  • Ease of assembly at ground level using standard tooling & 3 tonne capacity forklift / front loading telehandler unit
  • Low vibration in operation means tower can provide a secure elevated platform for lightweight equipment such as communication transponders, surveillance cameras, flood and spot lighting and phased array radars
  • Turbine operating & power delivery range from 4.0m/s to 22.5 m/s windspeed by applying active yawing
  • Integrated control system ensures 24/7 turbine utilisation across its operational range with a parking regime for WS 22.5 to 52.5 m/s to maintain survival
  • Latest pulley drive belt technologies adapted to provide a durable & low- cost PMG excitation solution
  • Tower base grillage cassette & support system is adaptable to site specific foundation soil interface conditions
  • Can be readily disassembled and relocated as required to accommodate operational efficiencies
  • Upper tower section bracket collar can be adapted to interface telecommunication transmission relay / sender units
  • Environmentally friendly to avian & chiroptera wildlife due to lower turbine rotational speed & visual ‘solidity’
  • Designed to IEC 61400-2 Class 3 wind loading conditions (max. at 52.5m/s (120mph))
  • Low ground-based RADAR signature with minimal interference effects on national Air Traffic Control facilities
  • Quiet in operation with reduced visual impact due to compact aesthetic footprint & comparably low operating RPM

Transportation and installation

The Crossflow IES is designed to comprise components that fit in standard 20’ftshipping containers for ease of delivery and security. Containers are retained on site for security of batteries, control system and as a base for PV panels.

The turbine is ground assembled, requiring only a small agricultural tele-handler type vehicle for those few components that cannot be lifted easily manually.

The turbine lift into operating position and lower for Maintenance uses an A-frame and hydraulically winched cable system. This offers low cost and high reliability, the portable winch itself being removed from site when not required.

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Potential Applications

  • Off-grid or remote power sources for low power communication facilities such as telecommunication or data transmitters
  • Rapidly deployable in event of disaster relief activities to provide power for emergency medical centres, water sanitisation and, when used in conjunction with satellite equipment, can provide a resilient off-grid communication and power solution
  • Air transportable for military applications such as forward operating bases and improvised airfield facilities
  • Turbine is adaptable to fluid pumping and energy storage solutions
  • Off-grid energy supply for remote communities and small businesses

Integrated Energy System (IES) Schematic

Integrated Energy System (IES) Schematic

Site assessment

The IES power requirements will vary from location to location as will the available wind and solar resource. The requirement for the number of individual modules (wind turbines, solar PV panels and battery modules) will be assessed on a site-by-site basis as will the ground conditions for the turbine tower foundation requirements.

Wind and pv resource

The initial site resource conditions can be obtained at high level from the NASA world-wide 10km wind and solar database. This can be further refined by using the DTU Global Wind Atlas at 1km resolution and WAsP software from DTU.

Homer Pro analysis

Use of Homer Pro analysis allows Crossflow to optimise the various solar, wind and battery modules for the specific load and site resource conditions to ensure energy reliability and minimise the Levelized Cost of Energy.


Local ground conditions will dictate the choice of wind turbine foundation. It will also be possible to co-locate the Telecommunication transponders and turbine tower to reduce local footprint and CAPEX. In some locations there will already be appropriate concrete foundations, however the design allows the use of ground anchored tower grillages to be installed without the need of concrete. These will require the installation of hydraulically driven earth anchors, helical screw piles or rock anchors as appropriate.

Funded by the ERDF

The Detailed Design of the Pre-production Prototype project is part funded by the European Regional Development Fund through the Welsh Government.