GROUP PROJECT PRESENTATION

Group:- RMD & MD (PEMP FT - 10) Title:-VERTICAL WIND TURBINE Project leaders:- Dr.Narahari,HOD, A&AE Department Dr.N.S.Mahesh, HOD, MME Department Project group:RMD MD Mr.Chandramouli H.R. Mr.Mohan patnaik Mr.Lokesh kumar. Mr.Lava kumar Mr.Srinath.k. Mr.Abinandan patil Mr.Srinath.P.V Mr.Raghavendra Mr.Narendra.
M. S. Ramaiah School of Advanced Studies

CONTENTS
 Aim ,Objective and Scope of the project.  Introduction  Methodology adopted  Design and Fabrication  Conclusion

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AIM & OBJECTIVE AIM:

To model and explore the Vertical Wind Turbine of a Savonius rotor (S-rotor) wind turbine adapted for household/domestic electricity generation

OBJECTIVES:
 Evaluate the best blade offset by field testing using a small prototype model. Produce a turbine capable of generating 5%~10% of the households electricity.  To show that using the Savonius turbine for household generation is a viable option.

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Objectives
To study the Savonius generator which relies solely on drag to produce a force that turns the turbine shaft.
To understand the fundamentals of turbine design, and to evaluate the best blade profile. To study the generation of electricity. To study the occurrence of self starting in low wind speeds. To calculate the performance of the wind machine To study the overall structure of the turbine
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Scope of the project

The 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.

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

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SAVONIUS TURBINE
The Savonius is a drag-type VAWT. 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.

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Blade Design & Manufacturing outline

 Conceptual Design of Rotating Blades  CAD model (using CATIA V5)  Blade material Selection  Manufacturing Process for the Blade  Blade Mounting

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Rotor Blades
The 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; Relatively low operating speed (rpm)

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Design criteria
The following are some rules for construction of a Savonius rotor. The size of the end plates, to which are mounted the buckets, should be about 5% larger than the diameter of the rotor. The 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. The use of augmentation devices such as concentrators or diffusers or combination of the two result in increased power coefficient
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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.

This design is also very simple, and can also be made easily from metal drums or pipe sections. The 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. This 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. Fig. 2 Blade profiles
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Conceptual Design

Nomenclature-

Fig. 3 Blade profiles D- Rotor Diameter q- Radius of circular arc p- Straight edge of blade H- Rotor Height s- End extend

m- Overlap Distance - Arc angle - Rotation angle

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Blade Size Calculation

Watts output = Pw = Au3 =1.742pAu3/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, 0.647 x 1m x 0.8m x (5.5)3 = 86.11 Watts

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Blade with dimensions

Fig.4 Blade dimensions in different views

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Catia model

Fig.5 Isometric view of blade

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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.

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Process for the blade profile

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

Fig. 6 Blade profiles

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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.
Fig.7 Blade mounting position on the shaft
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Structure design
B e a r in g C o v e r B e a r in g O u te r S h a ft

B e a r in g S pacer HUB
7 5 .0 2 5 .0 A

7 5 0 .0

Lock N ut In n e r S h a ft

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

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Str ct r
UB
0.02 A
75.0 25.0

si

Base:
A

750.0

Is a square frame of L angle or box structure of 750 Sq. A hub is welded to the frame at the centre, with a perpendicularity of 0.02mm, The hub will have a bore to suit the inner shaft diameter, this is a transition fit with a clearance of 0.1 mm.

Fr m t W l i

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Structure design

HUB
7 5 .0 2 5 .0 A

7 5 0 .0

Lock N ut

Inner Shaft

I n n e r S h a ft

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 22

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.

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. 2

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2 .

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. Then smaller pulley is mounted on the mounting plate, Shims are used for the adjustment of the centre height and tensioning. A flat belt is used for connection

r P ll y lt im m ll r P ll y M ti Pl t

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Asse
B e a r in g C o v e r B e a r in g O u te r S h a ft

L a rg e r B e lt B e a r in g S pacer
9 .0

u lle

Shi S a lle r u lle la te

HUB
0 .02 A
7 5 .0 2 5 .0

o u n tin g
A

7 5 0 .0

Lock N ut In n e r S h a ft

L - la te ra e

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B la d e
5 0 .0 6 12

o u n t in g T p 12
50.0


T p1
12

2 2 5 .0

2 2 5 .0

2 2 5 .0

2 2 5 .0

225.0

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anufacturing drawings
. 2
2 .

. 2
"

2 .

2 . 6 .

. . 2

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"

 

 

 

 

. . 2

# #   

Hub: Material is mild steel, The bore of 24 has a close tolerance of - 0.02, The top face must have a perpendicularity of 0.02 with respect to the bore. There is relief in between to reduce the are of contact, The top bore must be concentric to the bottom bore by 0.02mm

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M
. 2
2 .

f ct ri
Inside shaft:

dr

. 2
7

T
2 .
5

I
&& (

2 .

. 2

22 .

2 .
%

- . 2

'

M2 .
%

T s it it l ck t
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&&

2 .

@ @

&&

&&1

&&

'

' )

&&

9 8 8 && 9 8 8

s it ri 2

Material is mild steel, The overall OD is maintained as 28 mm Bottom there are threads to suit lock nut and is maintained as M24 X 1.5 There is a dia of 24 to suit the hub and there is a tolerance of 0.02 Then there is bearing seating to suit bearing ID of 25 mm, the perpendicularity has to be maintained Towards 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

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anufacturing drawings
0.02 A

7
42.00

Inside shaft:
0.02 A

Material is mild steel,

9.0

1069

To suit Bearing OD 42
54.00

The overall OD is maintained as 54 mm At top end there is bearing seating to suit bearing OD of 42 mm, the perpendicularity has to be maintained. Towards the other end there is a bearing seating for 42mm the concentricity w.r.t to other bearing seating and perpendicularity has to be maintained

0.02 A

9.0

42.00

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anufacturing drawings
2
FF R D F PI F QI F FI FE E D

. . . .

2 .
F EI F EI

. .
2 .

2 .

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F EI

E HP

F EI

FE E D

A
2 .
. . .

2 .

9 .

2.

2 .

FFFF E G

E HP

F EH

9
C B A

F E

F EI

2 .

. .

F EI

E HP

F EH

2 .

E HP

F EH

F EI

F EI

F E

2.

I C B A

. 2 A

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CATIA MODEL OF VAWT

Fig. 8 VAWT assembly

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BILL OF QUANTITY

1. FRAME 2. LOCK NUT 3. HUB WIND TURBINE 4. RIM 5. BOTTOM BEARING 6. INTERNAL SHAFT 7. OUTSIDE TUBE 8. TOP BEARING 9. SUPPORTING PLATE PULLEY 10. SPACER 11. PULLEY WITH DYNAMO 12. DYNAMO MOUNTING PLATE 13. SPACER FOR DYNAMO 14. BELT 15. BLADE 16. BUSHING

1NO. 2NOS. 1 NO. 1 NO. 1 NO. 1 NO. 1 NO. 1 NO. 1 NO. 1 NO. 1 NO. 1 NO. 1 NO. 1 NO. 2 NOS. 10 NOS.

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DETAILED VIEW OF VAWT

Fig. 9 Orthographic views

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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

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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 = 410 mm Therefore length of the belt = 2110 mm Considering initial tension of 2% ,length of the belt gets reduced to 2115- (0.02*2110) = 2068 mm; Therefore length of the belt = 2068 mm;

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Velocity ratio
Without slip: Diameter of rim= DA ; Diameter of pulley= DB NB = (DA/DB)* NA = (620/100)*60 = 372 rpm; NB = 372 rpm; With 2% slip: NB / NA = (100-s)/100 * (DA/DB); Velocity ratio = NB / NA= 6.1; NB = 365 rpm;

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Kinematic simulation using Adams

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Joints

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Simulation video

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Simulation video (top view)

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Fabrication
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. This means it can be easily machined & welded. Blade- Al. Belt- Nylon. The machines which were used for manufacturing the parts are milling, drilling, lathe and laser cutting machine.
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Welding MIG welding (Metal Inert Gas):

The 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. Temperature range is 3000- 6000 C

Advantages:
Very smooth welding. Faster & quicker process. Economical & easy to use.

Isometric view of blade in catia

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Machined parts

Hub

Dynamo assembly parts

Lock nut

Nylon belt
Blade dimensions in different views
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Positioning of Hub

Welding of Hub To the frame

Supporting ribs

Setting of bushes for Blade mounting

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Welding of bushes For blade mounting

Shaft mounting in the Hub

Lock nut for Inner shaft

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Modification done in fabrication 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

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Estimated Project Cost Material cost: Machining Cost: Fabrication Cost: Miscellaneous: Rs 6500/Rs 6150/Rs 7300/Rs 550/-

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 THANK YOU

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