FABRICATION OF VERTICAL AXIS WIND MILL

CHAPTER-1
INTRODUCTION
The transition towards sustainable and renewable energy solutions has fueled
innovation across various sectors, and within the realm of wind energy, the Vertical Axis Wind
Mill (VAWM) has emerged as a distinctive and promising technology. Unlike the conventional
Horizontal Axis Wind Turbines (HAWTs), which have dominated the landscape of wind power
generation, VAWMs feature a rotor shaft oriented vertically, revolutionizing the approach to
harnessing wind energy. This unique design holds the potential to address some of the
limitations associated with traditional wind turbines, offering advantages that extend from
improved omnidirectional wind capture to reduced visual and noise impacts. As the world
seeks cleaner and more efficient alternatives to traditional energy sources, the exploration of
unconventional designs like the VAWM becomes increasingly crucial.
The quest for sustainable and renewable energy sources has led to the exploration of
various technologies that harness the power of nature. One such technology that has gained
prominence in recent years is the Vertical Axis Wind Mill (VAWM), a distinctive and
innovative approach to capturing wind energy. Unlike the conventional horizontal axis wind
turbines that dominate the wind energy landscape, VAWM offer unique advantages and present
new possibilities for harnessing wind power in diverse settings. This introduction provides an
in-depth exploration of the fundamental principles, historical evolution, and contemporary
significance of vertical axis windmills, offering a comprehensive foundation for understanding
their role in the renewable energy landscape.

1.2 Historical Evolution of Vertical Axis Wind Mills:

Early Beginnings:
The concept of harnessing wind energy dates back centuries, with historical records
revealing the use of simple wind-driven devices for various applications. Early civilizations
employed windmills for milling grains and pumping water. The classic image of a windmill,
with its large blades turning on a horizontal axis, became synonymous with harnessing wind
power. However, as technology advanced, the limitations of the horizontal axis design became
apparent, especially in turbulent wind conditions.

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Emergence of Vertical Axis Wind Mills:

The idea of vertical axis windmills is not new, but it gained renewed attention in the
mid-20th century as researchers sought alternative designs for efficient energy capture. The
Darrieus rotor, a type of vertical axis wind turbine named after its French inventor Georges
Darrieus, emerged as a pioneering design in the 1930s. This vertical-axis rotor, characterized
by its slender, curved blades, exhibited promising features for harnessing wind energy in a
variety of conditions.

1.3 Fundamental Principles of Vertical Axis Wind Mills:

Vertical Axis Design:
VAWMs differ fundamentally from their horizontal counterparts in their orientation to
the wind. While horizontal turbines have blades that rotate around a central horizontal axis,
VAWMs have blades that spin around a vertical axis. This distinctive design offers several
advantages, including simplicity, scalability, and the ability to capture wind from any direction
without the need for complex yaw mechanisms.

Blade Configurations:
One of the key elements of VAWM design is the configuration of the blades.
Researchers have explored various blade shapes, including straight, curved, and helical
designs. The aerodynamic efficiency and structural integrity of these blades play a crucial role
in determining the overall performance of VAWMs. Understanding how different blade
configurations interact with the wind is essential for optimizing energy capture.

1.4. Aerodynamics of Vertical Axis Wind Mills:

Flow Patterns and Forces:
Aerodynamics is a critical aspect of VAWMs, and researchers employ advanced
techniques such as Computational Fluid Dynamics (CFD) simulations and wind tunnel
experiments to study the flow patterns and forces acting on the blades. The interaction between
the blades and the wind, including lift and drag forces, stall conditions, and turbulence, is a
complex yet essential area of investigation.

Starting Performance:
The ability of VAWM to start rotating and generate power in low-wind conditions is a
significant consideration for practical applications. Research has focused on understanding the

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starting torque and rotational speed of VAWMs, aiming to enhance their reliability and
performance across a range of wind speeds.

1.5. Performance Parameters and Optimization:

Power Coefficient:
Efficiency is a key performance metric for VAWM, often measured by the power
coefficient. This metric reflects the ability of the windmill to convert the kinetic energy of the
wind into mechanical power. Studies have delved into the variations of the power coefficient
under different wind conditions and blade configurations, providing valuable insights into the
factors influencing the energy output of VAWM systems.

Structural Integrity:
Ensuring the structural integrity of VAWM is crucial, especially in the face of turbulent
winds and dynamic loads. Researchers explore materials, design enhancements, and
construction techniques to improve the robustness and longevity of VAWM systems.
Addressing structural challenges is essential for the widespread adoption of VAWM
technology.

1.6 Applications of Vertical Axis Wind Mills:

Urban Environments:
The unique characteristics of VAWM, such as their ability to capture wind from any
direction and operate in turbulent urban winds, make them suitable for urban environments.
Researchers and urban planners are exploring the integration of VAWM into city landscapes
as a means of generating local, sustainable power.

Off-Grid and Remote Areas:

In off-grid and remote locations with limited access to conventional power sources,
VAWM offer a promising solution. Studies have investigated the feasibility of deploying
VAWM in remote areas to provide reliable and sustainable energy for communities that are off
the traditional power grid.

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1.7. Challenges and Future Directions:

Structural Design Challenges:
Despite the promising features of VAWM, challenges in structural design persist.
Researchers are actively working to address issues related to the dynamic loads imposed by
turbulent winds, ensuring that VAWM remain resilient and durable under varying conditions.

Comparative Studies:
A notable gap in current research is the comparative analysis between horizontal and
vertical axis wind turbines. Understanding the strengths and weaknesses of each design is
crucial for making informed decisions regarding their deployment in different settings. Future
research should focus on comprehensive comparative studies to guide the optimal choice of
wind turbine technology.

1.8. Savonius Wind Turbine:

Savonius turbines are one of the simplest turbines. Aerodynamically, they are drag type
devices, consisting of two or three scoops. Looking down on the rotor from above, a two-scoop
machine would look like an”S” shape in cross section. Because of the curvature, the scoops
experience less the drag when moving against the wind than when moving with the wind. The
differential drags cause Savonius turbine to spin. Because they are drag-type devices, Savonius
turbines extract much less of the wind’s power than other similarly-sized lift-type turbines.
Much of the swept area of a Savonius rotor may be near the ground, if it has a small mount
without an extended post, making the overall energy extraction less effective due to the lower
wind speeds found at lower heights.
Advantages of Savonius Turbines:
Savonius turbines are used whenever cost or the reliability is much more important than
efficiency. For example, most anemometers are Savonius turbines, because efficiency is
completely irrelevant for that application. Much larger Savonius turbines have been used to
generate electric power on deep-water buoys, which need small amounts of power and get very
little maintenance. Design is simplified because, unlike with Horizontal Axis Wind Turbines
(HAWTs), no pointing mechanism is required to allow for shifting wind direction and the
turbine is self-starting. They can sometimes have long helical scoops, to give smooth torque.
The most ubiquitous application of the Savonius wind turbine is the Flettner

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Ventilator which is commonly seen on the roofs of vans and buses and is used as a cooling
device. The ventilator was developed by the German aircraft engineer Anton Flettner in the
1920s. It uses the Savonius wind turbine to drive an extractor fan. The vents are still
manufactured in the UK by Flettner Ventilator Limited Small Savonius wind turbines are
sometimes seen used as advertising signs where the rotation helps to draw attention to the item
advertised. They sometimes feature a simple two- frame animation.
1.9 COMPONENTS OF VERTICAL AXIS WIND MILL
BLADES:
The blades of a VAWM are critical components that define its performance. Unlike the
elongated horizontal blades of HAWTs, VAWM blades are shorter and arranged vertically
around the rotor shaft. The design and material composition of these blades are paramount for
optimizing aerodynamic efficiency and energy capture. The use of advanced materials, such as
lightweight composites or durable metals, strikes a balance between structural integrity and
weight considerations.

ROTOR SHAFT:
The rotor shaft serves as the central axis of the VAWM, around which the blades rotate.
Positioned vertically, this orientation is a hallmark of VAWMs. The rotor shaft connects to the

Figure 1.9.1 shows Rotor shaft

generator or other power generation mechanisms, acting as the conduit for converting the
mechanical energy generated by the rotating blades into electrical power.

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GENERATOR:
The generator is a crucial component responsible for the conversion of mechanical
energy into electrical power. Various types of generators, including synchronous or
asynchronous models, may be employed in VAWMs. The selection depends on factors such as

Figure 1.9.2 shows Generator

desired power output, efficiency, and cost considerations. The generator is typically situated at
the top or bottom of the turbine, connected to the rotor shaft through a transmission system.

SUPPORT STRUCTURE:
The support structure provides the necessary stability and elevation for the VAWM.
This structure includes the tower and base, engineered to withstand wind loads and

Figure 1.9.3 shows Support Structure

environmental stresses. In addition to supporting the turbine's weight, the tower houses the
transmission system that transfers the rotational energy from the rotor shaft to the generator.
The support structure is crucial for ensuring the longevity and reliability of the VAWM.

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CONTROL SYSTEMS:
Control systems are integral to the operation of VAWMs. These systems may
encompass a range of technologies, including sensors to monitor wind conditions, pitch control
mechanisms to adjust blade angles for optimal performance, and safety features to shut down
the turbine in extreme conditions. Control systems contribute to the efficiency, safety, and
overall effectiveness of VAWMs in converting wind energy into electricity.

Figure 1.9.4 shows VAWM

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CHAPTER-2
2.1 LITERATURE SURVEY:
[1] Niranjana.S.J investigated the power generation by vertical axis wind turbine. In this paper
the power is generated by fixing the wind mill on the road high ways. when the vehicle is
passed through the road at high speed the turbine of the wind mill rotates and generates the
power sources. This analysis indicates that the vertical axis wind turbine can be able to attain
the air from all the direction and produces the power of 1 kilowatt for a movement of 25 m/s.
The efficiency of vertical axis wind turbine can be increases by modifying the size and shape
of the blade.

[2] Abmjit N Roy et al. analyzed the design and fabrication of vertical axis economical wind
mill. This paper indicates that vertical axis wind mill is one of the most important types of wind
mill. In this main rotor shaft is connected to the wind turbine vertically with the generator and
gear box which can be placed near the ground. Performance characteristics such as power
output versus wind speed or versus angular velocity must be optimized in order to compete
with other energy sources which make the process economically and eco-friendly. The
experimental result shows that wind turbine is placed on the top of the building in an ideal
position to produces electricity. The power generation becomes easy and it is used for various
applications such as street light, domestic purpose, agriculture etc.

[3] D.A. Nikam et al. analyzed the literature review on design and development of vertical
axis wind turbine blade. This paper explains that the wind mill such as vertical and horizontal
wind mill is widely used for energy production. The horizontal wind mill is highly used for
large scale applications which require more space and huge investment. Whereas the vertical
wind mill is suitable for domestic application at low cost. The generation of electricity is
affected by the geometry and orientation of the blade in the wind turbine. To optimize this by
setting the proper parameter for the blade design. The experimental result indicates that the
blade plays critical role in the performance and energy production of the turbine. The optimized
blade parameter and its specification can improve the generation of electricity.

[4] Altab Hossain et al. investigated the design and development of A 1/3 scale vertical axis
wind turbine for electrical power generation. In this paper the electricity is produce from the

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wind mill by wind power and belt power transmission system. The blade and drag devices are
designed in the ratio of 1:3 to the wind turbine. The experiment is conducted by different wind
speed and the power produced by the windmill is calculated. The experimental result indicates
that 567 W power produced at the speed of 20 m/s while 709 W power produced at the speed
of 25 m/s. From this, the power production will increase when the velocity is high.

[5] M. Abid et al. analyzed the design, development and testing of a savonius and darrieus
vertical axis wind turbine. This paper shows that vertical axis wind mill is more efficient when
compare to horizontal axis wind mill. The darrieus turbine consists of 3 blades which can start
alone at low wind speed. When savonius turbine is attached on the top of existing wind mill
which provide the self-start at low wind speed. The result indicates that the darrieus vertical
axis wind turbine acts as a self-starter during the testing. The function required the starting
mechanism which can be provided by the combination of NACA 0030 aerofoil and savonius
turbine. The high blade thickness of the NACA 0030 aerofoil will improves the selfstarting
capability of the turbine.

[6] ParthRathod et al. analyzed a review on combined vertical axis wind turbine. In this paper,
the increased efficiency is achieved based on the characteristics such as aspect ratio, tip speed
ratio, velocity and other geometry parameter. The experiment is conducted to increase the
power production and efficiency of a wind turbine. The development of design is optimized by
combining the blade structure and the flow performance. The result indicates that the efficiency
of turbine is always based on the wind speed and climatic conditions. The lowest aspect ratio
improves the power coefficient of the turbine. The power generation of combined rotor is high
compare to the single savonius and darrieus rotor.

[7] KunduruAkhil Reddy et al. investigated a brief research, study, design and analysis on
wind turbine. This paper evaluates the aerodynamic performance of variable speed fixed pitch
horizontal axis wind turbine blade using two- and three-dimensional computational fluid
dynamics. The primary objective of the paper is to increases the aero dynamic efficiency of a
wind turbine. The blades are designed using different type of airfoils which are associated with
angle of attack. The blade design is responsible for the efficiency of the wind turbine. The
design of the blade is done using Q- blade software. The result indicates that the power output

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is determined using blade elemental theory. The power output of designed blade design is
higher when compare to existing design of the blade.

[8] PiyushGulve et al. analyzed the design and construction of vertical axis wind turbine. This
paper indicates that vertical axis wind turbine is more efficient than horizontal axis wind
turbine because it requires compact space for producing same amount of electricity and less
noise. The result of the paper indicates that the efficiency of wind turbine may reduce due to
manufacturing error and frictional losses. It will be rectified by précising the design of the blade
more aerodynamically. From the above literature review, it is clearly understood that the
efficiency of wind turbine is always based on the parameters such as design and size of the
blade, aspect ratio, tip speed ratio, blade angles and velocity. The power production of
combined vertical and horizontal wind mill is high compare to vertical axis wind turbine and
horizontal axis wind turbine. It requires less space for high generation of electricity

Figure 2.1 shows Different Types of Windmills

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2.2 PREVIOUS RESEARCHES DONE:

Lot of researches has done for increasing efficiency of the Vertical Axis Wind Turbine.
They have developed basic wind turbines, and discover significant parameters that directly
involve to changing performances of turbines. Some of them are blade solidity, lift force, drag
force and angle of attack. And also, they introduce system integration with a wind deflector.
The starting torque and power coefficients characteristics of Horizontal axis wind turbines
(HAWT) are higher than the vertical axis wind turbines (VAWT). Because of this reason
commercial wind power market fills with HAWT. Anyhow, small vertical axis wind turbines
are more appropriate to urban environments because the reduced risk associated with their
slower rate of rotation and the lower noise pollution compare to their horizontal axis Wind
turbine. In research, a deflector system which can guide the wind towards the vertical axis wind
turbine blades has been introduced to increase the power coefficient, and tested with
computational fluid dynamics. They designed vertical axis wind turbine along with a wind
deflector system and simulations were done with computational fluid dynamics (CFD)
software which may be more reliable than the analytical or semi – empirical models adopted
with simplifying assumptions. Then the starting performances and the power performances
were analyzed. They took following results for the coefficient of performance and tip speed
ratio (λ) regarding performances in simulations. Furthermore, so many researchers have done
with considering blade profile. The modern VAWTs occupied blades that developed by NACA
which has ability to self-start. However, researchers are involved to modify common VAWT
and increase its efficiency.

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CHAPTER-3
3.1 PROBLEM DEFINITION:
Vertical axis windmills (VAWMs) have shown potential as a renewable energy source,
but current designs suffer from inefficiencies and lack optimal performance. The challenge is
to address issues such as low power generation efficiency, structural integrity, and reliability
of VAWMs. There is a need for research and development to enhance the design, efficiency,
and overall effectiveness of vertical axis windmills, making them more competitive and
sustainable in comparison to horizontal axis wind turbines. This project aims to identify and
overcome the key challenges associated with VAWMs, leading to the development of an
improved and economically viable solution for harnessing wind energy in urban and rural
environments."

3.2 OBJECTIVES:

1. Improve the efficiency of vertical axis windmills (VAWMs) in converting wind energy
into electrical power.
2. Develop VAWMs suitable for both urban and rural environments, considering space
constraints, noise levels, and aesthetic integration.
3. Enhance the structural integrity and reliability of VAWMs to ensure consistent
performance over an extended lifespan.
4. Reduce manufacturing and installation costs of VAWMs to make them more
economically viable compared to other renewable energy sources.
5. Design VAWMs capable of efficiently harnessing energy from variable wind
conditions, incorporating adaptive technologies.
6. Explore integration of VAWMs into smart grid systems for efficient energy distribution
and management.
7. Minimize the environmental impact of VAWMs, addressing factors such as wildlife
interactions, visual aesthetics, and noise pollution.
8. Design VAWMs that are easily scalable to accommodate varying energy needs in
different settings and applications.
9. Promote awareness and understanding of vertical axis wind energy technology through
educational programs and outreach initiatives.

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CHAPTER - 4
METHODOLOGY
4. MANUFACTURING PROCESS OF VERTICAL AXIS WINDMILL:
We gathered information on wind turbines and deflectors before deciding on a vertical
axis wind turbine for our project. As a result, they may be packed closer together in wind farms,
allowing more in a given space; they are quiet in operation; they produce lower forces on the
support structure; and, most importantly, they generate power with less wind. Vertical Axis
Wind Turbines come in two varieties. They are,
• Darrieus Wind Turbine
• Savonius Wind Turbine

4.1 PROPOSAL:
The proposed project aims to design, manufacture, and evaluate the performance of a
Vertical Axis Windmill (VAW) with a focus on efficiency, sustainability, and innovative
design. Recognizing the pressing need for cleaner and more sustainable energy sources, this
project centers on harnessing wind power using a unique vertical axis configuration. The
project will commence with a thorough conceptualization and design phase, utilizing advanced
Computer-Aided Design (CAD) software to model and simulate the windmill’s components.
Material selection will be a critical aspect, emphasizing high strength-to-weight ratios and
environmentally conscious choices. The manufacturing process will incorporate cutting-edge
techniques, such as 3D printing and precision machining, to transform the design into a
physical prototype. Rigorous testing under varying wind conditions will be conducted to
evaluate the windmill’s performance, with a subsequent optimization phase aimed at enhancing
efficiency and reliability. Throughout the project, an emphasis on sustainability will guide
decisions regarding materials, manufacturing processes, and environmental impact. The
documentation and reporting phase will consolidate findings, contributing valuable insights to
the broader field of renewable energy and facilitating future advancements in vertical axis
windmill technology. This project aligns with global efforts to transition towards cleaner
energy alternatives, addressing the challenges of climate change and promoting a
sustainable future.

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4.2 FLOW AND EFFICIENCY ANALYSING:

The project involves a comprehensive flow and efficiency analysis of a Vertical Axis
Windmill (VAW) to assess its performance and optimize its energy conversion capabilities.
Initially, Computational Fluid Dynamics (CFD) simulations will be employed to model and
analyze the airflow around the vertical axis windmill, providing insights into the aerodynamics
of the system. This analysis will delve into factors such as blade design, pitch angles, and rotor
configurations to understand their impact on the overall efficiency of energy capture. Through
this simulation-driven approach, we aim to identify areas for improvement in the design, with
a specific focus on 14minimizing drag, maximizing lift, and enhancing the overall energy
conversion efficiency. Subsequently, the windmill will undergo practical testing under varying
wind conditions to validate the CFD findings and fine-tune the design parameters. The
efficiency analysis will encompass power output, rotational speed, and torque, providing a
holistic understanding of the windmill’s performance. This iterative process of analysis,
simulation, and testing will contribute to optimizing the vertical axis windmill for enhanced
efficiency, making it a more viable and sustainable solution for renewable energy generation.
Ultimately, the project aims to provide valuable insights into the flow dynamics of VAWM,
paving the way for advancements in their design and contributing to the broader goal of
transitioning towards cleaner and more efficient energy sources.

Figure 4.2 shows Flow and Efficiency Analyzing

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4.3 DESIGN OF THE WIND TURBINE:

The design of the wind turbine for the vertical axis windmill is a critical aspect of
optimizing its performance and efficiency. The project's focus lies in creating a robust and
innovative turbine configuration that maximizes energy conversion from wind flow. The
design phase begins with a thorough analysis of aerodynamics using computational tools to
determine optimal blade shapes, sizes, and angles. Considering the unique characteristics of
vertical axis windmills, the design will prioritize capturing wind from all directions and
minimizing drag during rotation. Material selection is paramount, with an emphasis on
lightweight yet durable composites to ensure structural integrity and longevity. The
configuration of the rotor and blades will be tailored to balance the need for starting torque,
rotational speed, and stability, aiming for an optimal trade-off to achieve efficient power
generation across varying wind speeds. The design will also explore the potential for innovative
features such as self-adjusting blades or adaptive mechanisms to further enhance performance.
The resulting wind turbine design will undergo iterative refinement, incorporating insights
from simulations and practical testing to ensure that the vertical axis windmill operates with
optimal efficiency, making it a sustainable and effective contributor to renewable
energy solutions.

Figure 4.3 Design of The Wind Turbine

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Three types of different deflector shapes were considered for the analyzing. The
deflector shape which gives the best value was intended to be chosen as best in previous fig
represent the considered deflector shapes a, b and c. The dimensions of the three different
deflectors are as shown in the Fig below-

Figure 4.3.1 shows Different Deflector Shapes

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4.4 IMPLEMENTATION:
BLADES WITH PLASTIC:
• Utilize lightweight and durable plastic materials for the fabrication of the vertical axis
windmill blades.
• Employ Computer-Aided Design (CAD) to create aerodynamically efficient blade
profiles, considering factors such as curvature and surface area.

Figure 4.4 shows Blades with Plastic

• Optimize the blade design for structural integrity, balancing weight reduction with the
ability to withstand varying wind conditions.
• Evaluate the environmental impact of the chosen plastic material, ensuring it aligns
with sustainability goals.

SUPPORTING FRAME WITH L-IRON ROD:

• Construct the supporting frame using L-iron rods to provide a sturdy and reliable
structure.
• Weld or securely fasten the L-iron rods to form the vertical axis, ensuring proper
alignment and stability.

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Figure 4.4.1 shows Supporting Frame With L-Iron Rod:

• Consider the wind load and structural stresses in the design to prevent deformations and
ensure long-term durability.
• Incorporate a robust foundation or anchoring system to secure the vertical axis windmill
in place during operation.
SHAFT WITH STEEL HOLLOW ROD:
• Use a steel hollow rod as the central shaft to connect the vertical axis to the generator
or power transmission system.
• Ensure the hollow rod has sufficient strength to withstand torque and rotational forces.
• Implement precision machining to maintain the necessary tolerances for smooth
rotation.

Figure 4.4.2 shows Shaft with Steel Hollow Rod

• Consider anti-corrosive coatings or materials to protect the steel hollow rod from
environmental elements.

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4.5 MANUFACTURING PROCEDURE VERTICAL AXIS WINDMILL HAND

GRINDER:
A metal hand cutter, also known as a metal cutting shear or snip, is a manually operated
tool designed for precision cutting of various types of metal sheets. The cutter typically consists
of two sharp blades that are hinged together, allowing the user to apply force to cut through the
metal. The upper blade is movable, while the lower blade remains stationary. To operate the
metal hand cutter, the user places the sheet of metal between the blades, aligning the cutting
line with the cutting edge. By squeezing the handles together, the movable blade comes down
and shears through the metal with a scissor-like action. The design of the blades and the
leverage provided by the handles enable the tool to cut through metals of varying thicknesses
with ease. Different types of metal hand cutters are available for specific applications, such as
straight-cutting shears, curved-cutting shears, and combination snips for versatile cutting.

Figure 4.5 Shows Hand Grinder

WELDING PROCESS:
1. Setup:
• Welding Machine: Begin by setting up the welding machine, which includes a
power source and a welding electrode holder or gun.
• Electrode Selection: Choose an appropriate welding electrode based on the
metals being joined and the welding process (e.g., stick welding, MIG, TIG).
2. Preparation:
• Clean the Metal: Ensure that the metal surfaces to be welded are clean and free
from rust, paint, and other contaminants.

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• Joint Preparation: Properly prepare the joint by bevelling, chamfering, or

otherwise shaping the edges to facilitate better penetration and fusion.
3. Electrode Placement:
• Insert Electrode: Insert the chosen welding electrode into the electrode holder,
making sure it's securely clamped.
• Electrode Angle: Maintain the correct angle between the electrode and the
workpiece, which can vary based on the welding process and joint
configuration.
4. Safety Gear:
• Personal Protective Equipment (PPE): Wear appropriate PPE, including a
welding helmet, gloves, flame-resistant clothing, and safety glasses.
5. Arc Initiation:
• Striking the Arc: Create an electric arc by striking the electrode against the
workpiece or by using a high-frequency start (in TIG welding).
• Arc Stability: Once the arc is established, maintain a consistent arc length for
stable welding.
6. Welding Technique:
• Travel Speed: Control the speed at which you move the electrode along the joint
to achieve proper penetration and fusion.
• Weaving or Oscillating: Some welding techniques involve weaving or
oscillating the electrode to ensure even distribution of heat.
7. Deposition of Weld Metal:
• Melting Electrode: The heat generated by the electric arc melts the electrode,
creating a molten pool that fuses with the base metal.
• Filler Material (if applicable): In some processes, a separate filler material may
be added to the molten pool to enhance the weld.
8. Cooling and Solidification:
• Solidification: As the weld progresses, the molten metal solidifies, forming a
strong joint between the workpieces.
9. Post-Weld Cleaning:
• Cleaning Slag (for certain processes): In stick welding, for example, remove the
slag formed during the welding process using a chipping hammer or wire brush.

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10. Inspection:
• Visual Inspection: Inspect the completed weld visually to ensure it meets quality
standards.
• Non-Destructive Testing (NDT): Perform additional testing, such as X-rays or
ultrasonic testing, for critical applications.

Figure 4.5.1 Shows Arc Welding

SUPPORT FOR STEEL HOLLOW ROD:

Flanged bearings are a type of rolling-element bearing with an extended flange on one or
both sides. The flange is a flat, projecting rim that provides additional support and helps in the
proper positioning of the bearing within a machine or assembly. The flange serves several
purposes:
1. Axial Location:
The flange helps in axial location or positioning of the bearing. It prevents the
bearing from moving axially along the shaft or housing.
2. Ease of Installation:
The flange simplifies the installation process by providing a surface against
which the bearing can be pressed or secured. This can be especially useful in
applications where ease of assembly is important.

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3. Increased Stability:
The flange enhances the stability of the bearing within the housing. It helps in
maintaining proper alignment and reduces the risk of misalignment during operation.

4. Sealing:
In some designs, the flange can serve as a component of the sealing arrangement,
helping to prevent contaminants from entering the bearing and retaining lubrication.

Frame support bars:

Using an iron square bar as a support for a frame provides a robust and reliable solution
for structural stability. The first step involves meticulous design considerations, determining
load-bearing requirements and calculating appropriate dimensions. The selection of a suitable

Figure 4.5.2 Shows Frame Support Bars

grade of iron or steel, such as mild or structural steel, is crucial, taking into account
environmental conditions and load specifications. Cutting the iron square bar to the required
length and shaping the ends for proper connection are essential tasks. Attachment points must
be identified, and welding or fastening methods, such as bolts or screws, should be applied
securely. Alignment and leveling ensure proper integration with the frame, while protective
coatings guard against corrosion, especially in outdoor or corrosive environments. Thorough
inspection, including load tests, if necessary, verifies the stability of the support structure.

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Regular maintenance, addressing wear, corrosion, or damage, is crucial for sustaining the
integrity of the frame and ensuring long-term reliability. Adherence to local building codes and
consultation with structural engineers contribute to the safety and effectiveness of this support
approach.
Blade deflector:
By using material, it can be calculating total mass of deflector and mass center of deflector. It
was very important to know when considering balance of deflector. The center of mass should be
maintained at lower level for the better stability of deflector.

Figure 4.5.3 Shows Forces Acting on Deflector System

MOUNTED BEARING UNITS:

Re-engineered mounted ball bearing units represent a significant advancement in the
field of mechanical engineering and industrial applications. These units, comprising bearings
mounted in housings, have undergone a redesign to enhance their performance, durability, and
overall efficiency in various operational environments.
Key Features:
1. Improved Materials: Re-engineered units often incorporate advanced materials that
offer superior strength, corrosion resistance, and tolerance to extreme conditions. This
contributes to extended bearing life and reduced maintenance requirements.
2. Sealing Technology: Enhanced sealing mechanisms, such as advanced labyrinth seals
or multiple lip seals, help prevent contamination and retain lubrication. This is crucial
for applications in industries like manufacturing, agriculture, and mining, where
environmental factors can impact bearing performance.

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3. Precision Engineering: Re-engineering efforts focus on precision machining and

assembly processes to ensure tight tolerances and optimal alignment. This results in
reduced friction, enhanced load-carrying capacity, and quieter operation.

Figure 4.5.4 Shows Mounted Bearing Units

4. Innovative Lubrication Systems: Some re-engineered units incorporate innovative

lubrication systems, including automated lubrication or sealed-for-life solutions. These
advancements contribute to smoother operation and prolonged bearing life.
Benefits:
1. Increased Reliability: The improvements in materials, sealing, and precision contribute
to increased reliability and reduced downtime in industrial machinery and equipment.
2. Extended Service Life: Re-engineering efforts aim to maximize the lifespan of mounted
ball bearing units, leading to longer intervals between maintenance and replacement
cycles.
3. Cost-Efficiency: While the initial investment in re-engineered units may be slightly
higher, the long-term benefits, including reduced maintenance costs and increased
productivity, often outweigh the initial expenses.
4. Application Versatility: Re-engineered mounted ball bearing units are designed to cater
to a wide range of applications, from conveyors and fans to heavy machinery,
showcasing their versatility across various industries.
5. Environmental Adaptability: The incorporation of advanced materials and sealing
technologies enhances the ability of these units to withstand harsh environmental
conditions, making them suitable for applications in diverse industries and climates.

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In summary, re-engineered mounted ball bearing units represent a technological evolution

aimed at addressing the demands of modern industrial settings. These units bring together
advanced materials, precision engineering, and innovative features to deliver enhanced
reliability, extended service life, and cost-efficient solutions for a broad spectrum of
applications.

4.6 GENERAL AERODYNAMICS:

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

Thus the oncoming fluid velocity varies during each cycle. Maximum velocity is found
for and the minimum is found for , where is the azimuthal or orbital blade
position. The angle of attack, , 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.

It follows from geometric considerations of angular velocity as seen in the accompanying

figure that:

and:

Solving for the relative velocity as the resultant of the tangential and normal components
yields:

[7]

Thus, combining the above with the definitions for the tip speed ratio yields the following
expression for the resultant velocity:

[8]

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Angle of attack is solved as:

Which when substituting the above yields:

[9]

The resultant aerodynamic force is resolved either into lift (L) - drag (D) components or normal
(N) - tangential (T) components. The forces are considered acting at the quarter-chord point,
and the pitching moment is determined to resolve the aerodynamic forces. The aeronautical
terms lift and drag refer to the forces across (lift) and along (drag) the approaching net relative
airflow. The tangential force acts along the blade's velocity, pulling the blade around, and the
normal force acts radially, pushing against the shaft bearings. The lift and the drag force are
useful when dealing with the aerodynamic forces around the blade such as 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
normalised by the dynamic pressure of the relative airflow, while the normal and tangential
coefficients are usually normalised by the dynamic pressure of undisturbed upstream fluid
velocity.

A = Blade Area (not to be confused with the Swept Area, which is equal to the height of the
blade/rotor times the rotor diameter), R = Radius of turbine

The amount of power, P, that can be absorbed by a wind turbine:

Where is the power coefficient, is air density, is the swept area of the turbine, and is the wind
speed.

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4.7. PCB CIRCUIT BOARD

DB107 BRIDGE RECTIFIER:
The DB107 bridge rectifier is a key component in electronic circuits designed for
converting alternating current (AC) to direct current (DC). This rectifier employs a bridge
configuration comprising four diodes, arranged in a diamond shape. During the positive half-
cycle of the AC input, two forward-biased diodes permit the passage of the positive waveform,
while the other two diodes remain reverse-biased. As the AC input polarity reverses during the
negative half-cycle, the roles of the diodes switch, ensuring a continuous

Figure 4.7 shows DB107 Bridge Rectifier

flow of current. The result is a rectified DC output that effectively converts both positive and
negative halves of the AC cycle. To smooth out the pulsating DC output, often associated with
ripples, a filter capacitor is commonly connected across the output terminals. Widely used in
low-power applications, the DB107 bridge rectifier is a compact and cost-effective solution
found in power supplies for small electronic devices, battery chargers, and various household
appliances. Understanding its operation is crucial for designing and troubleshooting circuits
dependent on rectified DC power.

DIODE:
A diode that doesn't let electricity flow backward is called a rectifier diode. It acts like a one-

Figure 4.7.1 shows Diode

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way street for electrical current. When you apply voltage in one direction (forward), it easily
lets the current pass through. But if you try to send the current in the opposite direction
(reverse), it puts up a roadblock, allowing only a tiny bit of current to leak through. These
diodes are like traffic cops for electricity, making sure it flows in the right direction. They're
super useful in converting alternating current (AC) to direct current (DC) in things like power
supplies for your devices.

LED INDICATOR:
An LED indicator, or Light Emitting Diode indicator, is a small, energy-efficient light
source commonly used in electronics to signify a particular status or condition. LEDs are
characterized by their ability to emit light when an electric current passes through them. In the
context of indicators, LEDs are often employed to display information such as power on/off,

Figure 4.7.2 shows LED Indicator

battery status, connectivity, or operation status in electronic devices. They come in various
colors, and their low power consumption, long lifespan, and quick response make them ideal
for indicating different states or functions in a wide range of applications, from electronic
gadgets to industrial equipment.

1000 MICROFARAD CAPACITOR:

A 1000 microfarad capacitor plays a crucial role in electronic circuits, serving as a

Figure 4.7.3 shows 1000 Microfarad Capacitor

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storage device for electrical charge. The capacitor's function is to store and release electrical
energy when needed. With a capacitance of 1000 microfarads, it has the ability to store a
relatively large amount of charge, making it suitable for applications requiring temporary
energy storage or smoothing voltage fluctuations. In power supply circuits, for instance, a
capacitor of this capacity helps stabilize the voltage by releasing stored energy during periods
of high demand, ensuring a more consistent and reliable power output. Additionally, capacitors
are often used in audio circuits and electronic filters to enhance performance and reduce signal
noise.

PCB (Printed Circuit Board):

A breadboard is a temporary test platform used to prototype and test electronic circuits,
while a PCB is a permanent board made of a conducting material used to connect electronic

Figure 4.7.4 shows PCB (Printed Circuit Board)

components. Breadboards are easy to use and modify, but are not as durable as PCBs and do
not allow for miniaturization or mass production.

PULLEY AND BELT:

It seems like there might be a small typo in your query, but I'll assume you're asking
about "Pulley and Belt" systems. L= π (r1 + r2) + 2x + [(r1 – r2)2/x]
A pulley and belt system are a mechanical arrangement that uses rotating components
to transmit power or motion from one shaft to another. It consists of a pulley, which is a wheel
with a groove, and a belt that fits into the groove. This system is commonly used in various
applications to transfer rotational motion or power between different parts of a machine.

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The pulley can be attached to a motor or an engine, and as it rotates, the belt transfers
this rotational motion to another pulley on a different shaft. The belt wraps around the pulleys,
creating a frictional connection that allows the transmission of power.

Figure 4.7.5 shows Pulley

Key features and functions of pulley and belt systems include:
1. Power Transmission: The primary function is to transmit power efficiently between
shafts. This is commonly used in applications like conveyor systems, engines, and
various industrial machinery.
2. Speed Control: By changing the diameter of the pulleys or using multiple pulleys of
different sizes, the system can be used to control the speed of the driven component.
3. Direction Change: Pulley and belt systems can change the direction of rotation
between the input and output shafts.
4. Shock Absorption: The flexibility of the belt provides a degree of shock absorption,
protecting components from sudden shocks or overloads.
5. Maintenance Ease: Belts are replaceable, which makes maintenance easier compared
to other direct-drive systems.

Figure 4.7.6 shows Belt

These systems are versatile and find applications in industries ranging from manufacturing to
automotive, where they are utilized for tasks such as power transmission in engines, operating
fans, or driving conveyor belts. The design and selection of pulleys and belts depend on factors
like the required power transmission, speed, and space constraints within a given application.

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4.8. PRINCIPLE OF GENERATOR OPERATION

Generator:
The generator uses rotating coils of wire and magnetic fields to convert mechanical
rotation into a pulsing direct electric current through Faraday’s law of induction. A dynamo
machine consists of a stationary structure, called the stator, which provides a constant magnetic
field, and a rotating winding called armature which turn within that field. The motion of the
wire within the magnetic field causes the field to push on the electrons in the metal, creating
an electric current in the wire. On small machines constant magnetic field may be provided by
one or more permanent magnets; larger machines have constant the magnetic field provided by
one or more electromagnets, which are usually called field coils. The commutator was needed
to produce direct current. When a loop wire rotates in a magnetic field, the potential induced
in it reverses with each half turn generating an alternating current. However, in early days of
electric experimentation, alternating current generally no known use. The few uses for
electricity, such as electroplating, used direct current provided by messy liquid batteries. The
generation of electricity by a dynamo is based on a principle of magnetism called induction.
When the lines of force that pass from the north to the south pole of a magnet is cut by a wire
there is produced or induced in the wire a current of electricity. That is, if we take a loop or
coil of wire which has no current in it and a magnet which also has no current, and move the
loop or coil between the poles, a momentary current is produced. If a series of loops or coils
are used instead of one loop, a current may be generated continuously. This method of
generating electric current is called induction.

Figure 4.8 shows Generator

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Direction of an Induced Current:

The direction of an induced current depends upon two factors: (1) the direction of the
motion of the wire, and (2) the direction of the magnetic lines of force. A very valuable method
of determining the direction of current used in practical life is called Fleming’s Rule. Place the
thumb, forefinger, and centre finger of the right hand so as to form right angles to each other.
If the thumb points in the direction of the motion of the wire, and the fore finger in the direction
of the magnetic lines of force, the centre finger will point in the direction of the induced current.
It is very important to know the direction of the current in revolving a loop of wire between the
poles of a magnet in order to understand the working of a generator. The loop of wire between
the poles of the magnet. If the loop is rotated to the right, as indicated by the arrow head, the
wire XB moves down during the first half of the revolution. As the result of the first half of the
revolution, the current would flow in the direction AYBX. Repeat the reasoning for the second
half of the revolution. Notice that for every complete revolution, the current reverses its
direction twice. As the strength of the current depends upon the number of lines of force cut,
so the induced electromotive force starts at zero, goes to a maximum, and then back to zero in
the first half-turn. That is, the induced electromotive force reaches its maximum when the loop
is in a horizontal position because it cuts the most lines of force at this position. It cuts the least
number of lines of force at the beginning and at the end of each half-vertical revolution.

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4.9. STORAGE SYSTEM:

Inverter:
A power inverter, or inverter, is an electronic device or circuitry that changes direct
current (DC) to alternating current (AC) The input voltage, output voltage and frequency, and
overall power handling depend on the design of the specific device or circuitry. The inverter
does not produce any power; the power is provided by the DC source. A power inverter can be
entirely electronic or may be a combination of mechanical effects (such as a rotary apparatus)
and electronic circuitry. Static inverters do not use moving parts in the conversion process
Battery:
The runtime of an inverter is dependent on the battery power and the amount of power
being drawn from the inverter at a given time. As the amount of equipment using the inverter
increases, the runtime will decrease. In order to prolong the runtime of an inverter, additional
batteries can be added to the inverter. Battery used for this construction is Lead Acid Battery

Figure 4.9 shows Storage System flow chart

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4.10. 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.
3. They may be able to build at locations where taller structures, such as the horizontal type
can’t be installed.
4. Higher power utilization.
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 blows from any orientation, VAWT
can work without regard to its face. Economical and practical-Although onetime investment
expenses are larger, but you don’t have to pay higher tariffs forever.

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CHAPTER-5
5.1 OUTCOMES:
1. Increased availability of affordable and sustainable energy sources.
2. Improved energy security and reduced dependence on traditional fossil fuels.
3. Enhanced economic opportunities through the growth of the vertical axis windmill
industry.
4. Mitigation of environmental impact by promoting a cleaner and greener energy
alternative.
5. Expansion of renewable energy infrastructure in both urban and rural areas.
6. Job creation in manufacturing, installation, and maintenance of vertical axis windmills.
7. Empowerment of local communities to harness wind energy for their own needs.
8. Integration of vertical axis windmills into smart grid systems, contributing to grid
stability.
9. Reduction in greenhouse gas emissions and mitigation of climate change effects.
10. Increased resilience to fluctuating energy demands and variable wind conditions.

5.2 COST ESTIMATION:

Sl. No. Material Cost

1 Plastic Drum 1500
2 Hollow Steel Rod 1200
3 L- Shape Iron Bar and miscellaneous parts 2000
4 Mounted Ball Bearings x 2 1500
5 Pulley (Cycle Wheel) 300
6 Belt 50
77 Generator 250
8 Electrodes and Cutting blades 200
9 PCB Unit 200
10 Bult and Holder 150
Total Cost 7350

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5.3 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
contributes 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 area faster
route for everyday commute and in need of constant lighting makes this an efficient way to
produce natural energy.

5.4 RESULT:
Our study on vertical axis windmills showed they work really well, even in not-so-
perfect conditions. These windmills can be made from strong but light materials in advanced
places or simpler, local materials in less advanced areas. This means they're flexible and can
be used in many different parts of the world.
We also looked at putting a type of wind turbine, called Savonius, on top of bridges.
Turns out, this is a great idea! Placing these turbines high up on bridges lets them catch more
wind, making them work even better. This is important because we found that they could make
electricity and help light up streets. In cities, bridges are like fast roads for cars, and they always
need lights. So, using these wind turbines on bridges not only makes clean energy but also
helps with keeping the city well-lit.
In a nutshell, our findings suggest that these windmills are not only good for making
energy but also pretty flexible, fitting into different places around the world. Putting them on
bridges seems like a smart move, giving us a chance to make clean power and light up our
cities better.

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CHAPTER-6
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