VAWT Presentation

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PROJECT P

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Groupoup:-:- RMD & RMD & MD (PEMD (PEMP MP FT -FT - 10)10) Title:

Title:-VERTICAL WI-VERTICAL WIND ND TURBINETURBINE

Project leaders

Project leaders:-:- DrDr.Narahari,HOD, .Narahari,HOD, A&AE DepartmentA&AE Department Dr

Dr.N.S.Mahesh, HOD, .N.S.Mahesh, HOD, MME MME DepartmentDepartment Project

Project

group:-RMD MD

RMD MD

Mr.Chandramouli

Mr.Chandramouli H.R. H.R. MrMr.Lava .Lava kumar kumar  Mr.Mohan

Mr.Mohan patnaik patnaik MrMr.Srinath..Srinath.k.k. Mr.L

Mr.Lokesh okesh kumar. kumar. Mr.Abinandan Mr.Abinandan patilpatil Mr.Srinath.P.V Mr.Srinath.P.V Mr.Raghavendra Mr.Raghavendra Mr.Narendra. Mr.Narendra.



 AAiimm ,,OObjbjeeccttiiveve aanndd SSccoopepe ofof tthhee pprroojejecctt.. 

 IntroductionIntroduction 

 MetMethodohodologlogyy adopadoptedted 

 DeDesisigngn anandd FaFabrbricicatatioionn 

 ConclusionConclusion

CONTENTS

CONTENTS

AIM & OBJECTIVE

AIM & OBJECTIVE

AIM:

AIM:

T

T_{oo mmooddeell aanndd eexxpplloorree tthhee VVeerrttiiccaall WWiinndd} TT_{uurrbbiinnee ooff aa}

S

Saavvoonniiuuss rroottoorr ((SS--rroottoorr)) wiinw ndd ttuurrbbiinnee aaddaapptteedd ffoor  r   hous

householehold/dd/domomestesticic eleelectrctriciicityty genegeneratrationion

OBJECTIVES:

OBJECTIVES:



 EE_{vvaalluuaattee tthhee bbeesstt bbllaaddee ooffffsseett bbyy ffiieelldd tteessttiinngg uussiinngg aa ssmmaallll}

 pr

 prototototypypee modmodel.el. 

PPrroodduuccee aa ttuurrbbiinnee ccaappaabbllee ooff ggeenneerraattiinngg 55%%~~1100%% ooff tthhee househol

household¶d¶ss electrelectricityicity.. 

 TT_{oo sshohoww tthhatat ususiinngg tthhee SSaavovonniiuuss ttuurrbbiinnee ffoorr hhooususeehhololdd gegenneerraattiioonn}

Objectives

Objectives

T

T_{oo ssttuuddyy tthhee SSaavvoonniiuuss ggeenneerraattoorr wwhhiicchh rreelliieess ssoolleellyy oonn ddrraagg ttoo}

pr

prododucucee aa ffoorrcece tthhaatt ttuurrnnss tthehe ttuurrbibinene sshhafaftt.. 

TT_{oo uunnddeerrssttaanndd tthhee ffuunnddaammeennttaallss ooff ttuurrbbiinnee ddeessiiggnn,, aanndd ttoo}

ev

evalaluauattee tthehe bebestst blbladadee prprofofilile.e. 

TT_{oo ststududyy ththee gegeneneraratitionon ofof elelecectrtriicicityty..}



TT_{oo ssttuuddyy tthhee ooccccuurrrreennccee ooff sseellff ±±ssttaarrttiinngg iinn llooww wwiinndd ssppeeeeddss..}



TT_{oo ccalalcucullaattee tthhee peperrffoorrmmaannccee ofof tthhee wwiinndd mmaacchihinene}



Scope of the project

T_{he wind turbine set up is used to visualize the flow of wind}

energy which converts kinetic energy of wind in to mechanical energy, which can be diverted to generate electricity.

With the help of this set up homeowners generate their own clean power, thereby reducing Carbon Dioxide emissions.

It helps in putting the wind to work, the household electricity  bill should be decreased.

Using this set up, it easy to contain the generator and other  electrical parts at the ground level.

INTRODUCTION

Vertical-axis wind turbines are a type of wind turbine where the main rotor shaft is set vertically.

 T_{he vertical design means that blades pushed by the wind will}

turn the shaft to which they are connected.

Fig.1 Vertical Axis wind turbine (Savonius type)

SAVONIUS TURBINE

T_{he Savonius is a drag-type VAW}T_.

Savonius wind turbine cannot rotate faster than the speed of  the wind.

Savonius type vertical axis wind turbines turn slowly but generate a high torque.

Savonius turbines are suitable for small scale domestic electricity generation -especially in locations with strong turbulent winds.

Blade Design & Manufacturing outline



Conceptual Design of Rotating Blades



CAD model (using CA

T

_{IA V5)}



Blade material Selection



Manufacturing Process for the Blade

Rotor Blades

T_{he Savonius rotor concept never became popular, until recently,}

probably because of its low efficiency. However, it has the following advantages over the other conventional wind turbines:

Simple and cheap construction;

Acceptance of wind from any direction thus eliminating the need for reorientation;

High starting torque;

10

T_{he following are some rules for construction of a Savonius rotor .}

T_{he size of the end plates, to which are mounted the buckets,}

should be about 5% larger than the diameter of the rotor.

T_{he central shaft should be mounted to the end plates only, and not}

through the buckets.

An aspect ratio of about 2 is desirable from the economic point of  view.

Use only two buckets, as a higher number reduces the efficiency.

T_{he use of augmentation devices such as concentrators or diffusers}

or combination of the two result in increased power coefficient

Basic Blade Designs

It is very strong due to the central shaft, but slightly less efficient than the other two. However, the extra strength allows the rotor to be supported at one end only.

T_{his design is also very simple, and can also be made easily}

from metal drums or pipe sections. T_{he design is slightly}

more efficient than the one above as some of the air is deflected by the second vane as it exits the first one.

T_{his is the most efficient Savonius design. It not only has}

the advantage of air being deflected twice like the design above, but also that the vanes act partly like an airfoil when they are edge-on into the wind, creating a small lift effect and thus enhancing efficiency.

12

Conceptual Design

D- Rotor Diameter 

q- Radius of circular arc  p- Straight edge of blade

H- Rotor Height s- E_{nd extend} m- Overlap Distance - Arc angle - Rotation angle

Blade Size Calculation

Watts output = P_w =

½ Au

3 =1.74_2pAu3_/T_{= Watts (W)}

Power wind = 0.647Au3 W

Where A = area of the turbine, u = wind speed in m/s. At standard conditions, the power in .8m2 _{of wind with a}

wind speed of 5.5 m/s is,

Blade with dimensions

Catia model

Blade Material and Manufacturing

Material Properties requirements: Light weight

Corrosion resistant

Good compressive strength Machinability

Aluminum sheet

Lightweight and tough hardened aluminum sheet has been used for turbine blade.

Process for the blade profile

Arc bending

Arc bending has been done to get the shape what we require for our blade profile.

Blade mounting on the shaft

Some gap

has been given

between outer shaft and blade to make

turbine more

efficient. Because from this passage air can pass and hit the other blade by this combination rpm of the turbine has been increased.

B e a r i n g C o v e r    A L o c k N u t H U B I n n e r S h a f t B e a r i n g B e a r i n g O u t e r S h a f t S p a c e r   7 5 . 0 750 .0 2 5 . 0

Structure design

Possibilities for support. Shaft with one bearing

support at the bottom C frame with a top and

 bottom support

Shaft with 2 bearing at top and bottom and another  hallow shaft rotating over  the bearings

Fr m t b W l i

UB

75.0 750.0 25.0 0 .0 2 A  A Base:

Is a square frame of L angle or   box structure of 7_{50 Sq.}

A hub is welded to the frame at the centre, with a

 perpendicularity of 0.02mm,

T_{he hub will have a bore to suit}

the inner shaft diameter, this is a transition fit with a clearance of  0.1 mm.

Inner Shaft

Is a Hallow pipe, in the bottom the shaft is turned to 3 steps,

1 to suit the bearing ID 2 to suit the hub IB

3 there is a threaded portion in the end for a lock nut to lock in position.

Structure design

 A H U B L o c k N u t I n n e r S h a ft 7 5 . 0 7 5 0 . 0 2 5 . 0 Outer Shaft

Is a Hallow pipe, with two  bearing seating's on top and  bottom this is the only support

for the shaft, and it revolves freely on the inner shaft

¡  .¢  ¡  ¢ .¢  2¡ .¢  m ll r P ll y M ti Pl t im £  . £  2¤  ¤  r r P ll y lt O¥   t¦   r s§   ¨   ft t©   cycl¦   rim w¦   ldi     

lt Driv

Lager Pulley is welded to the outer shat with a concentricity of 0.05mm.

T_{hen smaller pulley is mounted on the mounting}

 plate,

Shims are used for the adjustment of the centre height and tensioning.

H U B L a r g e r u l l e B e a r i n g B e a r i n g O u t e r S h a f t S p a c e r   7 5 . 0 7 5 0 . 0 2 5 . 0       9 .       0 S a lle r u lle o u n t i n g l a t e S h i B e l t B e a r in g C o v e r   0 . 02A  A L - la te r a e L o c k N u t In n e r S h a ft

Asse

l

Ø1 2 Ø6T p 1 2       5       0  .       0       2       2       5 .       0       2       2       5  .       0       2       2       5 .       0       2       2       5  .       0 B l a d e o u n t i n g Ø12     6

T p

      5       0 .       0       2       2       5 .       0

    2   .        2   .        2   .        6   .       .     .        2    .     .      .   2    .      .   2 !    "   ."   2 !    #  . #       2 $

anufacturing drawings

Hub:

Material is mild steel,

T_{he bore of 2}4 _{has a close tolerance}

of - 0.02,

T_{he top face must have a}

 perpendicularity of 0.02 with respect to the bore.

T_{here is relief in between to reduce}

the are of contact,

T_{he top bore must be concentric to}

M 2% . &&  X' . (  ) '  0  .&&  )   2 (  .&&  )   2 (  .&&  '  1&&        2 2    . 3       2       2 2    . 3 4  . 3 4  . 3 )   25 . &&  T s it r i I 2 6   7 .7  2 6   8  . 8       2 9 8  . 8       2 9 )   2% . &&  @  -@  .@  2 T s it it l c k t

M

f ct ri dr

i

s

Inside shaft:

Material is mild steel,

T_{he overall OD is maintained as 28 mm}

Bottom there are threads to suit lock nut and is maintained

as M24 _{X 1.5}

T_{here is a dia of 2}4_{to suit the hub and there is a tolerance}

of 0.02

T_{hen there is bearing seating to suit bearing ID of 25 mm,}

the perpendicularity has to be maintained

T_{owards the other end there is a bearing seating for 25mm}

the concentricity w.r.t to other bearing seating and  perpendicularity has to be maintained

Ø54.00

7

Ø42.00

To suit

Bearing

OD 42

      9 .       0       9 .       0       1       0       6       9 Ø42.00 0.02 A  A       0 .       0       2       A       0 .       0       2       A

anufacturing drawings

Inside shaft:

Material is mild steel,

T_{he overall OD is maintained as 5}4 _mm

At top end there is bearing seating to suit bearing OD

of 4_{2 mm, the perpendicularity has to be maintained.}

T_{owards the other end there is a bearing seating for} 

4_{2mm the concentricity w.r.t to other bearing seating}

CATIA MODEL OF VAWT

1. FRAME 1NO.

2. LOCK NUT 2NOS.

3. HUB ± WIND TURBINE 1 NO.

4. RIM 1 NO.

5. BOTTOM BEARING 1 NO.

6. INTERNAL SHAFT 1 NO.

7. OUTSIDE TUBE 1 NO.

8. TOP BEARING 1 NO.

9. SUPPORTING PLATE PULLEY 1 NO.

10. SPACER 1 NO.

11. PULLEY WITH DYNAMO 1 NO.

12. DYNAMO MOUNTING PLATE 1 NO.

13. SPACER FOR DYNAMO 1 NO.

14. BELT 1 NO.

15. BLADE 2 NOS.

16. BUSHING 10 NOS_.

DETAILED VIEW OF VAWT

WIND TURBINE MODEL PROCEDURE

Based On Conceptual Design Model As Been Created Part By Part Using CATIA.

Applied the material properties for all part.

Assembly has done as per fabricating procedure. Detailing Is Done For Each Parts

Dimensional And Geometric Constraints Are Done For Sketches and model

Assembly Constrains Are Done As Per Simulation requirement and arrested the degree of freedom

Length of the Belt

Length of the belt (L):

Length of the flat belt (open) = /2*(D+d) + (D-d)2_/(4*c)+

2*c

Diameter of Rim = 620 mm; diameter of pulley = 100 mm; Centre to centre distance = 4_{10 mm}

T_{herefore length of the belt = 2110 mm}

Considering initial tension of 2% ,length of the belt gets reduced to 2115- (0.02*2110) = 2068 mm;

Velocity ratio

Without slip:

Diameter of rim= D_A ; Diameter of pulley= D_B  N_B = (D_A/D_B)* N_A = (620/100)*60 = 37_{2 rpm;}  N_B= 37_{2 rpm;} With 2% slip:  N_B / N_A = (100-s)/100 * (D_A/D_B); Velocity ratio = N_B / N_A= 6.1;  N_B= 365 rpm;

  As per the design requirement we have chosen following 

material for different parts.

For inner shaft, outer shaft, hub, pre load cap for bearing, Dynamo assembly parts, blade supporting shaft- Mild Steel .

Because its very cheap and most versatile. High strength & malleability, so it is soft. T_{his means it can be easily machined}

& welded. Blade- Al. Belt- Nylon.

T_{he machines which were used for manufacturing the parts are}

milling, drilling, lathe and laser cutting machine.

Welding

Isometric view of blade in catia

MIG welding (Metal Inert Gas):

T_{he gas which is used is Argon (Ar)}

MIG welder uses electrical current to raise the temperature of the base metal and fuse the filler metal together in an electrical arc.

T_{emperature range is 3000- 6000 C}

Advantages:

Very smooth welding.

Faster & quicker process.

Blade dimensions in different views

Machined parts

Hub Dynamo assembly parts

Positioning of Hub Welding of Hub

T_{o the frame}

Supporting ribs Setting of bushes for  Blade mounting

Welding of bushes For blade mounting

Shaft mounting in the Hub

For achieving the concentricity and accuracy of shafts.

Slots are made for the purpose of reducing the weight of the rim.

Primary design

of rim Sheet metal Modified assembly

of rim  Modification done in fabrication

Estimated Project Cost

Material cost:

Rs

6500/-Machining Cost:

Rs

6150/-Fabrication Cost:

Rs

7