Helical Axis Wind Mill

A Project Submitted
in Partial Fulfillment of the Requirements
for the Degree of

BACHELOR OF TECHNOLOGY
in
Electrical & Electronics Engineering
by
student name(roll no)
Under the Supervision of

Chandan Banerjee
(Designation)

Department of Electrical Engineering

United College of Engineering & Research, Allahabad (Code 010)

Dr. A.P.J. Abdul Kalam Technical University

Lucknow
May, 2018

ABSTRACT

1
The project is about creating a Gorlov Vertical Wind Turbine and testing

its performance. Throughout the course of the study, it is proven that the

turbine is much more efficient than its predecessors due to the nature of it

grasping wind, and harnessing its energy.

Conventional sources of power have become very expensive. Common

street lights consume a lot of energy; this project aims to use the wasted

energy of the wind to produce renewable energy source to produce

enough power to light one or more street light. In this project we are

going to design and assemble a helical wind turbine and attach it to one or

more streetlights.

The project will consist of a helical type turbine with an electric generator

attached to it directly via a coupling without the use of a gearbox allowing

the system to be simple and applicable on a wide scale.

2
 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 principles
of academic honesty and integrity and have not misrepresented or fabricated or
falsified any idea/data/fact/source 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 sources which have thus not been properly cited
or from whom proper permission has not been taken when needed.

DATE: STUDENT NAME

(ROLL)

VENUE:

3
 BONAFIDE CERTIFICATE

Certified that work presented in this report entitled “APPLICATION OF

BLDC MOTOR” for the award bachelor of technology from “DR. APJ
ABDUL KALAM TECHNICAL UNIVERSITY, LUCKNOW”,
embodies results of original work, and the studies are carried out by us and
the content of the thesis do not from the basis for award of any other degree
to the candidate or to anybody else from this or any other university/
institutions.

STUDENT NAME (ROLL NO)

NAME NAME

(PROJECT GUIDE) (HEAD OF DEPARTMENT )

4
 TABLE OF CONTENTS

Contents
ABSTRACT 2

DECLARATION 3

BONAFIDE CERTIFICATE 4

TABLE OF CONTENTS 5

Chapter 1 7

INTRODUCTION 7

1.1 PROJECT DEFINITION 7

1.2 PROJECT OBJECTIVES 7

1.3 PROJECT SPECIFICATIONS 8

1.4 PRODUCT ARCHITECTURE AND COMPONENTS 8

1.5 APPLICATION 8

1.6 SCOPE OF THE PROJECT 9

Chapter 2 10

LITERATURE REVIEW 10

2.1 PROJECT BACKGROUND 10

2.2 PREVIOUS WORK 13

2.3 GENERAL THEORY RELATED TO VERTICAL AXIS WIND TURBINE 14

Chapter 3 17

SYSTEM DESIGN 17

3.1 REQUIREMENTS, CONSTRAINTS AND SPECIFICATION 17

3.1.1 General specifications 17

3.1.2 Constraints and requirements 18

3.2 DESIGN METHODOLOGY 18

5
Product Subsystems & Components 19

3.3.1 ROTOR BLADES 20

3.3.2 SHAFT 21

3.3.3 Radial & Thrust Bearings 22

3.3.4 Electrical Parts 23

3.3.5 GENERATOR 24

3.4 VARIOUS OPERATIONS INOVLVED IN FABRICATION PROCESS 26

Gas cutting Torch 27

3.4.2 Advantages of the Gas Cutting. 27

3.4.4 RIVETING 29

Chapter 4 30

SYSTEM TESTING AND ANALYSIS 30

4.1 THEORETICAL WIND TURBINE POWER CALCULATION 30

4.2 APPLICATIONS OF WIND ENERGY 32

4.3 ADVANTAGE OF VERTICAL AXIS WIND TURBINE OVER HORIZONTAL

AXIS WIND TURBINE 32

4.4 BLOCK DIAGRAM OF WIND POWER GENERATION 34

4.5 REQUIREMENTS FOR PLACING 34

Chapter 5 36

CONCLUSION & FUTURE DEVELOPMENTS 36

5.1 CONCLUSION 36

5.2 FUTURE DEVELOPMENTS 36

Chapter 6 37

REFERENCES 37

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 Chapter 1

INTRODUCTION

1.1 PROJECT DEFINITION

This project is about designing and manufacturing an Aeroleaf Wind Turbine that can
convert wind by using Vertical Axis Wind Turbines (VAWT) to a useful energy. The
current power demanding in Saudi Arabia is very high compared to power
consumption world average, as reported by Arab news; Saudis consume three times
more electricity than the world average [1]. This high demanding should take the
focus of attention in thinking in different sources of energy. One of the best sources of
energy that can apply the concept of sustainability is renewable energy such as sun,
wind, and rivers. The positive point of wind energy is that unlike solar energy that
only used with sunlight, wind turbine can be useful all the 24 hours all the year.
Another concept of sustainability is the way that we should use in utilizing this
renewable energy efficiently, and environmentally friendly. This, in turn will
eliminate the environment hazard and improve Saudi Arabia communities’ health and
life style. Streets, public parks, schools, and public facilities are considering as main
power consumers, these consumers should be vulnerable to wind from time to time.
The idea of this project is to convert this wind by using Vertical Axis Wind Turbines
(VAWT) to a useful energy by using it as a power source that can serve these
consumers.

1.2 PROJECT OBJECTIVES

The main objective of this project is gaining power from wind. Therefore, this project
is green source of energy and has no effect on the life of earth. These wind energy

7
turbines are small and can produce up to 300 watts for each turbine. Another objective
of this project is gaining and exercising some engineering concepts such as:

● Learn about wind energy and different ways of convert it to a useful

power.
● Learn the different between Vertical Axis Wind Turbines (VAWT) &
Horizontal Axis Wind Turbines (HAWT).
● Learn the impact of energy & our rules as engineering students to provide
alternatives.

1.3 PROJECT SPECIFICATIONS

This project is 2.8-meter-high (tree & turbine), it is expected to produce total of up to
600 watts. The material that the tree is made of is galvanized carbon steel and the
turbine blades are made of aluminum alloy. The turbines can start working under low
wind speed and can cut-off if the speed is too high.

1.4 PRODUCT ARCHITECTURE AND COMPONENTS

The project main components are tow turbines which include (blades, shaft bearings)
for each turbine, electrical generator attached to the end of the shaft for each
generator. The generators are connecting through wires to the control banal, which
include (converter, controller and battery connected from and to the banal for the
popups of changing from and to DC & AC). Below figure1.1, identifying the initial
functional diagram that shows the expected project outlook. And initial real photo of
the project is in the below figure

8
 Fig:1 Project initial real photo

1.5 APPLICATION
This project idea is very simple, where it focuses on utilizing the wind energy by
designing and manufacturing two VAWT and attach them to a manufactured tree.
This tree can be installed across the public facilities. Facilities such as public parks, in
the top of the stadiums where wind is very high and around the stadiums, services’
buildings, and over the roads and streets. It can also install in a simulated tree.

1.6 SCOPE OF THE PROJECT

To utilize the available wind resources and to reduce the usage of non-renewable
energy resources. Wind energy is by far the fastest-growing renewable energy
resource. The wind energy industry so far has been supported by market incentives
backed by government policies fostering sustainable energy resources.
Large-scale wind facilities approaching the output rating of conventional power
plants, control of the power quality is required to reduce the adverse effects on their
integration into the network. These wind turbines can be used to provide constant
lighting. In most cities, bridges are a faster route for everyday commute and in need
of constant lighting makes this an efficient way to produce natural energy.

9
 Chapter 2

LITERATURE REVIEW

2.1 PROJECT BACKGROUND

Energy is the main economy base of any country. Sources of energy are not easy to
have. Having multiple sources of energy is extremely important to secure the basic
living requirement of any country. Utilizing the nature could help in converting some
of the natural phenomenon’s such as sun, wind, sea and oil into useful energy. This
kind of energy called renewable energy.

Science Daily Research Newspaper has defended renewable energy as “The most
common definition is that renewable energy is from an energy resource that is
replaced rapidly by a natural process such as power generated from the sun or from
the wind.” [2].

Recently, the increasing demand of renewable energy is very well noticed. According
to a report by the International Energy Agency, the increase of amount of electricity
produced from renewable sources increased from just over 13% in 2012 to 22% the
following year. They also predict that that figure should hit 26% by 2020 [3].

The traditional power plants in Saudi Arabia are mainly working on the fuel either
gas or oil which are not environmental friendly. EcoSpark environmental charity [4]
has considered oil power plants as one of the most contributors of environment
pollution. EcoSpark environmental charity has listed the below most significant
environmental impacts:

● Oil causes air pollution and greenhouse gas emissions.

● Oil uses large amounts of water, and creates water pollution and thermal
discharge.  Oil creates hazardous sludge and solid waste.
● Extracting and refining oil is environmentally destructive.
● Transporting oil is risky and can harm the environment.
● Oil is a non-renewable electricity source. Such of the above environment
affects lead us to think seriously about the renewable energy sources, which
will eliminate the environment hazard and improve health and life style.

10
Wind energy is one of the most important energy sources. The concept of wind
energy is transforming the wind’s kinetic energy into mechanical energy. This energy
drive blades that turn generators that produce electricity. Our project is fitting with
wind energy source. The idea of this project is to convert the wind by using Vertical
Axis Wind Turbines (VAWT) into power. They are two types of wind turbines,
Horizontal Axis Wind Turbines (HAWT) as shown in figure 2.1 that is more
commonly used across the world and they are used as a power plants.

Fig:2.1 VAWT overview layout

These kind of turbines are the most efficient of wind turbine. Cole Gustafson from
Dakota State University has mentioned the advantages and disadvantages of
horizontal axis vs vertical axis wind turbines, “In research studies evaluating wind
turbine performance, horizontal axis machines have been shown to be more efficient
than vertical axis machines. However, the blade span of horizontal wind turbines is
larger than vertical axis machines which limits placement confined spaces. Some
people also find the large blade area of horizontal axis machines objectionable” [5].

The other type of wind turbine is the Vertical Axis Wind Turbines (VAWT) as
shown in figure 2.2. VAWT is the most popular of the turbines that people are
using to make their home a source of renewable energy.

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 Fig:2.2 VAWT overview layout

VAWT is not as commonly used as the Horizontal Axis Wind Turbine. The reason
behind that is that VAWT is less efficient than HAWT when considered as a power
plant generator. However, for the small scales like homes, parks, or offices VAWT is
more efficient. “Vertical axis turbines are powered by wind coming from all 360
degrees, and even some turbines are powered when the wind blows from top to
bottom. Because of this versatility, vertical axis wind turbines are thought to be ideal
for installations where wind conditions are not consistent, or due to public ordinances
the turbine cannot be placed high enough to benefit from steady wind.” [6]. Figure 2.3
shows the configuration of HAWT vs VAWT.

Fig: 2.2

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2.2 PREVIOUS WORK
There are two different styles of vertical wind turbines. One is the Savonius model,
which is our project is based on, and the other type is the Darrieus model. The first
model looks like a gallon drum that is been cut in half with the halves placed onto a
rotating shaft. The second model is smaller and looks much like an egg beater. Most
of the wind turbines being used today are the Savonius models.

Renewable Energy UK website provided some information about these two model.
“A Savonius is a type of vertical axis wind turbine (VAWT) generator invented in
1922 by Sigurd Johannes Savonius from Finland though similar wind turbine designs
had been attempted in previous centuries."[7].

“A Darrieus is a type of vertical axis wind turbine (VAWT) generator. Unlike the
Savonius wind turbine, the Darrieus is a lift-type VAWT. Rather than collecting the
wind in cups dragging the turbine around, a Darrieus uses lift forces generated by the
wind hitting aerofoils to create rotation.” [8].

In Jun 2.15, International Research Journal of Engineering and Technology (IRJET)

has published a research titled “DESIGN, ANALYSIS AND FABRICATION OF
SAVONIUS VERTICAL AXIS WIND TURBINE” [9].

This research discussion was to showcase the efficiency of Savonius model in varying
wind conditions as compared to the traditional horizontal axis wind turbine. It
evaluated some observation that showed that at low angles of attack the lift force also
contributes to the overall torque generation. Thus, it can be concluded that the
Savonius rotor is not a solely drag-driven machine but a combination of a drag-driven
and lift-driven device. Therefore, it can go beyond the limit of Maximum power
coefficient Cp established for the purely drag-driven machines.

Some of this researched conclusions are that The vertical axis wind turbine is a small
power generating unit with the help of free source of wind energy. It is designed
under consideration of household use. Generally, At least 10% power of the
consumption can be fulfilling by the Savonius model.

The research has also resulted that this turbine is generally suitable for 8 to 10m of
height above ground level. Because at ground level velocity of air is very less. And

13
finally the alternate option for turbine blade material is reinforced glass fiber because
of its more elastic nature but it is costlier than aluminum alloy.

To have the best efficiency of the power output from our turbine, the team has done
some brainstorming in what are the most significant factor that affect the turbine, the
blade angle was agreed to be the most significant one.

By doing some researches, we fined an article that focusing in the turbine blade angle.

A research article published by Advances in Mechanical Engineering (AIME) with a

title of “EFFECT OF THE BLADE ARC ANGLE ON THE PERFORMANCE OF A
SEVONIUS WIND TURBINE” [10].

This article is focusing on how to improve the efficiency of the turbine by selecting
the best blade angle.

The effect of the blade arc angle on the performance of a typical two-bladed Savonius
wind turbine is investigated with a transient computational fluid dynamics method.
Simulations were based on the Reynolds Averaged Navier–Stokes equations, and the
renormalization group turbulent model was utilized.

The numerical method was validated with existing experimental data.

The results of this article indicate that the turbine with a blade arc angle of 160°
generates the maximum power coefficient cp 0.2836, which is the highest that gain
from the experiment.

2.3 GENERAL THEORY RELATED TO VERTICAL AXIS WIND TURBINE

The forces and the velocities acting in a Darrieus turbine are depicted in figure 1.
The resultant velocity vector, , is the vectorial sum of the undisturbed
upstream air velocity, , and the velocity vector of the advancing blade,
.

14
Thus, the oncoming fluid velocity varies, the maximum is found for and
the minimum is found for , where θ is the azimuthal or orbital blade
position. The angle of attack, α, is the angle between the oncoming air speed, W,
and the blade's chord. The resultant airflow creates a varying, positive angle of
attack to the blade in the upstream zone of the machine, switching sign in the
downstream zone of the machine.

From geometrical considerations, the resultant airspeed flow and the angle of attack
are calculated as follows:

Where is the tip speed ratio parameter

The resultant aerodynamic force is decomposed either in lift (F_L) – drag

(D) components or normal (N) - tangential (T) components. The forces are
considered acting at 1/4 chord from the leading edge (by convention), the pitching
moment is determined to resolve the aerodynamic forces. The aeronautical terms
lift and drag are, strictly speaking, forces across and along the approaching net

15
relative airflow respectively. The tangential force is acting along the blade's
velocity and, thus, pulling the blade around and the normal force is acting radially,
and, thus, is acting against the bearings. The lift and the drag force are useful when
dealing with the aerodynamic behavior around each blade, i.e. dynamic stall,
boundary layer, etc; while when dealing with global performance, fatigue loads,
etc., it is more convenient to have a normal-tangential frame. The lift and the drag
coefficients are usually normalized by the dynamic pressure of the relative airflow,
while the normal and the tangential coefficients are usually normalized by the
dynamic pressure of undisturbed upstream fluid velocity.

where

A = Surface Area

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ρ= Density of air

D= Drag component of aerodynamic force

N=Normal component of aerodynamic force

T=Tangential component of aerodynamic force

FL=Lift component of aerodynamic force

The amount of power, P , which can be absorbed by a wind turbine.

Where Cp is the power coefficient, ρ is the density of the air, A is the swept area of
the turbine, and ν is the wind speed

17
 Chapter 3

SYSTEM DESIGN

3.1 REQUIREMENTS, CONSTRAINTS AND SPECIFICATION

3.1.1 General specifications

Aeroleaf wind turbine is new way of producing energy form Vertical-axis method.
This new energy source is useful in the modern cities because of it is nice design and
free noise. These wind energy generators are. The Aeroleaf tree is designed hold two
wind Savonius turbine, which are small in size and can produce up to 300 watts.

The positive point of wind energy is that unlike solar energy that only can be used
with sunlight only. Wind energy can be useful all the 24 hours all the year. This
project is green source of energy and has no effect on the life of earth.

There are no effects on the environment at all. Moreover, it is reducing the CO2 and
CO gases that effect the environment in the earth. One of the biggest challenges is the
social accept of Aeroleaf Wind turbine.

3.1.2 Constraints and requirements

One of the most difficultly problem is the lack of necessary equipment needed for the
analysis and selection of materials accurately in the university. Also, in the market, I
was really difficult to find some of the needed materials.

These problems make the function of this project relying for some parts in design of
previous studies mentioned in chapter 2 by doing the reverse engineering.

Getting a sufficient wind, to analyze and test work. It was also the one of the berries
that we have encountered, because of the lack of wind in the area at that time, and the
lack of experience in aerodynamic science.

Beside the Lack of important resources, the lack of financial support was a major
obstacle in our way even though the budget was estimated.

18
Although the existence of moral support from our professors, Lack of sufficient time
was a real challenge to show up the work as long as there was only one semester to
complete the senior project.

3.2 DESIGN METHODOLOGY

The methodology applied to this project can be divided into six phases. These phases
are information gathering, concept generation, model generation, model analysis and
refinement, concept selection, and verification, these phases are shown in figure 3.2.

Fig: 3.2 Applied Phases of used Methodology

Prior any appropriate solution can be developed, a thorough investigation has to be

conducted in order to find out what solutions have already been proposed
(information gathering).

Once these solutions have been analyzed and the team has an understanding of why
the respective solutions are not currently being implemented, a solution generation
phase is taking place. Here various solutions are presented and evaluated against
criteria and constraints (concept generation). Solution concepts are then modeling

The results of the models are then analyzed and the model, as well as solution
parameters, may be tweaked (model analysis and refinement).

Once the team has satisfactorily modeled all solution concepts of interest, the concept
that performs best analytically, in addition to meeting all criteria and constraints, is
selected (concept selection). The analytical model may then be verified
experimentally, using a small scale modeling scheme or through a full scale
experimental model. The objective of this project is to design a vertical axis wind

19
turbine (VAWT) that could generate power under relatively low wind velocities. To
accomplish this goal, the objectives are to:

● Analyze how different geometry of the wind turbines would affect the output
power of the wind turbine.
● Vibrations analysis by testing how the vibrations caused from the rotations of
the wind turbines affect the structural integrity of various aspects buildings
structures.
● Compare the operation of turbines with respect to the numbers of attached
blades. To meet the above objectives, the tasks were to:
● Conduct background research and analysis on wind turbine technology.
● Design initially turbine blade for testing.
● Design tree to hold these turbines.
● Looking for power generator that has good efficiency with low startup speed.
● Create experimental set up.
● Manufacture parts and build model tree.
● Develop future design recommendations.

Product Subsystems & Components

Vertical axis wind turbine VAWT are one whose axis of rotation is vertical with
respect to ground. Generally, as shown in figure 3.3, the main components of this
turbine are:

● Blades
● Shaft
● Generator

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 Fig:3.3 Main components of VAWT

3.3.1 ROTOR BLADES

Savonius blades are a crucial and basic part of a wind turbine figure 3.4. They are
mainly made of aluminum, fiber glass or carbon fiber. We selected the aluminum
alloy as recommended in the study mentioned in chapter 2.2 because they provide
batter strength to weight ratio. The design of the individual blades also affects the
overall design of the rotor. Rotor blades take the energy out of the wind; they capture
the wind and convert its kinetic energy into the rotation of the hub. The arc angle was
selected based on the pervious study mentioned in chapter 2.2, which recommended
an angle of 160°

21
22
 Figure 3.4 Turbine Blade Design

3.3.2 SHAFT
The shaft is the part that gets turned by the turbine blades. It in turn is connected to
the generator within the main housing. A solid works tools have been used in
designing the blades and the shaft as shown in the below figure 3.5

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 Fig: 3.5 Turbine Blade and Shaft Design

3.3.3 Radial & Thrust Bearings

The bearing is integral part of the overall system. The lubricant and sealing elements
also play a crucial role. To enhance bearing effectiveness in the system, the right type

24
should be selected. However, the procedure of the selection is a science but we
restricted on three simple steps:

1- Confirm operating conditions and operating environment.

2- Select bearing type and configuration.

3- Select bearing dimensions.

The correct amount of an appropriate lubricant must be present to reduce friction in

the bearing was consider. As long as the sealing elements are important because of the
environment surrounding our project and keep the lubricant in, and away from the
dust and contaminants. On another side, the low speed of the system was considering
too in the selection with axis and radial forces which is the weights of upper system.

As result we came up with two ball bearing 6004RS as shown in figure 3.6 where can
function as thrust and radial bearing (sealed and self-lubricant) and can carry the
Static Load Rating and Dynamic Load Rating 5 KN and 9 KN respectively and the
distance between the two bearings was based on as simulation Xpress done by Central
University Campus.

ITME.no. DESCRIPTION
3 and 8 ball bearing_6004 RS

Figure 3.6 Selected Bearing Details

25
3.3.4 Electrical Parts
The turbines are connected to electrical parts in order to get the required
power. These parts are as shown in the below table 3.1.

Part Function
Electrical Converting the rotating speed to an electrical
Generator
Turbine
Controller
Combiner Combining the earned power from each turbine to one
output power
Charged electrically to provide a static potential for
Battery power or
released electrical charge when needed.
an electrical device that can interrupt the flow of
Fuse electrical current
when it is overloaded
Converter Converting DC current to AC current
Turbine Braking overload
Sensors
Consumption Reading battery percentage
reading

3.3.5 GENERATOR
The conversion of rotational mechanical energy to electrical energy is
performed by generator. Different types of generator have been used in wind
energy system over the years. For large, commercial size horizontal-axis wind
turbines, the generator is mounted in a nacelle at the top of a tower, behind the
hub of the turbine rotor. Typically wind turbines generate electricity through
asynchronous machines that are directly connected with the electricity grid.
Usually the rotational speed of the wind turbine is slower than the equivalent
rotation speed of the electrical network - typical rotation speeds for wind
generators are 5- 20 rpm while a directly connected machine will have an
electrical speed between 750-3600 rpm. Therefore, a gearbox is inserted
between the rotor hub and the generator. This also reduces the generator cost
and weight. The generator used for the prototype is the Low RPM permanent

26
magnet DC generator created by Wind Stream Power and is a 12-volt step
generator. The generator has an internal resistance of 21Ω.
The current generator can only operate continuously with a current of 1.5
amperes and at a max of 1.5 minutes with a current of 3 amperes the below
figures 3.6 and 3.7 are explaining the generator parts.

Fig:3.7 Figure 3.6 Generator parts

Fig 3.8 Generator parts with description

Bearing

27
For the smooth operation of Shaft, bearing mechanism is used. To have very less
friction loss, the two ends of shaft are pivoted into the same dimension bearing. The
Bearing has diameter of 2.54cm. Bearings are generally provided for supporting the
shaft and smooth operation of shaft

Fig 3.9 Actual used generator model

3.4 VARIOUS OPERATIONS INOVLVED IN FABRICATION PROCESS

The following were the fabrication techniques involved

1. Gas Cutting

2. Arc Welding

3. Riveting

28
3.4.1 GAS CUTTING

A cutting torch is used to heat metal to kindling temperature. A stream of oxygen is

then trained on the metal and metal burns in that oxygen and then flows out of the cut.

For cutting, the set-up is a little different. A cutting torch has a 60- or 90- degree
angled head with orifices placed around a central jet. The outer jets are for preheat
flames of oxygen and acetylene. The central jet carries only oxygen for cutting. The
use of a number of preheating flames, rather than a single flame makes it possible to
change the direction of the cut as desired without changing the position of the nozzle
or the angle which the torch makes with the direction of the cut, as well as giving a
better preheat balance . Manufacturers have developed custom tips for Mapp,
propane, and polypropylene gases to optimize the flames from these alternate fuel
gases

Gas cutting Torch

Fig:3.9 Gas cutting

The gases used in this process are

29
 1. LPG

2. Helium

3.4.2 Advantages of the Gas Cutting.

● Environment friendly (reducing the emission of CO2)

● High quality of cut surface

● Reduction of man-hours for finishing after cutting

● High productivity by high speed cutting.

30
3.4.3 ARC WELDING

Arc welding uses a welding power supply to create an electric arc between an
electrode and the base material to melt the metals at the welding point. They can use
either direct (DC) or alternating (AC) current, and consumable or non-consumable
electrodes. The welding region is sometimes protected by some type of inert or semi-
inert gas, known as a shielding gas, and/or an evaporating filler material. The process
of arc welding is widely used because of its low capital and running costs

The following gauge lengths of electrodes are used in this process 8, 10&12mm. The
number of electrodes used in this fabrication is around 40- 45 electrodes.

Arc Welding Equipment

Fig3.10 Arc welding tool

31
3.4.4 RIVETING

A rivet is a permanent mechanical fastener. Before being installed a rivet consists of a

smooth cylindrical shaft with a head on one end. The end opposite the head is called
the buck-tail. On installation the rivet is placed in a punched or pre-drilled hole, and
the tail is upset, or bucked (i.e. deformed), so that it expands to about 1.5 times the
original shaft diameter, holding the rivet in place. To distinguish between the two
ends of the rivet, the original head is called the factory head and the deformed end is
called the shop head or buck-tail.

Because there is effectively a head on each end of an installed rivet, it can support
tension loads (loads parallel to the axis of the shaft); however, it is much more
capable of supporting shear loads (loads perpendicular to the axis of the shaft). Bolts
and screws are better suited for tension applications.

RIVETING EQUIPMENT

32
 Fig:3.11 Rivet

Chapter 4

SYSTEM TESTING AND ANALYSIS

4.1 THEORETICAL WIND TURBINE POWER CALCULATION

Wind Power depends on:

∙ amount of air (volume)

∙ speed of air (velocity)

∙ mass of air (density)

The wind mill works on the principle of converting kinetic energy of the wind to
mechanical energy. The kinetic energy of any particle is equal to one half its mass
times the square of its velocity, or ½ mv2.

K.E=½ mv2. ………………….. (1)

K.E = kinetic energy

m= mass

v = velocity,

M is equal to its Volume multiplied by its density ρ of air

M = ρ AV ………………(2)
Substituting eqn(2) in eqn(1)
We get,
K E = ½ ρ AV.V2

K E = ½ ρ AV3 watts

ρ = density of air (1.225 kg/m3)

A = π D2 /4 (Sq.m)

D = diameter of the blade

33
 A = π*(1.22) 2 /4 A = 1.16Sq.m

Available wind power Pa = (½ ρ π D2 V3)/4

P = 1/8   D2 V3

TRAIL 1

FOR VELOCITY 4.5m/s

Pa = (½ ρ π D2 V3)/4

Pa = (½*1.225*π*1.222 *4.53)/4

Pa = 65.244watt

TRAIL 2

FOR VELOCITY 5.5m/s

Pa = (½ ρ π D2 V3)/4

Pa = (½*1.225*π*1.222 *5.53)/4

Pa = 119.12watt

TRAIL 3

FOR VELOCITY 7.5m/s

Pa = (½ ρ π D2 V3)/4

Pa = (½*1.225*π*1.222 *7.53)/4

Pa = 302.06watt

34
TRAIL 4

FOR VELOCITY 10m/s

Pa = (½ ρ π D2 V3)/4

Pa = (½*1.225*π*1.222 *103)/4

Pa = 716.00watt

4.2 APPLICATIONS OF WIND ENERGY

Wind-turbine generators have been built a wide range of power outputs from kilowatt
or so to a few thousand kilowatts, machine of low power can generate sufficient
electricity for space heating & cooling & for operating domestic appliances.

Low power WEC generators have been used for many years for the corrosion
protection of buried metal pipe lines.

Application of more powerful turbines up to about 50kw, are for operating irrigation
pumps, Navigational signal. Aero generators in the intermediate power range, roughly
100 to 25 KW can supply electricity to isolated populations.

4.3 ADVANTAGE OF VERTICAL AXIS WIND TURBINE OVER

HORIZONTAL AXIS WIND TURBINE
There are several reasons why we would choose a vertical axis wind turbine over a
horizontal axis windmill.

1. They are mounted lower to the ground making it easy for

maintenance if needed.

2. They start creating electricity at speeds of only 6 mph. And

3. Third, they may be able to be built at locations where taller structures,

such as the horizontal type, can't be.

4. Higher power utilization-- 20% higher than HAWT.

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 5. Lower noise level--only 27-37 DB, suitable for your living condition.

6. Safer operation--Spin at slower speeds than horizontal turbines,

decreasing the risk of injuring birds and also decreasing noise level.

7. Simpler installation and maintenance-- besides the traditional

installation site, it can be mounted directly on a rooftop, doing away
with the tower and associated guy lines.

8. Not affected by orientation variation—no matter the wind blow from

any orientation, VAWT can work without regard to its face.

9. Economical and practical-Although one-time investment expenses are

larger, but you don’t have to pay higher tariffs forever.

Advantages

a) It is a renewable source of energy.

b) Wind power systems are non-polluting so it has no adverse influence

on the environment.

c) Wind energy systems avoid fuel provision and transport.

d) On a small scale up to a few kilowatt system is less costly.

e) On a large scale costs can be competitive conventional electricity and

lower costs could be achieved by mass production.

f) They are always facing the wind - no need for steering into the wind.

g) Have greater surface area for energy capture -can be many times
greater.

h) Are more efficient in gusty winds – already facing the gust.

i) Can be installed in more locations - on roofs, along highways, in

parking lots.

Can be scaled more easily - from mill watts to megawatts.

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4.4 BLOCK DIAGRAM OF WIND POWER GENERATION

Fig 4.1 Block Diagram

4.5 REQUIREMENTS FOR PLACING

Site Selection considerations

The power available in the wind increases rapidly with the speed; hence wind energy
conversion machines should be located preferable in areas where the winds are strong
& persistent. The following point should be considered while selecting site for Wind
Energy Conversion System (WECS).

● High annual average wind speed

The wind velocity is the critical parameter. The power in the wind Pw, through a given
X – section area for a uniform wind Velocity is
Pw = KV3 (K is constant) It is evident, because of the cubic dependence on wind
velocity that small increases in V markedly affect the power in the wind e.g.
doubling V, increases Pw by a factor of 8.

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● Availability of wind V(t) curve at the proposed site This important curve
determines the maximum energy in the wind and hence is the principle
initially controlling factor in predicting the electrical o/p and hence revenue
return of the WECS machines, it is desirable to have average wind speed V
such that

V=12-16 km/hr i.e. (3.5 – 4.5 m/sec).

● Wind structures at the proposed site

Wind especially near the ground is turbulent and gusty, & changes rapidly
indirection and in velocity. This departure from homogeneous flow is collectively
referred to as “the structure of the wind”.

● Altitude of the proposed site

If affects the air density and thus the power in the wind & hence the useful WECS
electric power o/p. The winds tends to have higher velocities at higher altitudes.

● Local Ecology

If the surface is bare rock it may mean lower hub heights hence lower structure
cost, if trees or grass or ventation are present. All of which tends to destructure the
wind.

● Nearness of site to local center/users

This obvious criterion minimizes transmission line length & hence losses & costs.

● Nature of ground

Ground condition should be such that the foundations for WECs are secured,
ground surface should be stable.

● Favorable land cost

● Land cost should be favorable as this along with other sitting costs, enters into
the total WECS system cost.

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 Chapter 5

CONCLUSION & FUTURE DEVELOPMENTS

5.1 CONCLUSION

Our work and the results obtained so far are very encouraging and reinforce the

conviction that vertical axis wind energy conversion systems are practical and

potentially very contributive to the production of clean renewable electricity from

the wind even under less than ideal sitting conditions. It is hoped that they may be

constructed used high-strength, low- weight materials for deployment in more

developed nations and settings or with very low tech local materials and local skills

in less developed countries. The Savonius wind turbine designed is ideal to be

located on top of a bridge or bridges to generate electricity, powered by wind. The

elevated altitude gives it an advantage for more wind opportunity. With the idea on

top of a bridge, it will power up street lights and or commercial use. In most cities,

bridges are a faster route for everyday commute and in need of constant lighting

makes this an efficient way to produce natural energy

5.2 FUTURE DEVELOPMENTS

The development of effective alternators and dynamos can be used to harness wind

energy from relatively small winds. The use of materials like Acrylic Plastic Sheets

can be used to develop low cost HAWT.

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 Chapter 6

REFERENCES

1. K.F. Mihaj, K.K. Segamat and K.B. Ching, (2013), Conceptual Design of
Harvesting Energy System for Road Application, CiE-TVET 2013 Platform
Pembudayaan Penyelidikan.

2. M. Kumar, D. Parashar (2014), Piezoelectricity: A New way of taming Electricity,

Physics Education, Volume 30, no 4, pp. 01-05.

3. Royal Academy of Engineering (April 2014), WIND ENERGY implications of

large-scale deployment on the GB electricity system.

4. Salvadori S., Morbiato T., Mattana A., Fusto E., (2012), On the characterization of
wind profiles generated by road traffic, BBAA7, China proceeding, pp.-1367-1369.

5. Sinisa S, Campbell, Harris, Haris J., (2009), Urban wind energy UK &USA,
Earthscan.

6. S. Rammohan, C. M. Ramya, S. Jayanth Kumar, Anjana Jain and Rudra Pratap,

"Low frequency vibration energy harvesting using arrays of PVDF piezoelectric
bimorphs", Journal of ISSS, Vol. 3, No. 1, pp 18-27, March 2014.

7. Wind Energy implications of large-scale deployment on the GB electricity system

(April 2014) report published by Royal Academy of Engineering.

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