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MULTISTAGE WIND TURBINE

Chapter 1
Introduction

Fig 1.1 Offshore wind farm using 5MW turbines RE power 5M in the North Sea off the coast of Belgium.
A wind turbine is a device that converts kinetic energy from the wind, also called wind energy,
into mechanical energy; a process known as wind power. If the mechanical energy is used to produce
electricity, the device may be called a wind turbine or wind power plant. If the mechanical energy is used to
drive machinery, such as for grinding grain or pumping water, the device is called a windmill or wind pump.
Similarly, it may be referred to as a wind charger when used for charging batteries.
The result of over a millennium of windmill development and modern engineering, today's wind turbines are
manufactured in a wide range of vertical and horizontal axis types. The smallest turbines are used for
applications such as battery charging or auxiliary power on boats; while large grid-connected arrays of
turbines are becoming an increasingly important source of wind power-produced commercial electricity.

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1.1 Types of wind mill axis

Fig 1.2the three primary types:VAWT Savonius, HAWT towered; VAWT Darrieus as they appear in
operation
Wind turbines can rotate about either a horizontal or a vertical axis, the former being both older and more
common.

1.1.1 Horizontal axis


Horizontal-axis wind turbines (HAWT) have the main rotor shaft and electrical generator at the top of a
tower, and must be pointed into the wind. Small turbines are pointed by a simple wind vane, while large
turbines generally use a wind sensor coupled with a servo motor. Most have a gearbox, which turns the slow
rotation of the blades into a quicker rotation that is more suitable to drive an electrical generator.
Since a tower produces turbulence behind it, the turbine is usually positioned upwind of its supporting tower.
Turbine blades are made stiff to prevent the blades from being pushed into the tower by high winds.
Additionally, the blades are placed a considerable distance in front of the tower and are sometimes tilted
forward into the wind a small amount.
Downwind machines have been built, despite the problem of turbulence (mast wake), because they don't
need an additional mechanism for keeping them in line with the wind, and because in high winds the blades
can be allowed to bend which reduces their swept area and thus their wind resistance. Since cyclical (that is
repetitive) turbulence may lead to fatigue failures, most HAWTs are of upwind design.
Turbines used in wind farms for commercial production of electric power are usually three-bladed and
pointed into the wind by computer-controlled motors. These have high tip speeds of over 320 km/h
(200 mph), high efficiency, and low torque ripple, which contribute to good reliability. The blades are
usually colored white for daytime visibility by aircraft and range in length from 20 to 40 meters (66 to 130
ft.) or more. The tubular steel towers range from 60 to 90 meters (200 to 300 ft.) tall. The blades rotate at 10
to 22 revolutions per minute. At 22 rotations per minute the tip speed exceeds 90 meter per second
(300 ft/s). A gear box is commonly used for stepping up the speed of the generator, although designs may
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also use direct drive of an annular generator. Some models operate at constant speed, but more energy can be
collected by variable-speed turbines which use a solid-state power converter to interface to the transmission
system. All turbines are equipped with protective features to avoid damage at high wind speeds,
by feathering the blades into the wind which ceases their rotation, supplemented by brakes.

1.1.2 Vertical axis

Fig 1.3A vertical axis Twisted Savonius type 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

sites

where the wind direction is highly variable, for

when

integrated into buildings. The key disadvantages

example

on

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 aero foil 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.
With a vertical axis, the generator and gearbox can be placed near the ground, using a direct drive from the
rotor assembly to the ground-based gearbox, hence improving accessibility for maintenance.
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 exposed rural sites, noise may be a concern and an existing structure may not adequately resist
the additional stress.
Another type of vertical axis is the Parallel turbine similar to the cross flow fan or centrifugal fan it uses
the ground effect. Vertical axis turbines of this type have been tried for many years: a large unit producing up
to 10 kW was built by Israeli wind pioneer Bruce Brill in 1980s: the device is mentioned in Dr. Moshe Dan
Hirsch's 1990 report, which decided the Israeli energy department investments.

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Chapter-2

Literature review
2.1 Bentz equation:
This is main equation which gives complete relation between rotor diameters, wind speed, total
surface ratio (TSR) etc. We have adopted the relation according to Bentz equation in our design hypothesis.
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Fig 2.1 - Bentz equation deflected cash flow

And

(1)

(2)

2.2 Nor pat wing structure:


In the developmental Ohexs authored by HeuelsGooz illustration details about zero twist angle blades. In
our rotatory we developed this zero twist angle blades. We have taken the relations as per the Nor pat wing
which is experimentally proven maximum efficiency blade even in zero twist angle.

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2.3 Technical terminologies


1. Wind turbine: - It is a turbo machine which converts wind energy into mechanical energy.
2. Wind farm: -It is region in which a set of wind turbines are installed.
3. Wind plant: - when a wind turbine is installed for the sake of electric power then it is called
wind plant.
4. Attack wind: - a stream of wind which strikes the rotor of the wind turbine is called attack
wind.
5. Critical velocity: - it is the minimum required velocity of a wind which initiates the turbine
action of the wind mills called critical velocity. Generally it is 10-15 m/sec.
6. Rotor: - a rotor is an assembly of a wind blades which rotates due to turbine action.
7. Wind blade: - it is a structure over which the drift takes place Due to drag force of attack
wind.
8. Airfoil: - it is the cross section of wind blade.
9. Tip speed ratio (TSR):- it is a ratio of rotational speed of rotor to the wind speed.
10. Blade angle: - it is the angle between profile of blade and horizontal reference.
11. Twist angle: - it is angle generated along locus of root of a blade to the axis of blade.
12. Chord: - if the width of blade or length of airfoil at the beginning of blade at the junction of
rotor.

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Chapter-3

Project introduction.
Before going to our project details, first we will discuss some of the technical problems faced by present
wind power plant.

3.1 Problems
3.1.1 Deflection of wind.

Fig-3.1 Pattern of wind deflection

Whenever the wind strikes the wind turbine rotor the wind turbine harness the energy of the wind. So there is
a decrease in wind speed at the output of rotor. The velocity drop will be around 60 80% of the inlet
velocity of wind. This velocity drop causes the deflection of wind away from turbine.

3.1.2 Drop of velocity due to large distance between wind turbines.


Generally wind mills are installed with large distance between them. This is to increase the above mentioned
velocity drop by varying altitudes of surfaces.
But this distance itself causing decreasing of velocity by 10%.
No feasible technology to harness the deflected wind and also to increase the striking velocity of wind to the
consecutive wind turbine.
The solution to the above mentioned problem is the invention called as multistage wind turbine. The
development and analysis of prototype which proves our project.

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3.2Multi stage wind turbine


It is the integration of multistage turbine to obtain by combined effect.

Multistage arrangement

Fig-3.2 Graphical representation of MSWT

The rotar are arrang over a turbine with gradient increase in the rotar diameter. The rotor are attached to the
different shafts which facilitates independent rotation.

3.3 Expected airflow and working


Working:
The wind will attack the wind turbine. The first rotor rotates due to turbine action. The deflected
wind and direct wind attacks the next rotor. Next rotor also harness the energy. As first rotor is connected
with last rotor.
When first rotor rotates last rotor also rotates. As mentioned it creates effect along turbine.

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3.4 Project brief


The design, development and analysis of prototype which proves our concept is our project.
The project involves in following steps.

Step 1: Design of prototype


The prototype is designed by considering the parameters like TSR, Twist angle, airfoil structure and wind
rotor relation of the real wind turbine.

Step 2: Fabrication
The prototype is fabricated as per the design with the available material.

Step 3: Testing of prototype


Prototype is testing under artificially created wind environment and power is obtained, for different wind
velocities, different wing arrangement.

Step 4: comparison and analysis


The results are compared and analyzed. Overall process is to conclude whether the concept of multistage
wind turbine is practically effectible or not.

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Chapter-4

Design process
4.1 Design of prototype
The design process involves in the following discussion.

1) Airfoil :Blade of any wind turbine consists particular airfoil structure to suit the purpose of the
application, Static balancing and maximum airfoil efficiency. For the development of the blade
structure of the prototype, NACA 2412 was considered.

Fig-4.1 structure of airfoil

2) Design of wind turbine


As ours is a new kind of turbine, we can adapting an own nomenclature for the parts of turbine, which
consists of following parts
1)
2)
3)
4)
5)
6)
7)
8)

Solid shaft
Solid shaft attachment
Hollow shaft
Hollow shaft attacher
Wind blade
Holder
Base ( pillar )
platform

4.2 Design Hypothesis


4.2.1 Design of shafts

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Traditional design is adopted to design the shaft we are considering the loads like bending loads, torsional
load, deflection to decide the specification of shafts like diameter, length.

Determination of diameter of hollow shaft


Loads
Bending moment
M = F * perpendicular distance
M = 5 * 54.5
M = 272.5 N-mm
Torque from calculator
T = 0.98 Nm = 0.98 * 103 N-mm
Design
From design equation (shaft design)

2
16 ( C M M ) +(C T T ) 1
d 0=
max
1K 4

1
3

(3)

Assumed k =0.4
T max=

y
44
=
2N 22

CM = 1.5

N = factor of safety, y for Aluminum = 44 Mpa

CT =1.8

Obtained K= 0.52
On solving equation (1)
d 0=

d i 25
=
=48.07 mm
K 0.52

Available shaft = 50 mm
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d0 = 50mm

di = 25mm

Determination of dimension of solid shaft


Using equation of
s=

16T
3
d

d= 3

(4)

16 T
s

Where s=11.121
d=

16T
s

(5)

With considering bending load


d 3=

16
(C T T )2 +( C M M )2 (6)

With CT = 1.8, CM = 1.5


M= 250 N-mm
T= 0.48 N-mm
On solving equation (6)
d = 8.2 mm
Available shaft is 10mm
d= 10mm

Determination of length of shaft on the basis of balancing


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Reff Reff

52 mm

3410

34
15 10
85 LHS mm

RHS

Fig-4.2 Line diagram of balancing of weight


LHS (volume basis)
2

V s= r h

(r = 5) (h = 85)

Vs = 6672.5 mm3
Centre of gravity acts on 42.5mm from reference extra part
V e = ( R 2r 2 )h

(7)

V e = ( 17252 )64
Ve= 53053 mm3
VT = Ve + Vs = 5972.5 mm3
Action of center of gravity of whole object
L1 =

V S LS +V e Le
V s Ls +V e

(8)

L1 = 51.8 mm
Total couple
T L =mL1 VL
TL = 3.09 * 106
On RHS

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V S =R2L
Vs = 78.5 * L
@

Ls =

L
2

VsLs= 39.25 L2
Balancer
V B = ( R 2r 2 )Lh [R=17, r= 5, L= 52]
VB = 43105.92
@ LB = (L-26)
L1 =

( 39.25L2 ) +(43105.92)(L26)
V S +V B

Total couple
TL = m * L1
Equating Total couple
2

39.25 L +(43105.92)(L26)
2
6
( 39.25 L + 43105 )=3.0910
(39.25 L+43105)

On solving
L = 90.75 mm

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4.2.2 Design of Wind blade


Design of wind turbine blades involves in determining the specification of the wind blades like rotor length,
chord angle, twist angle etc
We employed the blade design tools [5], which provides all specification like chord thickness, rotor profiles,
thickness of chord etc if we enter the details of only rotor length.
So our design process is mainly concentrated to determine length between the rotors and the overall length
of the shaft of the wind turbine.
Design hypothesis here is the relation between wind velocity and rotor size. This is be obtained from Bentz
equation on which every wind turbine is designed.

Determination of radius of rotor on the basic of wind speed


We are using an air blower with discharge 2.5 m3/s (Q)
With constructing duck of 25cm diameter we can obtain 46 m/s velocity
At a distance we are obtaining velocity = 33m/s
Power of wind from duct
P= mv2
P = * 9.765 * 332
Pw = 5317.04 W

m = Q

(9)

m = 1.25 * 2.5
m2 = 9.765 Kg

Using concept of Cp = 0.3


Po = 1595.11 W
Power generated at the sec of wind turbine swept area (A). From literature
P = * R2 * V3

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Equating 1 & 2
R 2=

R=

2P
V 3

21595.11
=0.151m=15.1 cm
1.233.14333

As it is a swept area radius.


To calculate radius of blade
R=

Shaft diameter Attacher outer diameter


=
2
2

R1 = 15.12 1.7 = 13.38 13.4 cm


First radius
As velocity is discarded by 2/3. To achieve harnessing we need to increase area by 3/2 so diameter should be

3
2

= 1.2

d2 = 1.2 * d1 = 1.2 * 30 =36


RL2 = 18 cm
Effective radius of blade is R2 = 18 2.5 = 15.5 cm
Similarly for RL3
d3 = 1.2 * d2 =1.2 * 36 = 43.2
Effective radius of blade R3 = 21.6 2.5 = 19cm
R1 = 13.4cm, R2= 15.5cm, R3= 19cm
Specification of length of hollow shaft on the basis of balancing

40mm

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16mm

38mm

16mm

33mm

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L1

143mm

L2

Asblade radii is increasing by 1.22 times mass increased by 1.22 times


Because, m = * volume = * (A*L)
mL
For balancing, (From data from multi stage rotor of helicopter (NASA))
m1L1 = m2L2 (same concept adopted for gas turbine engine)
m1 * 40 = 1.22* m1 * 33
m1 * 40 = m1 * 40.29
Balanced.

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4.3Part design:
These are the part designs of each part of multi stage turbine which are designed as per the calculated
specification.

4.3.1 Solid Shaft

Fig-4.3 solid shaft

4.3.2 Solid shaft attacher

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Fig-4.4 solid shaft attacher

4.3.3Hallow shaft attacher

Fig-4.6 hallow shaft attacher

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4.3.4Holder:-

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Fig-4.7 Holder

Chapter-5

Fabrication of prototype
Fabrication can be explained in two stages
1. Fabrication of parts
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2. Fabrication of assembly

5.1 Fabrication of parts


Shaft and attaches
Shafts are machined as per the part designs we are using aluminum 6060 for the shafts.

Wind blade
The blades are fabricated with help of carpenter.Blades are fabricated as per the designed
specification we have used the teak beading wood as a material for blades which is water resistible, light
weight, strong, smooth surface.

Pillar
We employed the mechanical rod for purpose of pillar. We have used MS studs which are available
in market. It can hold the load of up to 6tons.

Holder
The holder is machined as per the part design. We have used the MS steel for this purpose which
provides high damping, strength and support stability to the shafts.

Assembly
The assembly is carried out in following steps.
1. It starts with installation of bearings inside the pocket of hallow shaft we have used bearing with
specification 6201. Inside this solid shaft is attaches to the hallow shaft.
2. The assembly of hallow and solid shaft are assembled inside the bearings which is facially attached
to the holder. The bearing here is 6206. This type of shaft arrangement is called step wise face
installation.
3. The holder is drilled with holes at the base. The studs are connected to these holes and other side of
rod are attached to base. Here we used plywood sheet which is embedded with aluminum which acts
as damper at the base.
4. Each blades is attached to the solid grooves of the solid attacher with the help of grub screws.
5. The entire attacher arrangement is a rotor, this rotor is attached to the shafts by means of face joint
arrangement.

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Final assembled modelFig-5.1 Side view and Front view

Fig-5.2 Iso-metric view

Final assembly.
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Fig-5.3: Final assembled model of MSWT

5.2 Experimental set up


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Fig-5.4: Pictorial representation of MSWT


Rotor 1

Rotor 2

Rotor 3

1 Hallow shaft rotor

5 - Studs

2 DC motor (acts as generator)

6 Solid base

3 Solid shaft rotor

7 Solid shaft

4 Belt drives8 Holder

5.2.1 The testing set up can be explained with 5 major elements:


1. Creation of Wind environment:
Wind is created using hand air blower. Different wind speeds are obtained by changing distance
between blower and turbine.
2. Conversion of wind energy to Mechanical energy:
The multistage wind turbine assembly does this.
3. Reduction mechanism:
Speed reduction between shafts and power generation system is obtained using belt drives &
pulleys. As pulleys are expensive for the small size application we are using the wheels of Toys as
pulleys.
4. Power Generation:

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Power is measured in terms of Voltage. Voltage is measured from Generator. Due to the
unavailability of generator for small scale we are Using DC motor (40v) as a Generator.
5. Platform and Pillar:
For the platform we are using the Plywood sheet. We connected Studs (M6) between Holder and
base which provides altitude, Support, Vibration Damping to the Turbine.

5.2.2 Testing Procedure:


In order to rotate the wind turbine the wind velocity is generated by the Air blower, which is directed on to
the Wind turbine to harness the kinetic energy of the wind, this intern rotates generator, and the Voltage
developed by it is measured with the help Multimeter. Velocities at mean rotor position at different positions
over the wind turbine length is measured with the help of Anemometer. Same procedure is carried out for
different wind speeds.

5.3 Testing
5.3.1 Over all aim of Testing is to obtain the output from following cases.
1. Single stageturbine.
2. Multistage with dependent rotors.
3. Multistage criss wing turbine
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VAi, VBi, andVCi Input velocity at rotor A, rotor B, and rotor C respectively.
VAo, VBo, and VCo output velocity at rotor A, rotor B, and rotor C respectively.
All the Velocities are in m/s,
Voltages are in mV (mili volt),
Source distance in cm (centimeter),
Speed in rpm.

5.3.2 CASE-1: Single stage turbine (SS)

Fig-5.5 single stage turbine


Sl

Source

no

distance

30

VAi

12.2

VAo

4.8

Vco

3.2

Voltage

Total

V1

V2

voltage

374

00

374

Speed

243

5.3.3 CASE-2: Multi Stage with Dependent Rotors (MSDR)

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Fig-5.6 single stage with induction fan


Sl

Source

no

distance

30

VAi

12.1

VAo

4.8

Vci

3.6

Vco

1.2

Voltage

Total

V1

V2

votage

312

00

312

Speed

226

5.3.4 CASE-3: Multistage Crisswing(MSC)

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Fig-5.7 multistage Criss wing


Sl

Source

no

distance

30

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VAi

12.4

Vao

5.2

Vbi

4.8

Vbo

3.7

Vci

3.2

Vco

1.2

Voltage

Total

Speed

V1

V2

voltage

hallow

solid

298

260

558

226

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Chapter-6

Results and Discussions


The model of the wind turbine developed was tested for different wind speeds ranging from 9m/s to 12m/s
for different configuration. The experimental trials conducted yielded the following results which are
presented in the graphical form.

6.1 Initial observation

Voltage is directly proportional to Speed and Velocity.

For single stage wind turbine critical velocity starts at 12.2m/sec but for multi stage it is at m/sec.

The criss wing arrangement is more effective (more speed) over parallel wing under same velocity so
gave a test for criss.

Comparison of speed of hallow shaft


Similar observations are seen as that of speed of solid shaft.By observing speed of both shafts we can say
that MSC will give more gain of shaft speed with any wind speed.
As voltage is directly proportional to shaft speed,It is observed that MSC will give maximum output and
maximum shaft speed under any wind speed.

Considering speed of solid shaft under multistage combination


Under any combination we can observe in the fig 5.2 that, the shaft speed increases with increase in wind
speed. Up to one particular speed the rate say (R1) is constant but suddenly the rate increases with increase
in wind speed (R2). Again from particular speed the rate remains constant (R3).
By observing the fig 5.2 we can say that the MS gives maximum gain at low wind speeds. But MSC and
gives maximum gain at high speeds.

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6.2 Graphical representation.


Comparison of single turbine and multistage with respect to wind speed

Fig. no 6.1
From the fig 5.3 it is observe that with increase in the wind speed output of both single stage and multi
stage also increases. At a wind speed 12.4 m/sec it is observe that output in single stage is 374mv but with
multi stage it is 558mv because we are generating energy from two generators. Which clearly show that in
multi stage we can gain maximum energy than a single stage.
The highest output is obtained with MSCThe difference of output between and SS is gradually increasing
with respect to wind speed.

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Comparison of MSC, MSDR and SS.

fig.no 6.2
By considering, when it is compared output of MSC, MSDR and SSfor wind speed 12 m/sec output of
586 mv of MSC and 312 mv fromMSDR and 374 mv from SSthis gain gradually increase with increase in
speed.
According to the outputMSC increases output by 36% over single stage. Multi Stage Criss increases 46%
over MSDR.Overall we can say that the Multi Stage Criss wing is more efficient than MSDR and SS.

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Comparison on Multi Stage of Dependent Rotor v/s Multi Stage Crissblades

Fig.no 6.3

Similar observation are seen as that of voltage of solid shaft. By observing voltage of both shafts we can say
that MSC will give maximum amount of energy than MSDR.
Overall MSC gives maximum output than a MSDR while comparing the readings

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Chapter-7

Scope of technology
7.1 Advantages
1) Increase in output
Results from our experimentation shows that with same wind speed output of turbine is
increased by 4.6 times with multistage wind turbine.

2) Critical velocity
Results from our experiments shows that the critical velocity of single stage is 5 m/sec. but
under MSWT the critical velocity is 4m/sec. it is caused due to the effect of multistage arrangement.
It pretends that the critical velocity can be decreased by 10 15% with MSWT concept. So
even under 15% less wind speed the turbine action is initiated. So we can generate wind from this
wind speed itself. This can be considered as one of the indirect advantage of MSWT.

3) Decrease of generation cost


With increase of power output by 4.6 times decrease of critical velocity by 10 15 %, with increase
of energy output of wind plant by 15% and equipment investment ( installation) by 1.6 times more than
conventional plant, maintenance increased by 40 %. We can say that generation cost is decreased by 60%
over present wind power generation. We made calculation by considering cost of present wind turbines
and generation cost

4) Reaches Peak load demands


As it is increasing output by 4.6 times with same available wind: we can say that it is more suitable
for peak load power plants as it reaches peak load demands, even at considerably low wind speeds.

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7.2 Limitations
1. High initial investments
As the arrangement contains more number of rotors, reduction gears, additional generators as per our
calculations we can say that the initial investment is 1.6times the investment of present wind turbine.

2. Design in complex
As it contains the step shaft arrangement with multiple rotors, design in complex. Here we also
need to consider dynamic balancing of turbine but in present wind turbine the static balance is more
sufficient.

3. Requirement of high strength materials for shafts


In MSWT shafts undergoes with more torsional loads, turbulence load. For this reason high strength
materials are needed for shafts.

4. More maintenance cost


Due to the presence of complex bearing arrangement, reduction gears, rotors we can say that
maintenance cost can be increased by 40% over conventional wind turbine.

5. More noise
As it creates more vertex and turbulence it produces more noise compared to conventional wind
turbines.

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7.3 Future development


We developed the prototype with fixed wind direction, fixed blade wind turbine.
The following can be implemented over present prototype

1. Implementation of wind tracing system


This prototype is unidirectional horizontal axis wind turbine. If we implement concept of wind tracing
(turbine prototype as per one wind direction) system we could expect some better efficiency.

2. Implementation of directional sensor to blades


Our prototype is fixed blade wind turbine. Implementation concept of direction sensors (in which blades
rotates about it axis as per wind availability) to get more torque and efficiency.

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Conclusion
We can come to the following inference by analyzing experimentally obtained results.

The critical speed of turbine in single stage is 8.5m/sec. but with multistage combination its

critical speed is 6.5m/sec because of the increase dia of multistage rotor.


Criss wing arrangement is 35% more efficient than parallel wing arrangement.
Criss wing arrangement decreases critical wind speed by 15% as compared to parallel wing
arrangement.

Over all the results from testing of prototype shows that Multistage Wind turbine increase power output by
4.6 times the single stage turbine with the same available wind speed. The maximum efficiency can be
obtained with Multistage Criss wing.

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References
[1]

Joanna L lewis, Building a national wind turbine industry, international journal of technology and

[2]
[3]
[4]
[5]

globalization 5, no (2011): 281 305.


Peter j schubel and richerd j crossly, wind turbine blade design, ISSN, no (1996): 3425 3449.
Magadiregabe , wind turbine theory journal of wind turbine association, (1981) : 1110 1136.
R.K.Hooks, Wind technology and energy, Edition 1991, john wisely and sons.
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