Final Project Black Book-2

A
PROJECT REPORT
ON
WIND MILL OPERATED HYDRAULIC PUMP WITH POWER
GENERATION
IN PARTIAL FULFILLMENT OF
DIPLOMA
IN
MECHANICAL ENGINEERING
SUBMITTED
BY
MR. PARTH V. PAREKH

MISS. DHANASHRI M. GULVE
MR. ASHOKKUMAR M. CHAUHAN
MR. ZAFAR Z. SHAIKH
Under the guidance of
MR. ZAID ANSARI
DEPARTMENT OF MECHANICAL ENGINEERING

H.J.THIM TRUST’S
THEEM COLLEGE OF ENGINEERING BETEGAON, CHIHLAR
ROAD, BOISAR (E)
2018-2019
Project Report
On
WIND MILL OPERATED HYDRAULIC PUMP
WITH POWER GENERATION
In partial fulfillment of
Diploma in Mechanical Engineering
Submitted by
PARTH PAREKH
DHANASHRI GULVE
ASHOKKUMAR CHAUHAN
ZAFAR SHAIKH
Project Guide
Prof. ZAID ANSARI
DEPARTMENT OF MECHANICAL
ENGINEERING
H. J. THIM TRUST’S
THEEM COLLEGE OF ENGINEERING
Boisar chilhar Road, Boisar (E), Tal. Palghar
Dist. Thane, Pin- 401501
2018-2019
Academic Year 2018-19
PAREKH PARTH VINOD 1416350091

1
GULVE DHANASHRI MAHENDRA 1616350018
CHAUHAN ASHOKKUMAR MUKHRAM 1616350031

SHAIKH ZAFAR ZULFIKAR 1616350112
2018-19
Mechanical Engineering
Declaration
I declare that this written submission represents my ideas in my own words

and where others ideas or words have been included; I have adequately cited and
referenced the original sources. I also declare that I have adhered to all principals of
academics honestly and integrity have not misrepresented or fabricated or falsified
any idea/data/fact/ sources in my submission. I understand that any violation of the
above will be cause for disciplinary action by the institute and can also evoke penal
action from the source which has thus not been properly cited or from whom proper
permission has not been taken when needed.
Mr. Parth V. Parekh

Miss. Dhanashri M. Gulve
Mr. Ashokkumar M. Chauhan
Mr. Zafar Z. Shaikh
Date: ___________________
Acknowledgement
It’s our pleasure to take this opportunity to thank with deep sense of gratitude
to our guide, staff members of Mechanical Department & everyone who have directly
or indirectly contributed to our project as a success. With immense pleasure we
express our deep sense of gratitude & vote of thanks to our project guide Lectr. Zaid
Ansari for his constant interest, motivation & valuable guidance during work &
completion of this project report.
We are very thankful to Lectr. Furqan Hassan, Lectr. Shoeb Khan and the
whole staff of the Mechanical Department for giving us the opportunity to work on
this project and for his extensive co-operation and guidance. We offer sincere thanks
to, Prof. Sayyad Layak Principal (Diploma) and Prof. Nitin Galwade (Head of
Department) for their inspiration and providing full administrative support and
departmental infrastructure facilities for this report.
We are also very thankful to all those who supported us without which project
would not have been completed successfully.
Mr. Parth V. Parekh

Miss. Dhanashri M. Gulve
Mr. Ashokkumar M. Chauhan
Mr. Zafar Z. Shaikh
Wind mill operated hydraulic pump using power generation
ABSTRACT
The Imminent exhaustion of fossil energy sources, spreading global warming,

expanding greenhouse effect, higher need of energy, less availability of power
supplies motivates us to use renewable source of energy like wind-energy which is
most prominent for our suitable application. With the rise in understanding of global
warming due to Carbon Dioxide produced by burning of fuels, the use of natural
energy resource is coming into picture. Now a day people are started using of natural
sources like wind, hydro, solar energy to produce electricity and providing power to
the various power-plants.
The aim of this project is to design a windmill energy system to produce
electricity along with pumping water system for multipurpose work. It is in this light
that this project looks at most suitable design and structural adjustments that can be
made or done on the wind mill to make it most efficient for electricity generation.
Windmills are machines that convert energy from the wind into useful work by
rotating. The rotation of a windmill often powers a motor or generator used to
produce electricity or mechanical work (moving objects).
Wind energy can be generated using windmills that provide mechanical
energy that is used directly on machinery e.g. water pump and grinder; or wind
turbines that provide electrical energy. The main objective of our project was to
design a windmill and therefore our scope will be limited to a windmill for water
pumping water. Vertical axis has the main shaft running. The main objective of our
project is to design and fabricate a windmill for pumping water. In this project, we
have used vertical axis multi blade wind turbine and single acting reciprocating pump.
Keywords: windmill, global warming, windmill energy system, pumping,

wind turbines, single acting reciprocating pump, etc.
CONTENTS
Sr.No. Contents Page

No.
LIST OF FIGURES i
LIST OF TABLES ii
NOMENCLATURE iii
1 INTRODUCTION 1
1.1 Preamble 1
1.2 Objective of Work 2
1.3 General introduction 3
1.4 Background 4
1.5 Types of windmills 5
1.5.1 Horizontal axis windmill 5
1.5.2 Vertical axis 5
1.5.3 Darrieus wind turbine 6
1.5.4 Giromill 6
1.5.5 Twisted savonius 6
2 LITERATURE REVIEW 7
2.1 Introduction 7
2.2 Literature survey 7
DESIGN OF WATER PUMPING WIND MILL 9
3.1 Design challenges 9
3.2 Background research 9
3 3.3 Effect of number of blades 9
3.3.1 Effect of blade number or aerodynamic performance 9
3.4 Methodology 11
3.4.1 Design procedure outline 11
3.4.2 Proposed design procedure 11
3.5 Initial blade design methodology 14
3.6 Initial design and shaping of blades 14
4 RISKS ASSESSMENT 16
4.1 Risks in project designing 16
5 FABRICATION 18
5.1 Resource requirement design 18
5.2 Construction , fabrication 18
5.3 Fabrication 19
5.3.1 Blades 19
5.3.2 Hub 19
5.4 Fabrication Processes 20
5.4.1 Rolling process 20
5.4.2 Cutting process 20
5.5 Assembly 20
6 HYDRAULIC RECIPROCATING PUMP 21
ASSEMBLY
6.1 Rotor blade 21
6.2 Blade hub 21
6.3 Crank shaft 21
6.4 Connecting rod 21
6.5 Gears 22
6.6 Shaft 22
6.7 Ball bearing 22
6.8 Pillow bearing 23
6.9 Displacement pump 23
6.10 Tower 24
6.11 Assembly 24
6.12 Working of hydraulic pumping system 25
7 POWER GENERATION ASSEMBLY 26
7.1 Rotor blade 26
7.2 Blade hub 26
7.3 Crank shaft 26
7.4 Connecting rod 26
7.5 Gears 27
7.6 Shaft 27
7.7 Ball bearing 27
7.8 Pillow bearing 28
7.9 Alternator 28
7.10 Battery 29
7.11 Assembly 29
7.12 Working of power generation system 30
8 CALCULATIONS 31
8.1 Gear properties 31
8.1.1 Gear calculations 32
8.2 Force and moment required to pump 33
8.3 Swept area 33
8.4 Discharge Capacity of Pump 34
9 COST ESTIMATION / ANALYSIS 35
10 PHOTOS CATALOGUE 36
11 CONCLUSION 38
12 FUTURE SCOPE 39
13 REFERENCES 40
LIST OF FIGURES
Sr.No. Figure No. Title Page no
1 1.1 Wind mill with combined systems 1
2 1.2 Wind mill 3
3 3.1 Tip speed vs. Power coefficient 10
4 3.2 Coefficient of performance vs. tip speed ratio 10
5 3.3 Blades (a) 15
6 3.4 Blades (b) 15
7 5.1 Rotor blades 19
8 5.2 Hub 19
9 5.3 Assembly of wind mill 20
10 6.1 Gear set 22
11 6.2 Ball bearing 22
12 6.3 Pillow bearing 23
13 6.4 Hydraulic pump 23
14 6.5 Tower 24
15 6.6 Hydraulic reciprocating pump assembly 24
16 6.7 Working of hydraulic pumping system 25
17 7.1 Gear set 27
18 7.2 Ball bearing 27
19 7.3 Pillow bearing 28
20 7.4 Alternator 28
21 7.5 Power generation assembly 29
22 7.6 Working of power generation system 30
23 8.1 Gears meshing 31
24 8.2 Force and moment required 32
i
LIST OF TABLES
Sr.No. Table No. Title Page no
1 4.1 Risks assessment 16
2 8.1 Gear specifications 31
3 8.2 Gear teeth 31
4 9 Cost estimation 34
ii
NOMENCLATURE
N - Number of Teeth
D - Pitch Diameter
P - Diametric Pitch
PA - Pressure Angle
P - power
ρ - air density
A - swept area of blades
r - radius of the blades,
V - velocity of the wind
h - head from water surface
to tank in meter
hL - head losses in meter
θ – angle
F - force required to lift the
water in newton
b - length of the
corresponding lever in
meter
iii
Wind mill operated hydraulic pump with power generation
INTRODUCTION
1.1 PREAMBLE:
The Imminent exhaustion of fossil energy sources, spreading global
warming, expanding greenhouse effect, higher need of energy, less availability of
power supplies motivates us to use renewable source of energy like wind-energy
2018-19
which is most prominent for our suitable application.
Fig.1.1 Wind mill with combined systems

It is in this light that this project looks at most suitable design and structural
adjustments that can be made or done on the wind mill to make it most efficient for
electricity generation. Windmills are machines that convert energy from the wind into
useful work by rotating. The rotation of a windmill often powers a motor or generator
used to produce electricity or mechanical work (moving objects).
electricity along with pumping water system for multipurpose work.
Wind energy can be generated using windmills that provide mechanical
energy that is used directly on machinery e.g. water pump and grinder; or wind
turbines that provide electrical energy. The main objective of our project was to
design a windmill and therefore our scope will be limited to a windmill for water
pumping water. Vertical axis has the main shaft running. The main objective of our
project is to design and fabricate a windmill for pumping water. In this project, we
have used vertical axis multi blade wind turbine and single acting reciprocating pump.
DIPLOMA IN MECHANICAL ENGINEERING, H.J. THIM TRUSTS THEEM COE BOISAR. Page 1
1.2 OBJECTIVE OF WORK:

As previously mentioned, the electricity producing wind turbine is an
already existing technology and this project is focused on redesigning and adapting
mechanical and electrical engineering principles to achieve the specified energy
output. Wind turbines are a form of renewable energy that will help the environment
by not producing emissions while creating electricity or mechanical energy.
The objectives of the present work are:
• Lifting the water without using electricity and fossil fuel.

• Setup must be nonpolluting and less noise operation.
• Setup cost should be less and maintenance free, one time investment is
preferable.
• It must produce some amount of power.
• Installation must be easy and cheap.
• Solution for the above problem must be ecofriendly.
• To predict the optimum value for alternator for maximum power generation.
• To provide thorough background information on wind energy and wind turbines.
• To design a suitable wind turbine to meet the specifications set out in the project
outline.
The main objective of the design project is to develop a mechanical system
that is capable of providing driving force to a generator using only the energy
contained in wind. The generator in the system is the mechanical-electrical
converter in the wind turbine and the gearbox and rotor blades need to be designed
to supply the generator with an input that will yield the desired output power.
Once this has been determined a rotor system and gearbox can be designed to
produce the required revolution speed and torque to supply mechanical power to
the generator. In selecting a generator consideration needs to be made as to what
type of current is being produced and where it will flow to, if it will be stored or if
it will be directly applied in an electrical device.
1.3 GENERAL INTRODUCTION:

electricity along with pumping water system for multipurpose work.
The wind is a clean and plentiful source of energy. Wind Power is the use
of wind’s force to generate some form of measurable power or work. Many
developing nations are without feasible methods of obtaining clean, drinkable water.
Obtaining water requires walking long distances or crossing through dangerous
territory, and this is often riddled with disease. Additionally, clean water is needed for
agricultural purposes to aid local hunter and to sell crops for economical advances.
Fig 1.2 Wind mill

One newer method to deliver water is by use of wind power to pump ground water
to the surface. The availability of power supplies is often limited, so some alternate form of
energy is required to convey water from the source to a point of consumption. Wind energy is
an abundant source of renewable energy that can be exploited for pumping water in remote
locations. A wind pump is a windmill used for pumping water, either as a source of fresh
water from wells. It is one of the oldest methods of harnessing the energy of the wind to pump
water.
The process of designing a wind turbine involves the conceptual implementation of
a number of electrical and mechanical subsystems to create a machine capable of converting
the energy contained in wind to useful electrical energy. This process is constrained by
various factors, the most notable being the economic viability of the design.
1.4 Back Ground:

Wind turbines were used in Persia (present-day Iran) about 500–900 A.D.
The wind wheel of Hero of Alexandria marks one of the first known instances of wind
powering a machine in history. However, the first known practical wind turbines were
built in Sistan, an Eastern province of Iran, from the 7th century. Wind turbines first
appeared in Europe during the Middle Ages. The first historical records of their use in
England date to the 11th or 12th centuries and there be reports of German crusaders
taking their windmill-making skills to Syria around 1190. By the 14th century, Dutch
wind turbines were in use to drain areas of the Rhine delta. Advanced wind mills were
described by Croatian inventor Fausto Vernation. In his book Machinae Novae (1595)
he described vertical axis wind turbines with curved or V-shaped blades.
The first electricity-generating wind turbine was a battery charging machine
installed in July 1887 by Scottish academic James Blyth to light his holiday home in
Marykirk, Scotland. Some month’s later American inventor Charles F. Brush was able
to build the first automatically operated wind turbine after consulting local University
professors and colleagues Jacob S. Gibbs and Brinsley Coleberd and successfully
getting the blueprints peer reviewed for electricity production in Cleveland, Ohio.
Although Blyth’s turbine was considered uneconomical in the United Kingdom
electricity generation by wind turbines was more cost effective in countries with
widely scattered populations.
As far back as 1877, a windmill was first used as a means of generating
electricity. Designed by Professor James Blyth of Anderson’s College in Scotland,
this 10-meter-high turbine was successfully used to charge accumulators to power his
holiday cottage in Kincardinshire. While wind power did see further development
during the early to mid-20th century, the real push for its development began in the
early 1970s. It was at this time that concerns with fossil fuel use came to a head. From
1974 through the mid-1980s, funding from the National Science Foundation and the
US Department of Energy enabled NASA to develop the United States’ first utility-
scale wind turbines. Four different turbine designs were developed, pioneering the
technology that led to the efficient wind farms of today. It was also around this time
that NASA developed the Viterna method, a model that takes into account the three
dimensional effects and stall behavior of turbines to better predict their performanc
1.5 Types of Windmill:

Wind turbines can rotate about either a horizontal or a vertical axis, the
former being both older and more common. They can also include blades (transparent
or not) or be bladeless. Vertical designs produce less power and are less common.
1.5.1 Horizontal Axis:

Horizontal-axis wind turbines (HAWT) have the main rotor shaft and
electrical generator at the top of a tower, and must be pointed into the wind. Small
turbines are pointed by a simple wind vane, while large turbines generally use a wind
sensor coupled with a servo motor. Most have a gearbox, which turns the slow
rotation of the blades into a quicker rotation that is more suitable to drive an electrical
generator. Any solid object produces a wake behind it, leading to fatigue failures, so
the turbine is usually positioned upwind of its supporting tower. Downwind machines
have been built, because they don’t need an additional mechanism for keeping them in
line with the wind. In high winds, the blades can also be allowed to bend which
reduces their swept area and thus their wind resistance. Generally, in the past
horizontal axis wind mills were used. The multi-bladed wind pump or wind turbine
atop a lattice tower made of wood or steel hence became, for many years, a fixture of
the landscape throughout rural America. These mills, made by a variety of
manufacturers, featured a large number of blades so that they would turn slowly with
considerable torque in moderate winds and be self-regulating in high winds. A tower-
top gearbox and crankshaft converted the rotary motion into reciprocating strokes
carried downward through a rod to the pump cylinder below. Today, rising energy
costs and improved pumping technology are increasing interest in the use of this once
declining technology
1.5.2 Vertical Axis

Vertical-axis wind turbines have the main rotor shaft arranged vertically.
One advantage of this arrangement is that the turbine does not need to be pointed into
the wind to be effective, which is an advantage on a site where the wind direction is
highly variable. It is also an advantage when the turbine is integrated into a building
because it is inherently less steerable. Also, the generator and gearbox can be placed
near the ground, using a direct drive from the rotor assembly to the ground-based
gearbox, improving accessibility for maintenance. However, these designs produce
much less energy averaged over time, which is a major drawback. The key
disadvantages include the relatively low rotational speed with the consequential
higher torque and hence higher cost of the drive train.
1.5.3 Darrieus Wind Turbine

“Eggbeater” turbines, or Darrieus turbines, were named after the French inventor,
Georges Darrieus. They have good efficiency, but produce large torque ripple and
cyclical stress on the tower, which contributes to poor reliability. They also generally
require some external power source, or an additional Savonius rotor to start turning,
because the starting torque is very low. The torque ripple is reduced by using three or
more blades which results in greater solidity of the rotor. Solidity is measured by
blade area divided by the rotor area. Newer Darrieus type turbines are not held up by
guy-wires but have an external superstructure connected to the top bearing.
1.5.4 Giromill
A subtype of Darrieus turbine with straight, as opposed to curved, blades. The
cycloturbine variety has variable pitch to reduce the torque pulsation and is self-
starting. The advantages of variable pitch are: high starting torque; a wide, relatively
flat torque curve; a higher coefficient of performance; more efficient operation in
turbulent winds; and a lower blade speed ratio which lowers blade bending stresses.
Straight, V, or curved blades may be used.
1.5.5 Twisted Savonius

Twisted Savonius is a modified savonius, with long helical scoops to provide smooth
torque. This is often used as a rooftop windturbine and has even been adapted for
ships.
LITERATURE REVIEW
2.1 Introduction:
Wind Turbines are one of the recent machines for wind energy conversion.
Wind turbines are mainly classified into horizontal axis wind turbines (HAWT) and
vertical axis wind turbines (VAWT). The horizontal axis wind turbines are mostly
used for electricity generation and also for water pumping. However, to use the recent
wind turbines for water pumping, the average wind velocity of the region should be
greater than 4 m/s. Windmills are one of the oldest methods of harnessing the wind
energy to pump water. But currently, the technology has experienced are viral due to
the increasing price of fossil fuel all over the world. The content of this chapter is an
overview of the available literature and information on wind turbine design that will
ultimately be used as a foundation throughout the design project.
2.2 Literature Survey

Omar Badran, [1] wind energy pumping systems are more reliable than
diesel ones because they do not require frequent maintenance, are safer due to the
auto stop features in case of failure, do not consume fuel, and do not pollute the
environment. Also from the present study, we can conclude that research and
development projects in the field of wind energy are of utmost importance to Jordan,
despite the scarce financial resources and the high cost of R&D, because Jordan does
not have any source of conventional energy. Research and Development organizations
in Jordan should be encouraged to sponsor the development of 9 electrical wind
energy conversion systems packages. Availability in the local market, detail of
fabrication processes, and available on-site technical assistance. The manufacturing of
modern wind pumps locally will generally pump water at lower costs than imported
classical multi-bladed windmills, which should be considered in assessing the
potential of wind energy for water pumping.Also it can be concluded from the present
study that the water supply in Jordan for a man, his cattle and his land could be
safeguarded with the help of a windmill installation.
• Diameter of rotor = 7.5m
• Number of blades = 24
• Tower height= 12 m
• Solidity ratio is 54%

• Pump cylinder diameter =104 mm
• Pump stroke length =350 mm
• Power transmission is through crank shaft
• Average wind speed = 8 m/s.
Misrak Girma,Abebayehu Assefa, [2]. In this paper, the feasibility of a
wind-powered water pumping system is conducted for three selected sites in Ethiopia.
The designed system has a capacity to supply a daily average drinking water of 10, 12
and 15 m3/day for 500, 600 and 1000 peoples in Siyadberand Wayu, Adami Tulu and
East Enderta sites, respectively, with average per capital water consumption of 20
liters per day per person. The cost of pumping water is determined as 0.08, 0.05 and
0.036 $/m3 for Siyadberand Wayu, Adami Tulu and Enderta sites, respectively. The
results indicate that replacing the existing expensive Diesel-based systems by wind-
powered systems will play a significant role in achieving the country’s MDG
targets.If there is low and medium wind energy potential (greater than 2.8m/s) which
can be applicable for water pumping. Size of wind mill always depends upon diameter
of rotor.
• Diameter of rotor is 5.7 m
• No of blades =24
• It is direct single acting piston pump.
• Water consumption = 10m^3 / day
• Total head = 75 meter 10
• Density of air = .92 kg/m3
• Reference area =P(hyd)/P(wind)=Ra=24.87
• Rotor Diameter = 5.63 m
• Pipe diameter = 25mm
• Pump diameter = 115mm
• Hydraulic power = 337 W
• Tower head = 16 m
• Transmission gear ratio is direct
• Itsrotorishorizontal
DESIGN OF WATER PUMPING WINDMILL

3.1 Design Challenges
The goal of this project was to design a windmill that could generate power
under relatively low wind velocities. To accomplish this goal, the objective were to 1)
Analyze how different geometry of wind mill within various enclosures affect
windmill’s output. 2) Test how to vibrations caused from rotations of blades affect
structure of windmill. To meet these objectives, the task were to:
• Complete background research on windmill
• Design blades for testing
• Create experimental setup
• Manufacture parts
• Develop future design recommendations
3.2 Background Research

Background research includes reviewing a previous project, Low cost wind mill for
ground water lifting developed by Mr. Josua Kirsch and Engr. Ashiq Hussain, which
provided a foundation for current project.
3.3 Effect of Number of Blade

Comparison of coefficient of efficiency between two blade and three blade. Three,
six, and twelve blade system. The major factors involved in deciding the number of
blades includes:
1. The effect on power coefficient;
2. The design TSR (tip-speed ratio);
3. The means of yawing rate to reduce the gyroscopic fatigue.
3.6.2 Effect of Blade Number, On Aerodynamic Performance

Various experiments results were publish in internet or book what the exact
number of blade that have good aerodynamic performance? Solidity of material, kind
of material, coefficient of friction on the blade surface, chord (width) of blade turbine
and much others. One that very interesting to make conclusion and discussion is
relation between number of blade and coefficient of performances of wind turbine
machines. The best blades number from 3 until 12. When designing number of blade,
the number of blade that we choose influences the aerodynamic performance like
coefficient of performances. Modern wind turbines are neither built with many rotor
blades nor with very wide blades even though turbines with high solidity have the
advantage of enabling the rotor to start rotating easily because more rotor area
interacts with the wind initially. Since, our current goal is to convert the wind energy
into electricity, rotors will not benefit with high solidity because it is neither cost
effective nor efficient. The number of the blades of a turbine has great impact on its
performance. Picture below shown coefficient of performances between 3, 6, and 12
blades with same solidity and same speed 5 m/s.
Fig 3.1: Tip Speed vs. Power Coefficient
Fig 3.2: Coefficient of Performance vs. Tip Speed Ratio
3.4 Methodology
3.4.1 Design procedure outline:
There are a variety of different approaches that can be taken in wind turbine
design and accordingly there are also a number of issues that need to be taken into
account. The design procedure outlined in “(McGowan 2003)” (p248), sets guidelines
for the design of a wind energy converter and has been taken into consideration for
application in this project.
3.4.2 Proposed Design Procedure:
1. Determine application: The first step in the design process is determining

for what type of application the turbine is being designed for. There is also a
difference in blade configuration for water pumping wind mills when
compared to multi bladed electricity producing turbines.
2. Review previous experience: This section of the process deals with the
review and investigation of the previous design of similar wind turbines.
Reviewing previous work helps with troubleshooting and allows the designer
to narrow down the available options and gain some direction as to conducting
the design process.
3. Select topology: As there are a wide variety of different wind turbine
designs, mainly varying with the rotor type and orientation, it is important to
identify the most suitable option for the proposed application. The options
include: - Rotor axis orientation: horizontal / vertical – Power control: stall,
variable pitch, controllable aerodynamic surfaces and yaw control – Rotor
position: upwind or downwind – Yaw control: driven yaw, free yaw, fixed
yaw – Rotor speed: constant or variable – Design tip speed ratio and solidity –
Hub type – Number of blades
4. Preliminary loads estimate: In the early stages of design it is important to
have an approximate idea of what sort of loading the wind turbine will be
subject to. This helps in narrowing down the design of individual components
and employed techniques such as scaling and ‘rule of thumb’. The estimates
made in the preliminary stages of design are adjusted throughout the project.
5. Develop tentative design: Once an overall design layout has been

determined, the preliminary turbine design can be developed. The design can
be broken up into a number of smaller sub systems such as: - Electrical
Generator – Gearing system – Drive train – Hub – Yaw system – Rotors –
Nacelle and tower Modelling will be conducted using Pro Engineer and
SOLID Works.
6. Predict performance: It is important to develop a power curve of the turbine
which depicts the performance of the turbine at different speeds. This
primarily will relate to the rotor design but also incorporates the type of gear
box and generator and the associated losses in each.
7. Evaluate design: Like all engineering designs the structural and mechanical
integrity of the proposed wind turbine needs to be thoroughly evaluated to
ensure the turbine can operate safely and effectively under various types of
loading. As the turbine is exposed to the forces of nature it needs to be
designed with irregular weather patterns taken into consideration. The
turbine’s components will constantly be subject to fatigue loading and an
increase in wind speed can cause shock loading to occur which needs to be
taken into consideration in the design stages. The turbine will also be subject
to static, steady, cyclic, impulsive, stochastic transient and resonance induced
loads and will need to be able to withstand these loads under all credible
conditions, both normal and extreme. The main loads of concern are those
occurring around the rotor and hub. This is a primary area of focus in the
design of the proposed wind turbine.
8. Estimate costs and cost of energy: Before the wind turbine reaches
prototyping or production stages a careful cost analysis needs to be conducted
to determine if the design is economically viable. It is necessary to effectively
quote the construction cost of the turbine in both prototyping and production
stages and also to then determine a productivity cost, the cost of producing
energy. In the prototyping stages relatively high costs can be expected due to
the work involved with designing each individual component the associated
fabrication and machining costs. In the production stages the individual
component cost will drop quite significantly in relation to quantity and the
possible off the shelf availability of certain components.
9. Refine design: Once preliminary design, design evaluation and cost

estimation has been completed the refinement stage is reached. Changes are
made in accordance to the findings of the mentioned evaluation processes.
Material selection, component strength and component appearance may be
changed to conform with costing, structural and mechanical integrity and also
aesthetic appeal. Once the changes have been employed the redesigned turbine
will then be subject to re-evaluation to ensure the design still conforms to all
safety standards.
10. Build prototype (If time permits): Once the design process has been
completed a prototype should be designed to verify any assumptions made,
test concepts and insure that the turbine can be fabricated, installed and
operated as expected. Due to the time limit of the project and the nature of the
work associated in completing a prototype, this stage has only been partially
completed.
11. Test prototype After installation of the prototype the turbine is subject to a
variety of field tests to determine the physical capabilities of the design and to
determine the wind turbine’s rated power output. Once again due to the time
restraints of the project the different subsystems will be tested to determine
their individual performance levels.
3.5 Initial blade design methodology

The design of the turbines rotors is perhaps the most mathematically
involving element of the entire turbine design. The rotors use aerodynamic lift to
provide a turning moment and consequently an input torque to the gearbox. The sizing
and configuration of the blades is based upon the relative power coefficient of the
turbine and the energy in the stream tube. The energy in the stream tube depends on
the swept area of the blades and the wind speed. For the purpose of this project,
mathematical modelling and analysis is ibergla to determine the rotor sizing,
however some assumptions have to be made in order to obtain a realistic geometry.
The design of the blades used in this project is based on blade element theory and the
Betz equation and will investigate the blade shape for ideal rotors with and without
wake rotation.
For experimental purposes a set of scaled blades will be created for testing
and employment in a small wind turbine to be constructed during the duration of the
project, time permitting. The blades will be based on the ideal blade shape for a rotor
without wake rotation. The blades will be created using a iberglass mould which
will then be filled with two part expanding foam. The cured foam will take up the
shape of the blade and once cured will be glassed to give increased strength and
rigidity. Due to the nature of the blade crafting technique it will be very difficult to
achieve symmetry in all of the blades and this will ultimately attribute to some
dynamic instability. Post shaping blade balancing techniques are employed to ensure
that dynamic stability and safety of the rotor.
3.6 Initial design and shaping of blades
Introduction: The initial design of the turbine rotors was based upon the
Betz equation and the design guidelines for a rotor without any wake rotation. This
data was sourced from the text Wind Energy Explained and was used to create a
computer model for testing and reference during shaping. The initial aim was to create
the blade shape using a light weight foam, also commonly used for making surf
boards, however due to problems encountered with the foam’s structural properties a
different material was used. Aerodynamic performance is fundamental for efficient
rotor design. Aerodynamic lift is the force responsible for the power yield generated
by the turbine and it is therefore essential to maximize this force using appropriate
design. A resistant drag force which opposes the motion of the blade is also generated.
by friction which must be minimized. Turbines operate for long periods at ground
level where insect and dust particulate build up is problematic. This build up known
as fouling can have detrimental effects on the lift generated. Provision is therefore
made for the reduced sensitivity to fouling of wind turbine specific aero foil designs.
The structural requirements of turbine blades signify that aero foils with a high
thickness to chord ratio be used in the root region. Such aero foils are rarely used in
the aerospace industry. Thick aero foil sections generally have a lower lift to drag
ratio. Special consideration is therefore made for increasing the lift of thick aero foil
sections for use in wind turbine blade designs.
Fig 3.3 Blades (a)
Fig 3.4 Blades (b)
RISKS ASSESSMENT
4.1 Risks in project designing
The design and construction of a wind turbine incorporates various risks
and hazards that need to be brought to the attention to anyone who is involved in the
processing of parts, assembly and operation of the machine. The majority of risks and
hazards are common in industry and there is professional training available to prepare
individuals for safe operation within a hazardous environment.
The majority of hazards associated with the project are:
Hazard / Risk Description / significance/ likelihood/ exposure Consequences/
counter measures
Fumes During the fabrication the fumes can cause nausea and extreme
headaches and if exposed to them for extended periods can cause
brain damage. If proper breathing masks and eye protection are
used during the handling of the chemicals the risk is minimized.
Protective clothing and gloves should also be applied to avoid
contact with skin.
Machining The machining and fabrication of parts is a hazardous procedure
Fabrication mainly due to the exposure to moving parts and cutting equipment.
Interference with the equipment can result in serious injury;
abrasions, cuts, bruising. To avoid contact and minimize the risk of
these occurring, no loose fitting clothing should be worn during
operation of the equipment. Steel toed boots, ear muffs and
appropriate eye protection should be worn during the operation of
equipment. If possible the work should be carried out under the
supervision of professionals.
Electrical As the turbine is used to produce electrical energy there is an

apparent electrical hazard. Interference with electricity can cause
significant damage to a person or even death. The amount of energy
being produced by the turbine poses a significant risk to anyone
who comes into contact with it. This being said only professional
electrical technicians should conduct any work on the generator, the
transmission and the storage unit. All wiring and connections must
be effectively insulated and tested on a periodic basis to avoid short
circuiting which could cause damage to the electrical network.
Operational Once in operation the rotors of the turbine are in constant motion.
There is a slight contact risk for personnel conducting maintenance
on the turbine. The rotors must be stalled before any maintenance is
conducted on the turbine to avoid contact. Contact can result in
cuts, bruises, breaking of limbs and may cause a fall from a height
that could be fatal.
Table No.4.1 Risks Assessment
FABRICATION
5.1 Resource Requirements Design
As the project deals mainly with the design and implementation of a wind
turbine and actual construction is only a secondary project objective that will only be
conducted if time permits, the majority of resources will be in the form of software
and literature.
The design of the wind turbine will be based on existing technology which
will be investigated in the literature review. This will provide the background
knowledge and aid in optimising the technical design parameters of the project;
materials, geometry, structure, electrical generator selection etc... The University
Library will be the primary source of information aiding the design procedure along
with private publications from industry.
The geometric and physical design and modelling will require a CAD
package such as PRO Engineer or SOLID Works. The software is available for use at
the university along with ANSYS for finite element analysis of the design and testing
of individual components.
5.2 Construction, fabrication

If construction of the turbine is to take place a wide variety of machinery, tooling and
additional tooling is required.
These are listed below:
- Milling centers (tooling)
- Metal lathe (tooling) - Welding equipment (TIG, MIG)
- Workshop equipment (general tooling)
- Testing facilities (Tensile, impact, fatigue, wind tunnel
5.3 FABRICATION
Parts Detail
5.3.1 Blades
Nine Blades of GI sheet, thickness=0.8mm (gauge 22)
Length=30 inches (762mm), length of arc=8 inches
Fig.5.1 Rotor blades

5.3.2 Hub
Hub of mild steel on which blades are attached.
Fig5.2 Hub
5.4 Fabrication Processes
5.4.1 Rolling Process

In metalworking, rolling is a metal forming process in which metal stock is
passed through one or more pairs of rolls to reduce the thickness and to make the
thickness uniform
5.4.2 Cutting Process
Process which is used to remove material from a metal work piece through
the process of shear deformation. Single-point tools are used to remove material by
means of one cutting edge, in shaping, turning, plaining and other similar operations.
5.5 Assembly
An assembly line is a manufacturing process (most of the time called a
progressive assembly) in which parts (usually interchangeable parts) are added as the
semi-finished assembly moves from workstation to workstation where the parts are
added in sequence until the final assembly is produced.
Fig5.3 Assembly of wind mill
HYDRAULIC RECIPROCATING PUMP ASSEMBLY

6.1 Rotor Blade
Rotor blades are the most important in a windmill powered water pump
assembly as it captures wind. A Galvanized iron material which proved to be helpful
for generation of mechanical work leading to the generation of water pump. It has
high corrosion resistance and the coated layer has good adhesion and ductility
properties which proved for working of windmill blade in adverse environmental
conditions with high wind speeds.
6.2 Blade Hub

The material of the blade hub is wood disc. It is used to transfer motion
from the shaft to the slider crank disc.
6.3 Crank Shaft

Another most important component for the smooth functioning of prototype
is crankshaft. Crankshaft should poses high strength, rigidity and toughness due to
these requirement they are manufactured by casting and forging production
techniques. Crankshaft is component connected between the turbine blade and
connecting rod. With the rotation of turbine blade, certain mechanical motion is
obtained which is transmitted to the crankshaft leading to rotary motion of connecting
rod with piston in the pumping assembly.
6.4 Connecting Rod

Connecting rod is long slender component between crankshaft and piston
assembly via sew-saw mechanism. Mechanical motion obtained from the crankshaft
for the reciprocation of piston rod in pumping assembly is transmitted via connecting
rod. Connecting rod should have high ultimate tensile stress, resistance for the
bending, fatigue stresses so it should be manufactured by casting and forging
production techniques.
6.5 Gears
The type of gearing system and configuration depends upon the selected
induction motors synchronous speed. The lower the synchronous speed the better, as
this will require a lower gearing ratio and will consequently result in a lower input
torque requirement. In gearing reduction systems there is a high speed input with a
low speed high torque output. As we are reversing the cycle and gearing-up to achieve
higher rotational speeds, torque will be the primary factor that will attribute to the
effective functionality of the gearing system.
Fig 6.1 Gear set

6.6 Shaft
The shaft is a component which is connected between the blade hub and the
slider crank disc. The shaft converts motion of the windmill.
6.7 Ball Bearing

These are machine components designed to provide support for rotating
elements by taking pure radial loads, pure thrust loads or a combination of the two.
They are made of inner and outer radial race with incorporated hardened steel balls
which geometrically have contacts with the two races at a point.
Fig 6.2 Ball bearing
6.8 Pillow bearing

A pillow block is a pedestal used to provide support for a rotating shaft with
the help of compatible bearings & various accessories. Housing material for a pillow
block is typically made of cast iron or cast steel.
Fig 6.3 Pillow bearing

6.9 Displacement Pump
This consists of cylinder, piston, and connecting rod which reciprocate in
cylinder. A rubber sealed piston with a one way valve and water outlets at the top.
Water passes through the top only on the lifting stroke of the piston. These rely on a
piston, which is close fitting within a cylinder containing water. By lifting the piston a
vacuum is created which displaces the water up the pipe. Its inlet is from downward
and outlet is upside.
Fig. 6.4 Hydraulic pump
6.10 Tower
The tower raises the turbines assembly well above the turbulent air current
close to the ground and captures higher wind speeds. Tower design is particularly
critical, as it must be as economically possible, robust, enable access to the turbine for
maintenance and yet not add unnecessary to the cost of the system.
It is made of M.S which has a high resistance to breakage. Mild steel, as
opposed to higher carbon steels, is quite malleable, even when cold. This means it has
high tensile and impact strength. Higher carbon steels usually shatter or crack
under stress, while mild steel bends or deforms. Tower with height 6ft. (180 inches)
and width 25 inches.
Fig 6.5 Tower

6.11 Assembly
added in sequence until the final assembly is produced. With the main shaft coming
from wind blades on which big diameter gear is coupled. Big diameter gear meshes
with the two small gears. One small gear on which hydraulic system will work and on
the other power generation system will work. The small gear has clutch type
mechanism, as it will get engage and disengage with the rotations of main gear. With
the guide wheel arrangement the reciprocating shaft of pump will work as required.
Fig 6.6 Hydraulic Reciprocating Pump Assembly
6.12 Working of hydraulic pumping system

The system uses a wind mill to utilize the wind energy to operate a
hydraulic pump. The kinetic energy of the wind is converted is converted into
mechanical energy in the form of rotary motion which is then converted into
reciprocating motion using mechanisms. The wind mill first converts the kinetic
energy of the wind into mechanical energy in form of rotary motion. The rotary
motion is transferred to a shaft connected to the rotor hub of wind mill. A gear is
mounted on the shaft which meshes with another gear mounted on a connecting shaft.
the connecting shaft has a disengagement mechanism mounted on it. The
disengagement mechanism is used to stop and start the transfer of motion as per
requirement of the pump.
The rotary motion of the connecting shaft is converted into reciprocating
motion using crank mechanism. A guide way is used to guide the guide roll to which
the piston rod of the pump is attached. The crank is attached to the guide roll on one
side and on a gear on another side. The gear connected to crank is mounted on the
connecting shaft. The guide roll is moved in reciprocating motion due to the motion
of the crank. The disengagement mechanism is a gear changing mechanism used as a
clutch for engagement and disengagement. We have combined both systems, so we
have mounted two gears on the same main shaft. One gear meshes with the power
generation system and the other gear meshes with the pumping system.
Fig 6.7 Working of hydraulic pumping syste
POWER GENERATION ASSEMBLY
7.1 Rotor Blade

Rotor blades are the most important in a windmill powered water pump
assembly as it captures wind. A Galvanized iron material which proved to be helpful
for generation of mechanical work leading to the generation of water pump. It has
high corrosion resistance and the coated layer has good adhesion and ductility
properties which proved for working of windmill blade in adverse environmental
conditions with high wind speeds.
7.2 Blade Hub

The material of the blade hub is wood disc. It is used to transfer motion
from the shaft to the slider crank disc.
7.3 Crank Shaft

Another most important component for the smooth functioning of prototype
is crankshaft. Crankshaft should poses high strength, rigidity and toughness due to
these requirement they are manufactured by casting and forging production
techniques. Crankshaft is component connected between the turbine blade and
connecting rod. With the rotation of turbine blade, certain mechanical motion is
obtained which is transmitted to the crankshaft leading to rotary motion of connecting
rod with piston in the pumping assembly.
7.4 Connecting Rod

Connecting rod is long slender component between crankshaft and piston assembly
via sew-saw mechanism. Mechanical motion obtained from the crankshaft for the
reciprocation of piston rod in pumping assembly is transmitted via connecting rod.
Connecting rod should have high ultimate tensile stress, resistance for the bending,
fatigue stresses so it should be manufactured by casting and forging production
techniques.
7.5 Gears
The type of gearing system and configuration depends upon the selected
induction motors synchronous speed. The lower the synchronous speed the better, as
this will require a lower gearing ratio and will consequently result in a lower input
torque requirement. In gearing reduction systems there is a high speed input with a
low speed high torque output. As we are reversing the cycle and gearing-up to achieve
higher rotational speeds, torque will be the primary factor that will attribute to the
effective functionality of the gearing system.
Fig 7.1 Gear set

7.6 Shaft
The shaft is a component which is connected between the blade hub and the
slider crank disc. The shaft converts motion of the windmill.
7.7 Ball Bearing

These are machine components designed to provide support for rotating
elements by taking pure radial loads, pure thrust loads or a combination of the two.
They are made of inner and outer radial race with incorporated hardened steel balls
which geometrically have contacts with the two races at a point.
Fig 7.2 Ball bearing
7.8 Pillow bearing

A pillow block is a pedestal used to provide support for a rotating shaft with
the help of compatible bearings & various accessories. Housing material for a pillow
block is typically made of cast iron or cast steel.
Fig 7.3 Pillow bearing

7.9 Alternator
A wind turbine alternator is an electrical machine making the conversion
from mechanical energy to electrical energy in a wind turbine (see that word ). The
wind turbine alternator is by principle a multiphase AC synchronous machine and
more particularly a 3 phase machine delivering a balanced system of AC voltages and
currents, in which both statoric and rotoric magnetic fields are rotating synchronously
that is to say at the same speed. Therefore it is an AC electrical generator. The
excitation of the alternator or inductor can be made by coils with DC currents
implemented on the rotor or much more frequently nowadays by permanent magnets
bonded to the rotor. There are structures of wind turbine alternators with internal rotor
and external stator on one hand and structures of wind turbine alternators with internal
stator and external rotor on the other hand.
Fig 7.4 Alternator
7.10 Battery
Electrical batteries or accumulators are regularly used in wind energy
applications and can be charged by wind energy system.
Lead acid batteries are a good choice since they are well suited for trickle
charging. In terms of electrical output they have a high efficiency of 80 – 90 %, and in
terms of energy, their efficiency is 70-80%. Thick plates are used in special batteries
for large installations.
Small installations can cause bank of ordinary automotive batteries. The main cause
of deterioration is overcharging or being left for in the discharged state.
Nickel cadmium batteries are not usually used in wind power applications
as they have low efficiency at low intensities and lower than lead acid batteries at all
intensities. The advantages are that they are not damaged by overcharging nor by
occasional over discharging, they do not self-discharge, and not easily damaged by
freezing temperatures compared with the lead acid batteries.
7.11 Assembly
added in sequence until the final assembly is produced.With the main shaft coming
from wind blades on which big diameter gear is coupled. Big diameter gear meshes
with the two small gears. One small gear on which hydraulic system will work and on
the other power generation system will work. The small gear has clutch type
mechanism, as it will get engage and disengage with the rotations of main gear.
Fig 7.5 Power Generation Assembly
7.12 Working of power generation system

The wind mill is used to utilize wind energy to generate electricity. The
wind mill converts the kinetic energy of wind into mechanical energy in the form of
rotational motion. The rotary motion of the rotor of the wind mill is transferred to the
main shaft which is mounted on the hub of rotor.
A driving gear is mounted on the main shaft. The gear on the main shaft
meshes with another gear mounted on a connecting shaft. The connecting shaft is
connected to a gearbox which helps in increasing the torque ratio to meet the optimum
speed required by the alternator. The gearbox is connected to the alternator which
generates AC current. The electricity generated is stored in a battery.
The AC current is converted to dc current using a converter circuit before
being supplied to battery. The energy is then utilized as per requirement via an
inverter. The inverter converts the dc current obtained from the battery into AC
current.
Fig 7.6 Working of power generation system
CALCULATIONS
8.1 Gear Properties

SR PARAMETERS VALUE SR PARAMETERS VALUE
NO. (GEAR NO: 1) NO. (GEAR NO:2)
1 Number of Teeth (N) 19 1 Number of Teeth (N) 67

2 Pitch Diameter (D) 4.75 2 Pitch Diameter (D) 16.75
3 Diametric Pitch (P) 4 3 Diametric Pitch (P) 4
4 Pressure Angle (PA) 20 4 Pressure Angle (PA) 20
Table no. 8.1 Gear Specifications
8.1.1 Gear calculations:

Gear ratio =
This format uses a fraction to express a gear

ratio.
SR 1.GEAR 2. GEAR
NO. TEETH TEETH
1. 19 67
Table No. 8.2 Gear Teeth
For this gear pair,
The gear ratio = = 3.5 Fig 8.1 Gears Meshing
This is another way of saying that gear 1 rotates 3 times while gear 2 rotates 1
time. It’s the same as saying the gear ratio is 3.5:1. If we know the number of times
gear A rotates we can divide that number by 3.5 to find the number of times gear 2
rotates.
You can now ask the class: What’s a way to find a gear ratio without
actually turning the gears?
Add the teeth ratio expression to the equation you wrote earlier:
Gear ratio= =
Gear ratio = 67/19 =3.5
Gear ratio =
Formula = P = ρ A V3
Where,
P is power,
ρ is air density,
A is swept area of blades given by A = π r2 where r is the radius of the blades,
V is the velocity of the wind
Given data:
Wind speed v = 4.5 m/s, radius (r) = 0.91 m, air density ρ = 1.23 kg/m3.
The area is given by,
A = πr2
A = π ×0.912
A = 2.60 m2
The wind power formula is given by,
P= ρAV
P = × 1.23 × 2.60 × (4.5)3
P = 145.70 watts
8.2 Force and moment required to pump water:

Because the potential energy, Eg = mgh is the same at the starting position as
when the conrod has rotated one full rotation, the mass of the conrod is omitted from
these calculations. The extra weight from the conrod on the way up is compensated by
help from gravitational force on the way down.
The force F required to lift the water in the pump is: hL
F= [N]
Where,
ρ is the density of water in kg/m3 ;
g is the gravitational acceleration in m/s2 ; Fig 8.2 Force and moment required
A is the area of the pump in m2 ;

h is the head from water surface to tank in meter;
hL is the head losses in meter; and θ is the angle (figure). It depends on b, the
length of the lever; and l, the length of the conrod. It is computed with:
Given data:
b = 0.05 m
l = 1.21 m
The maximum moment required occurs when the lever is in a 90° angle in
relation to the pump, and is computed with:
Mpump = Fb [NM]
Where,
F is the force required to lift the water in newton and
b is the length of the corresponding lever in meter
Given value:
ρ = 1000 kg/m3
g = 9.81 m/s
h=3m
hL = 0.0177 m
F=
8.3 Swept Area

The swept area is the plane of wind intersected by the generator. As such,
the height of the blades times the diameter of rotation will produce the square meters
or feet of the swept area.
As = (π/4)*D2
8.4 Discharge Capacity Of Pump:
Wind speed(V): 4.5 m/s

V = R
Where, R = radius of wind turbine = 0.9 m
4.5 = ×0.9
 = 5 rad/s
Angular speed of rotor (): 5 rad/s
v = r
v = 5×0.085
v = 0.425 m/s
Linear velocity of piston rod of pump (v): 0.425m/s
Q =V/t
Q=Ad/t
Where,
A = cross sectional area of a section of a pipe,
d/t = v
Q = Av.
A (Area) = 0.001 m2
v = 0.4 m/s
Q = A* v
Q = 0.001* 0.4
Q = 0.0004 m3 /s.
Q = 0.4 liters/ sec.
COST ESTIMATION / ANALYSIS
Sr No. Components Quantity Price

1 Shaft 2 320
2 Gear 6 400
3 Alternator 1 1750
4 Clutch 1 800
mechanism
5 Hydraulic pump 1 2000
6 Structure - 4000
material
7 Pillow bearing 7 1830
and bolts
8 Blades 9 1300
9 Blades shaping - 300
cost
10 Conical bearing 1 150
11 Labour cost - 1000
12 Circular plate 3 160
13 Transportation - 1000
Total 15000
Table No. 9 Cost estimation
PHOTOS CATALOGUE
CONCLUSION
The goal of project is accomplished from the requires analysis and
fabrication of prototype that is utilization of wind power to pumping water and
generate electricity. From result we have seen the efficiency of aerodynamic shape
blade.
Our work is to show that the horizontal axis wind energy conversion system
are practical and potentially very contributive. Thus we have used our new design of
wind turbine to pump out water. This will provide liters of water for drinking purpose.
At the low wind velocity in the range below 3.5 m/s, the discharge is not so much
effective, however with increased speed of wind energy considerably enhanced to the
rate of v3 , therefore discharge becomes high.
Gears and bearings are subject to very high heat losses due to friction and
this will be greatly minimized by application of oil and grease and therefore greatly
improving the efficiency. All materials used are locally available and at a low cost
making the model economically viable.
Small scale wind energy conversion systems are an effective,
environmentally friendly power source for household and other applications.
Although they are subject to climatic behavior and do not always deliver a constant
supply of energy, they can be adapted to energy storage units that allow the selective
distribution of the energy once it has been converted.
The resultant design of the project is a small scale 145.70 watts electrical
energy producing at 3.5 m/s wind speed. Its design is based on a horizontal axis wind
turbine for the application of charging a battery bank in remote communities, rural
areas.
FUTURE SCOPE
Although the efficiency of power generation using wind mill is not that high
as required, the various advantages of it like zero pollution, free of cost power
generation and the ever reducing cost of the system makes it a preferable option of
power generation.
Once the optimum operating conditions are determined, the gear box and
generator can be redesigned to a configuration that produces maximum efficiency.
This design can then be manufactured and tested to determine the realistic operating
performance in an uncontrolled environment.
As the turbine was designed primarily from a mechanical perspective, there is
allot of electrical based engineering to do to ensure a safe, effective electrical power
regulation and distribution circuit is constructed. Basic electrical theory and circuits
were investigated during the course of the project however no specifications were
made with respect to the sizing of electrical items and units.
REFERENCES
1. Hayder kadhim khashan, “Design and development of wind power water

lifting pump mechanism” ,International journal of science technology and
engineering, volume 2, issue 12, June 2016
2. Wind Power Plants: Fundamentals, Design, Construction and Operation, R.
Gasch, J. Twele, et al., Springer Verlag, 2012
3. Abdeen, M. O., “Energy for Water Pumping in Rural areas in Sudan”,
Journal of Engineering and Technology. 2001.
4. .Abdulateef, A. J., “Parametric Study on a Horizontal Axis Wind Turbine
Proposed for Water Pumping”, International Journal of Engineering Research.
Vol. 3 No. 10. 2014.
5. Wind Power Plants: Fundamentals, Design, Construction and Operation, R.
Gasch, J. Twele, et al., Springer Verlag, 2012
6. . Wind pump handbook (pilot edition) prepared by S.K Tewari and R.P.
Gupta, Tata Energy Research Institute, 1982.
7. Omar Badran, Wind turbine utilization for water pumping in Jordan written
by published in 2003
8. Misrak Girma, Abebayehu Assefa published on 8 December 2015.
Feasibility study of a wind powered water pumping system for rural Ethiopia
9. Eisa, E.I. 1983. Renewable energy potential and applications in Sudan. In:
Proceedings of the Round Table on Renewable Energy, 1016 King
Street,Virginia: USA
10. Omer, A.M. 1998. Horizons of using wind energy and establishing
windstations in Sudan. Dirasat Journal 25(3): 545-552. Amman: Jordan.
11. K.Suresh Babu, N.V.Subba Raju, M. Srinivasa Reddy, Dr. D. Nageswara
Rao, the material selection for typical wind turbine blades using a madm
approach& analysis of blades‖, MCDM 2006, Chania, Greece, June 19-23,
2006.
12. Sharatk. Tiwari, “An analysis of the appropriateness of wind and other
energy system for irrigation water pumping”, India, 1991

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A

MR. PARTH V. PAREKH

DEPARTMENT OF MECHANICAL ENGINEERING

PAREKH PARTH VINOD 1416350091

CHAUHAN ASHOKKUMAR MUKHRAM 1616350031

I declare that this written submission represents my ideas in my own words

Mr. Parth V. Parekh

Mr. Parth V. Parekh

The Imminent exhaustion of fossil energy sources, spreading global warming,

Keywords: windmill, global warming, windmill energy system, pumping,

Sr.No. Contents Page

Fig.1.1 Wind mill with combined systems

1.2 OBJECTIVE OF WORK:

• Lifting the water without using electricity and fossil fuel.

1.3 GENERAL INTRODUCTION:

The aim of this project is to design a windmill energy system to produce

Fig 1.2 Wind mill

1.4 Back Ground:

1.5 Types of Windmill:

1.5.1 Horizontal Axis:

1.5.2 Vertical Axis

1.5.3 Darrieus Wind Turbine

1.5.5 Twisted Savonius

2.2 Literature Survey

• Solidity ratio is 54%

DESIGN OF WATER PUMPING WINDMILL

WITH POWER GENERATION

3.2 Background Research

3.3 Effect of Number of Blade

3.6.2 Effect of Blade Number, On Aerodynamic Performance

Fig 3.1: Tip Speed vs. Power Coefficient

Fig 3.2: Coefficient of Performance vs. Tip Speed Ratio

3.4.2 Proposed Design Procedure:

1. Determine application: The first step in the design process is determining

5. Develop tentative design: Once an overall design layout has been

9. Refine design: Once preliminary design, design evaluation and cost

3.5 Initial blade design methodology

Fig 3.3 Blades (a)

Fig 3.4 Blades (b)

Electrical As the turbine is used to produce electrical energy there is an

5.2 Construction, fabrication

Fig.5.1 Rotor blades

5.4 Fabrication Processes

5.4.1 Rolling Process

Fig5.3 Assembly of wind mill

HYDRAULIC RECIPROCATING PUMP ASSEMBLY

6.2 Blade Hub

6.3 Crank Shaft

6.4 Connecting Rod

Fig 6.1 Gear set

6.7 Ball Bearing

Fig 6.2 Ball bearing

6.8 Pillow bearing

Fig 6.3 Pillow bearing

Fig. 6.4 Hydraulic pump

Fig 6.5 Tower

Fig 6.6 Hydraulic Reciprocating Pump Assembly

6.12 Working of hydraulic pumping system

Fig 6.7 Working of hydraulic pumping syste

POWER GENERATION ASSEMBLY

7.1 Rotor Blade

7.2 Blade Hub

7.3 Crank Shaft