DESIGNANDFABRICATIONOFSAVONIUSVERTICALAXIS WINDTURBINE

AProjectreportsubmittedinpartialfulfillmentoftherequirementforthe awardofdegreeofBACHELOROFTECHNOLOGY IN MECHANICALENGINEERING SubmittedBy SATISHCHANDRABALINENI07241A0356 SIVARAMAKRISHNA.R07241A0360 B.SRIRAMKUMAR07241A0364 G.VIJAYKUMAR07241A0368 UndertheGuidanceof

Dr.ADAPARAMARAO
Prof&Dean,CounselingandCareerGuidence

DepartmentofMechanicalEngineering, GOKARAJURANGARAJUINSTITUEOFENGINEERINGAND TECHNOLOGY (AffiliatedtoJawaharlalNehruTechnologicalUniversity) 2007-2011

ABSTRACT We know that there is enough wind globally to satisfy much, or even most, of humanity's energy requirements if it could be harvested effectively and on a large scale. Vertical axis wind turbines (VAWTs), which may be as efficient as current horizontal axis systems, might be and significantly cheaper to build practical, simpler maintain than horizontal axis wind

turbines (HAWTs).They also have other inherent advantages, such as they are always facing the wind, which might make them a significant player in our quest for cheaper, cleaner renewable sources of electricity. VAWTs might even critical in mitigating grid interconnect stability and reliability issue currently facing electricity producers and suppliers. Additionally, cheap VAWTs may provide an alternative to the rain forest destruction for the growing of bio-fuel crops. Vertical-axis wind turbines (VAWTs) are a type of wind turbine where the main rotor shaft is set vertically. Among the advantages of this arrangement are that generators and gearboxes can be placed close to the ground, and that VAWTs do not need to be pointed into the wind. Major drawbacks for the early designs (Savonius, Darrieus, and cycloturbine) included the pulsatory torque that can be produced during each revolution and the huge bending moments on the blades. In this project we attempt to design and fabricate a Savonius Vertical Axis Wind Turbine.

TableofContents INTRODUCTION..4 SCOPE OF PROJECT ....................................................................................8 LITERATURE REVIEW..9 POWER AND SOURCE ...............................................................................10 CHARACTERISTICS ..11 REQUIREMENTS OF PLACING ................................................................13 VERTICAL AXIS WIND TURBINE..15 GENERAL THEORY....................................................................................17 TYPES OF VERTICAL AXIS WIND TURBINE........................................20 MATERIALS USED IN WIND TURBINES ...............................................27 DESIGN OF WIND TURBINE ....................................................................30 SPECIFICATIONS OF WIND TURBINE ...................................................33 FABRICATION TECHNIQUES ..................................................................34 CALCULATIONS............................................................................................. APPLICATIONS OF WIND ENERGY............................................................ CONCLUSION AND FUTURE DEVELOPMENTS BIBILOGRAPHY

INTRODUCTION
If the efficiency of a wind turbine is increased, then more power can be generated thus decreasing the need for expensive power generators that cause pollution. This would also reduce the cost of power for the common people. The wind is literally there for the taking and doesn't cost any money. Power can be generated and stored by a wind turbine with little or no pollution. If the efficiency of the common wind turbine is improved and widespread, the common people can cut back on their power costs immensely. Ever since the Seventh Century people have been utilizing the wind to make their lives easier. The whole concept of windmills originated in Persia. The Persians originally used the wind to irrigate farm land, crush grain and milling. This is probably where the term windmill came from. Since the widespread use of windmills in Europe, during the Twelfth Century, some areas such as the Netherlands have prospered from creating vast wind farms. The first windmills, however, were not very reliable or energy efficient. Only half the sail rotation was utilized. They were usually slow and had a low tip speed ratio but were useful for torque. Since its creation, man has constantly tried to improve the windmill. As a result, over the years, the number of blades on windmills has decreased. Most modern windmills have 5-6 blades while past windmills have had 4~8 blades. Past windmill also had to be manually directed into the wind, while modern windmills can be automatically turned into the wind. The sail design and materials used to create them have also changed over the years.

In most cases the altitude of the rotor is directly proportional to its efficiency. As a matter of fact, a modern wind turbine should be at least twenty feet above and three hundred feet away from an obstruction, though it is even more ideal for it to be thirty feet above and five hundred feet away from any obstruction. Different locations have various wind speeds. Some places, such as the British Isles, have few inhabitants because of high wind speeds, yet they are ideal for wind generation. Did you know that the world's largest wind farm is located in California, and the total wind power generated there exceeds 1,400 megawatts of electricity? (A typical nuclear power plant generates 1,000 megawatts.) Some geographic features such as mountains also have an influence upon wind. Mountains can create mountain breezes at night, because of the cooler air flowing down the mountain and being heated by the warmer valley air causing a convection current. Valleys are affected in much the same way. In the daytime, the cooler air is above the valleys and the hot air is above the mountains. The hot air above the mountain rises above the valleys and cools, thus creating a convection current in the opposite direction and creating a valley wind. The oceans create convection currents, as well as they mountains or valleys. In the day, the hotter air is above the same and the cooler air is above the ocean. The air heats up over the sand and rises above the ocean and then cools, creating the convection current. At night, the cooler air is above the sand and the warmer air is above the ocean, so the air heats up over the ocean and cools over the sand. As you can clearly see, the time of day also affects the wind. We know that for windmills to operate there must be wind, but how do they work? Actually there are two types of windmills -- the horizontal axis windmills and the vertical axis windmills. The horizontal axis windmills
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have a horizontal rotor much like the classic Dutch four-arm windmill. The horizontal axis windmills primarily rely on lift from the wind. As stated in Bernoulli's Principle, "a fluid will travel from an area of higher pressure to an area of lower pressure." It also states, "as the velocity of a fluid increases, its density decreases." Based upon this principle, horizontal axis windmill blades have been designed much like the wings of an airplane, with a curved top. This design increases the velocity of the air on top of the blade thus decreasing its density and causing the air on the bottom of the blade to go towards the top ... creating lift. The blades are angled on the axis as to utilize the lift in the rotation. The blades on modern wind turbines are designed for maximum lift and minimal drag. Vertical axis windmills, such as the Durries (built in 1930) use drag instead of lift. Drag is resistance to the wind, like a brick wall. The blades on vertical axis windmills are designed to give resistance to the wind and are as a result pushed by the wind. Windmills, both vertical and horizontal axis, have many uses. Some of them are: hydraulic pump, motor, air pump, oil pump, churning, creating friction, heat director, electric generator, Freon pump, and can also be used as a centrifugal pump. There are many types of windmills, such as: the tower mill, sock mill, sail windmill, water pump, spring mill, multi-blade, Darrieus, savonis, cycloturbine, and the classic four-arm windmill. All of the above windmills have their advantages. Some windmills, like the sail windmill, are relatively slow moving, have a low tip speed ratio and are not very energy efficient compared to the cyclo-turbine, but are much cheaper and money is the great equalizer. There have been many improvements to the windmill over the years. Windmills have been equipped with air breaks, to control speed in strong winds. Some vertical axis windmills have even been equipped with hinged
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blades to avoid the stresses at high wind speeds. Some windmills, like the cyclo-turbine, have been equipped with a vane that senses wind direction and causes the rotor to rotate into the wind. Wind turbine generators have been equipped with gearboxes to control [shaft] speeds. Wind turbines have also been equipped with generators which convert shaft power into electrical power. Many of the sails on windmills have also been replaced with propeller-like airfoils. Some windmills can also stall in the wind to control wind speed. But above all of these improvements, the most important improvement to the windmill was made in 1745 when the fantail was invented. The fantail automatically rotates the sails into the wind. Most wind turbines start to generate power at 11 m/s and shut down at speeds near 32m/s. Another variable of the windmill's efficiency is its swept area. The swept area of a disk--shaped wind wheel is calculated as: Area equals pi times diameter squared divided by four (pi equals 3.14). Another variable in the productivity of a windmill is the wind speed. The wind speed is measured by an anemometer. Another necessity for a windmill is the tower. There are many types of towers. Some towers have guy wire to support them and others don't. The towers without guy wires are called freestanding towers. Something to take into consideration about a tower is that it must support the weight of the windmill along with the weight of the tower. Towers are also subject to drag. Scientists estimate that, by the 21st Century, ten percent of the world's electricity will come from windmills.

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.

LITERATURE REVIEW

POWER & SOURCES The Source of Winds

In a macro-meteorological sense, winds are movements of air masses in the atmosphere mainly originated by temperature differences. The temperature gradients are due to uneven solar heating. In fact, the equatorial region is more irradiated than the polar ones. Consequently, the warmer and lighter air of the equatorial region rises to the outer layers of the atmosphere and moves towards the poles, being replaced at the lower layers by a return flow of cooler air coming from the polar regions. This air circulation is also affected by the Coriolis forces associated with the rotation of the Earth. In fact, these forces deflect the upper flow towards the east and the lower flow towards the west. Actually, the effects of differential heating dwindle for latitudes greater than 30oN and 30oS, where westerly winds predominate due to the rotation of the Earth. These large-scale air flows that take place in all the atmosphere constitute the geostrophic winds. The lower layer of the atmosphere is known as surface layer and extends to a height of 100 m. In this layer, winds are delayed by frictional forces and obstacles altering not only their speed but also their direction. This is the origin of turbulent flows, which cause wind speed variations over a wide range of amplitudes and frequencies. Additionally, the presence of seas and large lakes causes air masses circulation similar in nature to the geostrophic winds. All these air movements are called local winds.

The power in the Wind

The power in the wind can be computed by using the concepts of kinetics. 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, Kinetic Energy = mv2. Amount of Air passing is given by m = AV Where m = mass of air transversing A=area swept by the rotating blades of wind mill type generator = Density of air V= velocity of air Substituting this value of the mass in expression of K.E. = AV.V2 watts = AV3 watts .. (2) Second equation tells us that the power available is proportional to air density (1.225 kg/m3) & is proportional to the intercept area. Since the area is normally circular of diameter D in horizontal axis aero turbines, then, A = D2 4 Put this quantity in equation second then Available wind power Pa = D2 V3 8
10

..(1)

(Sq. m)

watt

CHARACTERISTICS & SPECIFICATIONS OF WIND TURBINES

Wind Speed
This is very important to the productivity of a windmill. The wind turbine only generates power with the wind. The wind rotates the axis (horizontal or vertical) and causes the shaft on the generator to sweep past the magnetic coils creating an electric current.

Blade Length
This is important because the length of the blade is directly proportional to the swept area. Larger blades have a greater swept area and thus catch more wind with each revolution. Because of this, they may also have more torque.

Base Height
The height of the base affects the windmill immensely. The higher a windmill is, the more productive it will be due to the fact that as the altitude increases so does the winds speed.

Base Design
Some base is stronger than others. Base is important in the construction of the windmill because not only do they have to support the windmill, but they must also be subject to their own weight and the drag of the wind. If a weak tower is subject to these elements, then it will surely collapse. Therefore, the base must be identical so as to insure a fair comparison.

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BLOCK DIAGRAM OF WIND POWER GENERATION

WIND

WIND TURBINE

WIND

AC ALTERNATOR

ENERGY STORAGE

LOAD UTILIZATION

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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.

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 V12-16 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.

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Altitude of the proposed site

The winds tends to have higher

If affects the air density and thus the power in the wind & hence the useful WECS electric power o/p. 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.

& costs.

Nearness of site to local center/users

This obvious criterion minimizes transmission line length & hence losses

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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VERTICAL AXIS WIND TURBINE

Vertical-axis wind turbines (or VAWTs) have the main rotor shaft arranged vertically. Key advantages of this arrangement are that the turbine does not need to be pointed into the wind to be effective. This is an advantage on sites where the wind direction is highly variable, for example when integrated into buildings. The key disadvantages include the low rotational speed with the consequential higher torque and hence higher cost of the drive train, the inherently lower power coefficient, the 360 degree rotation of the aerofoil within the wind flow during each cycle and hence the highly dynamic loading on the blade, the pulsating torque generated by some rotor designs on the drive train, and the difficulty of modeling the wind flow accurately and hence the challenges of analyzing and designing the rotor prior to fabricating a prototype. CAD MODEL OF VERTICAL AXIS WIND TURBINE

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With a vertical axis, the generator and gearbox can be placed near the ground, hence avoiding the need of a tower and improving accessibility for maintenance. Drawbacks of this configuration include (i) wind speeds are lower close to the ground, so less wind energy is available for a given size turbine, and (ii) wind shear is more severe close to the ground, so the rotor experiences higher loads. Air flow near the ground and other objects can create turbulent flow, which can introduce problems associated with vibration, such as noise and bearing wear which may increase the maintenance or shorten the service life. However, when a turbine is mounted on a rooftop, the building generally redirects wind over the roof and this can double the wind speed at the turbine. If the height of the rooftop mounted turbine tower is approximately 50% of the building height, this is near the optimum for maximum wind energy and minimum wind turbulence. It should be borne in mind that wind speeds within the built environment are generally much lower than at

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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, undisturbed upstream air velocity, advancing blade, . , is the vectorial sum of the

, and the velocity vector of the

Thus, the oncoming fluid velocity varies, the maximum 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. From geometrical considerations, the resultant airspeed flow and the angle of attack are calculated as follows:

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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 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.

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where A = Surface Area = 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, is the density of the air, A is the swept area of the turbine, and is the wind speed

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TYPES OF VERICAL AXIS WIND TURBINES

Darrieus wind turbine
Commonly described as "Eggbeater" turbines, or Darrieus turbines, were named after the French inventor, Georges Darrieus. They have good efficiency, but produce large torque ripple and cyclical stress on the tower, which contributes to poor reliability. They also generally require some external power source, or an additional Savonius rotor to start turning, because the starting torque is very low. The torque ripple is reduced by using three or more blades which results in greater solidity of the rotor. Solidity is measured by blade area divided by the rotor area. Newer Darrieus type turbines are not held up by guy-wires but have an external superstructure connected to the top bearing. The Darrieus design, the aerofoils are arranged so that they are symmetrical and have zero rigging angle, that is, the angle that the aerofoils are set relative to the structure on which they are mounted. This arrangement is equally effective no matter which direction the wind is blowingin contrast to the conventional type, which must be rotated to face into the wind. When the Darrieus rotor is spinning, the aerofoils are moving forward through the air in a circular path. Relative to the blade, this oncoming airflow is added vectorially to the wind, so that the resultant airflow creates a varying small positive angle of attack (AoA) to the blade. This generates a net force pointing obliquely forwards along a certain 'line-of-action'. This force can be projected inwards past the turbine axis at a certain distance, giving a positive torque to the shaft, thus helping it to rotate in the direction it is already travelling in. The aerodynamic principles which rotate the rotor are equivalent to that in autogiros, and normal helicopters in autorotation.

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As the aerofoil moves around the back of the apparatus, the angle of attack changes to the opposite sign, but the generated force is still obliquely in the direction of rotation, because the wings are symmetrical and the rigging angle is zero. The rotor spins at a rate unrelated to the windspeed, and usually many times faster. The energy arising from the torque and speed may be extracted and converted into useful power by using an electrical generator. The blades of a Darrieus turbine can be canted into a helix, e.g. three blades and a helical twist of 60 degrees, similar to Gorlov's water turbines The aeronautical terms lift and drag are, strictly speaking, forces across and along the approaching net relative airflow respectively, so they are not useful here. We really want to know the tangential force pulling the blade around, and the radial force acting against the bearings. When the rotor is stationary, no net rotational force arises, even if the wind speed rises quite highthe rotor must already be spinning to generate torque. Thus the design is not normally self-starting. Under rare conditions, Darrieus rotors can self-start, so some form of brake is required to hold it when stopped.

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Working Model of Darrieus Wind turbine

A Darrieus wind turbine used to generate electricity on the Magdalen Islands

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Giromill
A subtype of Darrieus turbine with straight, as opposed to curved, blades. The cycloturbine variety has variable pitch to reduce the torque pulsation and is self-starting.The advantages of variable pitch are: high starting torque; a wide, relatively flat torque curve; a lower blade speed ratio; a higher coefficient of performance; more efficient operation in turbulent winds; and a lower blade speed ratio which lowers blade bending stresses. Straight, V, or curved blades may be used. Giromill VAWTs are also self-starting.

A Giromill-type wind turbine

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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 drag when moving against the wind than when moving with the wind. The differential drag causes the Savonius turbine to spin. Because they are dragtype 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.

Working Methodology of Savonius Wind Turbine

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ADVANTAGES OF SAVONIUS TURBINES Savonius turbines are used whenever cost or 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. Savonius and other vertical-axis machines are good at pumping water and other high torque, low rpm applications and are not usually connected to electric power grids. They can sometimes have long helical scoops, to give smooth torque. The most ubiquitous application of the Savonius wind turbine is the Flettner 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.

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Indias Market Overview of Wind Energy

Overview
The development of wind power in India began in the 1990s, and has significantly increased in the last few years. Although a relative newcomer to the wind industry compared with Denmark or the US, India has the fifth largest installed wind power capacity in the world. In 2009-10 India's growth rate is highest among the other top four countries. The worldwide installed capacity of wind power reached 157,899 MW by the end of 2009. USA (35,159 MW), Germany (25,777 MW), Spain (19,149 MW) and China (25,104 MW) are ahead of India in fifth position. The short gestation periods for installing wind turbines, and the increasing reliability and performance of wind energy machines has made wind power a favored choice for capacity addition in India. India has a vast supply of renewable energy resources. India has one of the worlds largest programs for deployment of renewable energy products and systems 3,700 MW from renewable energy sources installed.

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Materials Usage in Current Wind Turbines

A wide range of materials are used in wind turbines. There are substantial differences between small and large machines and there are projected changes in designs that will accommodate the introduction of new material technologies and manufacturing methods. To arrive at a total, the material usage is weighted by the estimated market share of the various manufacturers and machines types. In general the materials used for wind turbines are Steel, Aluminum, Copper and Reinforced Plastic In this project we have used Aluminum discs and aluminum sheets. The following are certain important properties present in the materials.

PROPERTIES OF MATERIALS USED

Youngs modulus
It is defined as the ratio of stress and strain, where the strain does not have units. Therefore youngs modulus has the units of stress,N/mm2 , Mpa , Gpa The value for Aluminum is 70 GPa

Hookes Law
This law states that stress is directly proportional to strain within the elastic limit.
where E= Youngs Modulus.

Yield Stress
It is the value of stress at which the material continues to deform at constant load conditions. The value for Aluminum is 20Mpa

Ultimate Stress
It is the maximum stress induced in the specimen & it occurs in the plastic region. The value for Aluminum is 70Mpa

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Fracture Stress
As the reduction in cross sectional area continues, the load bearing capacity of specimen reduces gradually. At a certain stage cross sectional of specimen is so small that it cannot sustain the load & hence it breaks. The stress at which the specimen breaks is known as fracture stress. It is generally less than ultimate stress for ductile materials.

Hardness
It is the measure of resistance to penetration &abrasion, which is a function of stress required to produce some specified type of failure. It is generally expressed as a number.

Toughness
The ability of material to absorb energy in the plastic range is known as toughness. Toughness per unit volume of the material is known as modulus of toughness.

Poissons ratio
The ratio between lateral strain and longitudinal strain is known as Poissons ratio. The value for Aluminum is 0.35

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Principle of Dynamo Operation

The dynamo 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 set of rotating windings called the 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 the constant magnetic field may be provided by one or more permanent magnets; larger machines have the constant 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 of wire rotates in a magnetic field, the potential induced in it reverses with each half turn, generating an alternating current. However, in the early days of electric experimentation, alternating current generally had no known use. The few uses for electricity, such as electroplating, used direct current provided by messy liquid batteries. Dynamos were invented as a replacement for batteries. The commutator is essentially a rotary switch. It consists of a set of contacts mounted on the machine's shaft, combined with graphite-block stationary contacts, called "brushes", because the earliest such fixed contacts were metal brushes. The commutator reverses the connection of the windings to the external circuit when the potential reverses, so instead of alternating current, a pulsing direct current is produced

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DESIGN OF WIND TURBINE

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DESIGNING OF VERTICAL AXIS WIND TURBINE

A wind mill is machine for wind energy conversion. A wind turbine converts the kinetic energy of the winds motion to mechanical energy transmitted by the shaft. A generator further converts it to electrical energy. So it is necessary to keep in mind, while designing the windmills structural part.

Design of blade
Wind turbine blades have on aerofoil type cross section and a variable pitch. While designing the size of blade it is must to know the weight and cost of blades. In the project three blade with vertical shaft are used, it has a height & width of 73cm & 122cm respectively. The angle between two blades is 600. So if one Blade moves other blades comes in the position of first blade, so the speed is increases.

Blade Profile
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Shaft Designing
While designing the shaft of blades it should be properly fitted to the blade. The shaft should be as possible as less in thickness & light in weight for the six blade, the shaft used is very thin in size are all properly fitted. So no problem of slipping & fraction is created, it is made up of hollow Aluminum which is having very light weight. Length of shaft & diameter are 18 inches & 2.54cm respectively. And at the top and bottom ends mild steel of length 1inch each are respectively are fixed to give strength to the hollow shaft.

Design of Bearing
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. Bearing are generally provided for supporting the shaft and smooth operation of shaft. We have used ball bearings for the purpose of ease of maintenance

An Electric Dynamo
For generation of electricity from the designed our vertical axis wind turbine, we chose a Bicycle dynamo which has the capacity to light a bulb of 12 V. This electric dynamo has the capacity.

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SPECIFICATIONS OF THE WIND TURBINE

BASE DIMENSIONS Height Width 24 inches 21 inches

BLADE DIMENSIONS Height Diameter Thickness Angle Angle b/w blades 18 inches 13 inches 0.125 inches 45 60

SHAFT DIMENSIONS Diameter Length 2.54cm 18 inches

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FABRICATION TECHNIQUES

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VARIOUS OPERATIONS INOVLVED IN FABRICATION PROCESS

The following were the fabrication techniques involved 1. Gas Cutting 2. Arc Welding 3. Riveting

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 90degree 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
[2]

. Manufacturers have developed custom tips for Mapp, propane, and

polypropylene gases to optimize the flames from these alternate fuel gases

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Gas cutting Torch

The gases used in this process are

1. LPG

2. Helium 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.

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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 4045 electrodes.

Arc Welding Equipment

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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

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CALCULATIONS

39

THEORTICAL CALCULATIONS
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 mv 2. K.E= mv2. .. (1) K.E = kinetic energy m= mass v = velocity, M is equal to its Volume multiplied by its density of air M = AV Substituting eqn(2) in eqn(1) We get, K E = AV.V2 K E = AV3 = density of air (1.225 kg/m3) A = D2 /4 D = diameter of the blade A = *(1.22) 2 /4 A = 1.16Sq.m Available wind power Pa = ( D2 V3)/4 (Sq.m) watts .. (2)

P = 1/8 D2 V3

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TRAIL 1
FOR VELOCITY 4.5m/s

Pa Pa Pa

= ( D2 V3)/4

= (*1.225**1.222 *4.53)/4
= 65.244watt

TRAIL 2
FOR VELOCITY 5.5m/s

Pa Pa Pa

= ( D2 V3)/4

= (*1.225**1.222 *5.53)/4
= 119.12watt

TRAIL 3
FOR VELOCITY 7.5m/s

Pa Pa Pa

= ( D2 V3)/4

= (*1.225**1.222 *7.53)/4
= 302.06watt

TRAIL 4
FOR VELOCITY 10m/s

Pa Pa Pa

= ( D2 V3)/4

= (*1.225**1.222 *103)/4
= 716.00watt

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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.

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. 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.
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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 variationno 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 dont 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. j) Can be scaled more easily - from mill watts to megawatts.

43

CONCLUSION

&

FUTURE

DEVELOPMENTS

44

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, lowweight 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

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 VWAT

45

BIBLIOGRAPHY
Eggleston, David M. Wind Turbine Engineering Design. Van Nostrand Reinhold, 1987. Hunt, Daniel V. Wind power: A Handbook on Wind Energy Conversion Systems. Van Nostrand Reinhold, 1981. Kovarik, Tom, Charles Pupher, and John Hurst. Wind Energy. Domus Books, 1979. Park, Jack. The Wind Power Book. Cheshire Books, 1981. Putnam, Palmer Cosslett. Power from the Wind. Van Nostrand Company,

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PHOTOS

47

BLADE PROFILE

48

CYCLE DYNAMO

49

50