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DESIGN & CONSTRUCTION OF VERTICAL AXIS WIND

TURBINE

PROJECT REPORT (2013-2014)

Submitted by

NAME REG.NO

JEYAPANDIAN.K 12244610

JOHN JEBARAJ.M 12244611

KAVIN.P 12244613

KAVIYARASU.M 12244614

KOLANCHINATHAN.S 12244615

KUMARARAJA.S 12244616

GUIDE BY

Dr.N.RAJAMANICKAM

Submitted in partial fulfillment of the requirements for the award of the

DIPLOMA IN MECHANICAL ENGINEERING of the state board of technical

education, Government of Tamilnadu.

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT POLYTECHNIC COLLEGE,

COIMBATORE -641014.

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GOVERNMENT POLYTECHNIC COLLEGE,

COIMBATORE -641014.

DEPARTMENT OF MECHANICAL ENGINEERING

PROJECT REPORT (2013-2014)

BONAFIDE CERTIFICATE

This is to certify that the project titled ”DESIGN & CONSTRUCTION OF

VERTICAL AXIS WINDTURBINE” is approved record of the work done by

Mr.P.KAVIN Register No.12244613 in partial fulfillment of the requirements for the

award of the Diploma in Mechanical Engineering of the State Board of Technical

Education , Government of Tamilnadu during the academic year 2013-2014.

GUIDE HOD

(N.RAJAMANICKAM) (ESTHAR SUGANTHI PRAMOTH)

Submitted for the Board Examination Held on …………………………..

INTERNAL EXAMINER EXTERNAL EXAMINER

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ACKNOWLEDGEMENT

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ACKNOWLEDGEMENT

We are pleased to express our gratitude and thanks to our respected Principal

Mr.A.MATHIVANAN, M.E., B,Tech, Ed., F.I.E.,M.I.S.T.E., C.Eng. for the facilities made

available in the institution.

It‟s our solace thanks to the head of the department of mechanical engineering

Mrs. ESTHAR SUGANTHI PRAMOTH, M.E., for providing support at every stage without

whom, the project would not be a successful one.

We extent our deep gratitude to our project guide Dr.N.RAJAMANICKAM, M.E.,

PhD,

We are grateful to express our thanks to all the staff members, friends, lab technicians

and classmates who helped us directly and indirectly to finish the project.

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CONTENTS

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CONTENTS

CHAPTER NO - CHAPTER NAME - PAGE NO

Synopsis - 01

01 - Introduction - 02

02 - Literature Review - 04

03 - Principle of working &

Design - 07

04 - Fabrication - 21

05 - Results &

Discussion - 23

06 - Cost analysis - 27

07 - Conclusion - 29

List of reference - 31

Photography - 32

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SYNOPSIS

It is understood that, the electricity demand can be increased every day. It leads current

shortage. It is a main reason for unwanted power cuts in Tamilnadu. So, it is necessary to find

easy ways for produce electricity. In present time, the electricity can be produced form Non-

renewable energy sources like thermal, nuclear and hydro. These resources exist in few years

only. So, the electricity should be produced from Renewable energy sources.

Wind is the one of the renewable energy source. It is available in any other places in the

world. So, it is important to utilize this resource. From this the wind turbines are used. It is a

machine which converts wind energy into electrical energy. Two types of wind turbines are used

for produce electricity. They are

1) Horizontal axis wind turbines (HAWT)

2) Vertical axis wind turbines (VAWT)

Vertical-axis wind turbines 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, were attempted to design and fabricate a Savonius Vertical Axis Wind

Turbine. It is a small scale wind turbine. So, less amount of output (electricity) can be generated

easily.

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CHAPTER-1

INTRODUCTION

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1. INTRODUCTION

Energy is the ability to do work. While energy surrounds us in all aspects of life, the

ability to harness it and use it for constructive ends as economically as possible is the challenge

before mankind. Alternative energy refers to energy refers to energy sources which are not based

on the burning of fossil fuels or the splitting of atoms. The renewed interest in this field of study

comes from the undesirable effects of pollution (as witnessed today) both from burning fossil

fuels and from nuclear waste byproducts. Fortunately there are many means of harnessing energy

which have less damaging impacts on our environment.

The alternatives are

Solar

Wind

Geothermal

Tides

Biomass

Hydroelectric

By using Wind, it is planned to produce more energy, so for getting energy wind mills are

used. By using Vertical axis wind mill electricity can be easily generated. The design and

construction of Vertical axis wind mill is simple when compared to Horizontal axis wind mill. In

vertical axis wind mill, the wind from all the direction touches the wind blades and makes the

blade to rotate. It also operates in less wind velocity.

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CHAPTER-2

LITERATURE REVIEW

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2. 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 b y 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=1/2 mv2

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Amount of air passing is given by

m =ρ A V………………………………………………..(1)

where

m- Mass of air transversing

A- Area swept by the rotating blades of wind mill type generator

ρ- Density of air

V- Velocity of air (Wind)

Substituting this value of the mass in expressions of K.E.

=1/2 ρ A V.V2 watts

=1/2 ρ A V3 watts....................................(2)

Second equation tells us that the power available is proportional to air density (1.225 kg/m3) and

is proportional to the intercept area. Since the area is normally circular of Diameter D in

horizontal axis aero turbines, then

A=ΠD2/4 (sq. m)

Put this quantity in equation second then

Available wind power Pa=ρ Π D2 V

3/8 watt

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CHAPTER-3

PRINCIPLE OF WORKING

&

DESIGN

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3.1 BLOCK DIAGRAM

WIND WIND

Fig.3.11-Block diagram of wind turbine operation

WIND TURBINE

GENERATOR

ENERGY STORAGE

LOAD UTILISATION

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3.2 PRINCIPLE OF WORKING

Fig3.21:- Principle of working, indicated from top view of the rotor blade.

The flow of wind touches the rotor blade, the rotor blade and shaft starts rotating. So

from this rotation the power is transmitted to the large gear (Drive) in the gear box with the help

of shaft. The large gear is attached to the small gear (Driven) in the generator. So the rotation is

more in generator when comparing to the shaft rotation due to gear mechanism. From this the

generator rotates and produces the electricity. Here ball bearings are used to rotate the shaft

easily and smoothly. If we fix the vertical axis wind turbine above the building, the lower

supporting structure is not necessary. From this we can reduce the cost. The performance of

Vertical Axis Wind Turbine is more than the Horizontal Axis Wind Turbine.

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3.3 DESIGN

The main parts of the wind turbine and their design specifications are explained in this chapter.

3.31 Savonius Rotor Blade

It is a rotated part of this wind turbine. This Savonius wind turbine was invented by the

Finnish (Finland) engineer Sigurd Johannes Savonius in 1922. So the rotor blade is named with

his name. The rotor blade have „S‟ Shape. It is also known as ”S-Rotor”. The rotor blade is made

from Aluminum plate with the help of rolling machine. The rotor blade is bolted with shaft.

The dimensions of the rotor blade are

Length-900 mm

Breadth-620 mm

Thickness- 3mm

It is made up of aluminum. The aluminum were chooses for light weight and also it has

the following properties

a) Yield stress-20 Mpa

b) Ultimate stress-70 Mpa

3.32 Shaft

It is used to transmit torque from rotor blade to the gear box. It is inserted in upper

supporting structure with two ball bearings and flange bearing for smooth rotation. It is a hollow

shaft, made up of Galvanized Iron (G.I). In this shaft, rotor blade is bolted in upper end, and the

spur gear (Low speed) is inserted in lower.

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The dimensions of the shaft are

Length-1700 mm

Diametre-32 mm

3.33 Supporting Structure

It is a supporting part of the wind turbine. It is made up of Cast Iron (C.I). It is welded

with 10 mm thick circular plate with four holes for bolting. It is bolted with top of the gear box.

The shat and ball bearings are placed inside the supporting structure. The dimensions are as

follows

Length-520 mm

Outer Diameter- 120 mm

Bore- 70 mm

3.34 Gear Box

It is a static part of wind turbine. It is made up of sheet metal. The spur gears (Drive and

Driven) and Flange bearing are placed inside the gear box. This box have 50 mm hole in top side

for shaft inserting. Also, it‟s have a door with locking arrangement for generator maintenance.

The dimensions are as follows

Length & Breadth- 400 mm

Height-510 mm

3.35 Bearings

In this wind turbine, the bearings are used in the shaft for smooth rotation. Here two ball

bearings and one flange bearing are used. The ball bearings are used in mid place of the shaft.

Also, the flange bearing is used in dead end of the shaft. The dimensions are as follows

Outer diameter-70 mm

Bore-32 mm

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3.36 Generator

It is a main part of wind turbine. The electricity can be produced from the generator. It is

a DC generator, permanent magnet type. The output can be tested by using DC bulb. The yoke

can be made up of mild steel. The generator is fixed (bolted) in gear box. The specifications are

as follows

Type- DC permanent magnet

RPM-1500

Current-6 A

Voltage-12 V

3.37 Spur Gear

Here the spur gears are used in shaft and generator for torque transmission. One gear has

large size and another have small size. The large size gear is used in shaft (Drive), and small size

gear is fixed in the generator‟s rotor (Driven). These two gears are coupled with each other(Gear

Mechanism). The gears are made up of Cast Iron (C.I). The dimensions are as follows

Large gear (Drive) Small gear (Driven)

Outer diameter-170 mm Outer diameter-69 mm

Bore-32 mm Bore-20 mm

No. of teeth- 65 No. of teeth-26

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3.38 DRAWINGS

LIST OF FIGURES

Sl.NO Figures

3.381 Gear Box

3.382 Savonius Rotor

3.383 Hollow Shaft

3.384 Spur Gear ( Low speed)

3.385 Spur Gear (High speed)

3.386 Supporting Structure

3.387 Savonius vertical axis wind turbine

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Fig-3.381: Gear Box

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Fig-3.382: Savonius Rotor Blade

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Fig-3.383: Hollow Shaft

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Fig-3.384 Spur Gear (Drive)

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Fig-3.385: Spur Gear (Driven)

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Fig-3.386: Supporting Structure

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Fig-3.387: Savonius vertical axis wind turbine

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CHAPTER-4

FABRICATION

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4. FABRICATION

The fabrication process of the wind turbine is as follows

4.1) Rolling

The Rotor blade is made from aluminum plate by rolling operation. This operation was

done in rolling machine. This machine has three rollers. The plate was inserted between rollers,

and to make bends. After this bending process, the rotor blade shows “S” shape.

4.2) Bolting

The rotor blade-shaft, Supporting structure-Gear box, Gear box-Flange bearing, Gear

box-Generator are bolted with M12 Nut and bolt with 2 washer in a set of nut and bolt. The small

gear and generator were bolted with M8 nut.

4.3) Arc welding

In upper supporting structure, a circular plate is welded with a pipe. Also, in lower

supporting structure, square plates are welded with square hollow steel bar. The both welding are

Arc welding.

4.4) Grinding

The unwanted metal portions are removed by grinding process. This process was done

by using grinding machine. In this project, we were done grinding in shaft for insert of bearings.

4.5) Gas cutting

It is making a hole in gear in upper side of the gear box by using gas cutting.

4.6) Painting

In this process the outer and inner area of the wind turbine are painted with Wight color.

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CHAPTER-5

RESULTS

&

DISCUSSION

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5.1 RESULTS & DISCUSSION

The maximum power of Savonius wind turbine is given by (Practical Power)

Pmax=0.36 Kg/m3 X h X r X v

3 in Watt (W)

Here

h- Height of the rotor blade in metre (0.62 m)

r- Radius of the rotor blade in metre (0.28)

V- Wind velocity in m3/sec

Pmax-Maximum power of Savonius wind turbine in Watt

If the wind velocity is 10 m3/sec means

Pmax=0.36 X 0.62 X 0.28 X 103

=69.55 W

70 W

This is Mechanical power. But electrical power can be denoted by

P=VI in Watt (W)

Here

V-Voltage in Volt (V)

I-Current in Amphere (A)

From Generator‟s specification

Voltage= 12 V

Current= 6 A

So, the electrical power is given by

P = 12 X 6

P = 78 W

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5.2 ADVANTAGES & DISADVANTAGES

The advantages and disadvantages of this wind turbine are discussed in this chapter.

ADVANTAGES

+ They can catch wind from any direction.

+ They are produced less noise.

+ They starts at low wind velocity.

+ Towers can be much lower.

+ Low installation costs.

+ They are Bird and bat friendly.

+ It is a renewable Energy Source

DISADVANTAGES

- Large effective area required.

- Can‟t use in very height.

- It is used in wind season only. (Common disadvantage of wind turbines)

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5.3 APPLICATIONS

Wind- turbine generator have been built a wide range of power outputs from

kilowatt (Kw) or so to a few 1000 Kw, machine of low power can generate

sufficient electricity for space heating & cooling & for operating domestic

appliances.

Low power Wind Energy Conversion (WEC) generator have been used for many

years for the corrosion protection of buried metal pipe lines.

Application of more powerful turbines up to about 50 Kw, are for operating

irrigation pumps, Navigational signal. Aero generator in the intermediate power

range, roughly 100 Kw-25 Kw can supply electricity to isolated population.

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CHAPTER-6

COST ANALYSIS

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6. COST ANALYSIS

Sl.

No

Part Material

Cost (Rs)

Labor Cost

(Rs)

Total Cost

(Rs)

01. Savonius Rotor

Blade

1450 500 1950

02. Hollow Shaft 180 - 180

03. Supporting

Structures

350 200 550

04. Gear Box - 2500 2500

05. Bearings 550 - 550

06. Generator 750 - 750

07. Spur Gear

550 50 600

08. Accessories 1000 - 1000

Overall Cost (Rs) 8080

Labor cost

The labor cost of this project for done welding, gas cutting, rolling etc.,

Accessories cost

The accessories cost of this project for purchase Bolts, Nuts, Paint, Thinner etc.,

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CHAPTER-7

CONCLUSION

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7. CONCLUSION

In this project, Design & Construction of vertical axis wind turbine has been done

successfully. The output of 12 V has been generated. In wind season the output can be increased.

Vertical axis wind mill is the easiest way to produce electricity. This project is a proof for this.

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LIST OF REFERENCE

The following books and websites are taken for reference.

1) Renewable energy sources form N.V.Publications authored by Mr.M.Parasuram.

2) Strength of materials by R.S.Kurmi.

3) www.wikipedia.com/ wind turbine.

4) www.wikipedia.com/ vertical axis wind turbine.

5) www.wikipedia.com/ Savonius vertical axis wind turbine.

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PHOTOGRAPHY

Fig: 1-Fabricated View of wind turbine

Fig: 2- View for generator and gears are placed inside the gear box