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=
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45
Rated Power Vs Velocity
0
1000
2000
3000
4000
5000
6000
7000
0 5 10 15 20 25
Velocity (m/s)
P
o
w
e
r
(
W
a
t
t
s
)
Rated Power Vs
Velocity
Velocity Power
0 0
1 0.724608
2 5.796864
3 19.56442
4 46.37491
5 90.576
6 156.5153
7 248.5405
8 370.9993
9 528.2392
10 724.608
11 964.4532
12 1252.123
13 1591.964
14 1988.324
15 2445.552
16 2967.994
17 3559.999
18 4225.914
19 4970.086
20 5796.864
Fig 15 : Rated Power Vs Velocity for r= 1.7
[20] Table 6: Velocity and Power (MATLAB) r= 1.7
46
3.6 R.P.M:
The R.P.M () corresponding to a wind velocity (V) and maximum power is chosen to
suit the type of load the wind turbine will require to drive but it must be chosen that the
peripheral velocity of the blade tip is between 1 & 8 times the wind velocity. If the ratio
is 8, the wind turbine would be a high-speed type suitable for driving an electric
generator and the number of blades required will be either two or three. If the ratio is one,
the wind turbine would be a lower speed type requiring 12 blades.
V 2 60
D 2
8 7 120
2 3.55
301rpm
5rad / sec
e=
t
=
t
e=
e=
47
The coordinate points of RAF6 airfoil section are plotted and given in a number of
stations as:
X
Y
Y
A
0.347479 0.181751 1.026482 9.6910
-4
0.657521 0.245835 0.694449 0.001232
0.986812 0.254921 0.480078 7.2910
-4
1.317146 0.256175 0.361829 4.5510
-4
1.647423 0.255079 0.288225 3.0510
-4
1.977565 0.25304 0.288225 2.1810
-4
2.307597 0.250552 0.202221 1.6310
-4
2.637548 0.247823 0.175016 1.2610
-4
2.967439 0.244953 0.153768 110
-4
3.297287 0.241996 0.136721 8.1510
-5
Area under X-Curve is calculated by Simpsons Rule:
1 1 [( ) 4( odd ordinate) 2( even ordinate)] [ ]
3 2
n n n
h h
A y y y y o = + + + + +
here, h = interval between ordinates
b a
h
n
=
where,
1.77
0.8 7
31.64
0.1769
hub
tip
hub V
b r m
a r
a
= =
= = =
O
=
[21] Table 7: Coordinates and Area MATLAB code
48
n = number of intervals = 9
1.77 0.1769
0.177
9
h
= =
0.495358
3.865275
0.792573
0.000682
A ydr
A xdr
y dr
V
= =
= =
' =
=
3.7 THRUST:
The total thrust applied on the 3 blades can be calculate by the formula:
2
2
1
2
1
(3)(1.225)(7 )(3.865275)
2
348.02
116 /
p =
=
=
=
T B V xdr
T N
T N Blade
3.8 TORQUE:
Torque can be calculated by the formula:
2
2
1
Q B V ydr
2
1
3 1.225 7 0.495358
2
Q 44.6N.m
=
=
=
p
49
3.9 POWER TRANSMITTED:
The Power transmitted is given by:
Q 2
P
60
44.6 2 300
P
60
P 1400Watt
=
=
=
te
t
0r P = 1.4kW
1.4kW > 500W
i.e. the Blade Power is sufficient for our design.
3.10 STRUCTURAL DESIGN CALCULATION
The design calculation for wind turbine is done on the rated speed of wind. So as the
wind turbine could with stand the extreme conditions.
3.10.1 Thrust:
The thrust on each blade at a wind speed of 10.5m/s is given as
tip
hub
r
2 xdr
r
2
1
T V
2
1
(1.225)(10.5) (3.865275)
2
T 261N/ Blade
T 783N
=
=
=
=
p
50
3.10.2 Tangential / Centrifugal Force:
The Tangential Force F
C
(which is along the chord of the blade) on the blade of wind
turbine at a wind speed of 10.5m/s is given by
tip
hub
r
2
C
r
2
C
C
C
1
F V y dr
2
1
F 1.225 10.5 0.792573
2
F 53.52N/ Blade
F 160.56N
' =
=
=
=
p
3.10.3 Mass of the Blade:
The Volume of the blade is determined by the trapezoidal rule, which is given as:
n 1 2 a 1
h
V [(a a ) 2(a a .... a )]
2
o = + + + + +
where,
a
o
,a
1
,a
2
,,a
n
are the cross-section areas at station 0, 1, 2, 3, 4, .., n along
the length of the blades.
h = Interval between two sections
The General cross-section area of blade ate different chord length is given as:
9 2 2 2
B
t
A 81.4 10 [c (c ) ]
0.06
=
where,
t = thickness at different station
c = chord length at different stations.
Here,
V = 2000m
3
51
Mass of Blade is given as
blade M V =p
where,
= density of fiber glass = 0.000682
blade
blade
blades
M 0.000682 2000
M 1.364kg / blade
M 4.1kg
Total Weight=4.1 9.81=40.14N
=
=
=
52
3.11 STRESSES DUE TO AERODYNAMIC LOADING OF THE BLADE:
3.11.1 Stress due to Aerodynamic Force (Bending Sress)
a
a
ba
a a
2
a
6
3 2 2
5
a
3
ba
5
2
ba
M y
M
J z
z a b
4
I
M
y
B.M z
69 10
1.25 10 ( )[ a (0.1a )]
2 4
a 0.0773m
z 3.62 10
1.25 10
3.62 10
34.5MN/ m
o = =
t
=
o
=
= o
t
=
=
=
o =
o =
53
3.11.2 Stresses Due to Centrifugal Force (Tensile Stress)
2
C
tc
2 2
2 2
tc
2 2
2
tc
mV
F R
A A
( AR) V V V
RA RA
R
2000 (1.77) (31.64)
6.27MN/ m
o = =
p p
= =
o = p e
=
o =
54
DESIGN OF
MECHANICAL
COMPONENTS
55
HUB DESIGNING
56
Design of Mechanical Components
4. DESIGN OF HUB
4.1 TANGENTIAL STRESSES:
2 3
t ba S 34.5MN/ m 5 10 psi o = = =
4.2 RADIAL STRESSES:
4.3 MATERIAL OF HUB:
AISI 1006, Mild steel:
= 7850 kg/m
3
= 0.283 lb/in
3
t
= Tensile Strength = 330 MPa = 48 Kpsi
y
= Yeild Strength = 280 MPa = 41 Kpsi
= Poisons Ratio = 0.3
2 3
r tc S 6.27MN/ m 0.91 psi o = = =
57
4.4 CALCULATION FOR RADIUS OF HUB
4.4.1 On the Basis of Radial (Centrifugal) Stresses
2 2 2
r S cwN [(3 )(R r )] v = +
c = 0.00000355
r = shaft radius = 0.4in
N = 300rpm
4.4.2 On the Basis of Axial (Tangential) Stress
2 2 2
t S cwN [(3 )R (1 3 )r ] v v = +
St = 5 10
3
psi
R = 0.4in
R = 6.61in = 0.168m
4.5 CALCULATION FOR HUB THICKNESS
t N C
r
t
r
F F F
S
A 2(R r)t
(F 100)
t
2 S (R r)
+
= =
=
Where,
58
F
T
= 800N
S
r
= 0.91
10
3
psi
= 6.27MN/m2
r = 0.01016
t = 0.02m
t = 21.95mm
4.6 CALCULATION OF VOLUME OF HUB
2
2
4 3
Volume of Hub A t
V R t
(0.168) (0.02195)
V 8.86 10 m
t
t
=
=
=
=
4.7 MASS OF HUB
4
Mass of Hub Volume of Hub
7850 8086 10
Mass of Hub=7kg
p
=
=
59
DESIGN OF BOLTS
60
5. DESIGN OF BOLTS
5.1 FORCES ACTING ON BOLTS
Using Cast Iron Bolts having UTS = 180Mpa
Total force acting on the bolt = F
T
= F
N
+ F
C
F
N
= 800N/m
F
T
= 800
1.77
F
T
= 1.416kN
5.2 FOR CENTRIFUGAL FORCE
2
2
C
2
2
C
m(R )
m
F
R R
mR
4.1 1.77 31.64
F 7.264kN
v
O
= =
= O
=
=
5.3 FORCE ON EACH BOLT
Number of Bolts = 12
5.4 DIAMETER OF BOLT:
Since we are using Cast Iron Bolts
T
one bolt
one bolt
8.68 F
F
Number of Bolts 12
F 723.4N
= =
=
61
i.e. UTS = 180Mpa
all
T
all
6
5
2
5
3
180
15Mpa
12
F
A
724
A
15 10
A 4.83 10
d
4.83 10
4
d 7.84 10 m
d 7.84mm 8mm
o
o
t
= =
=
=
=
=
=
= ~
62
GEAR DESIGN
63
6. GEAR DESIGN
6.1 REASON FOR USING HELICAL GEARS
In designing of gear box for our project we are using helical gear because of the
following reasons
o The twisted teeth of the helical allow more teeth in contact at one time, thus
distributing the load more widely.
o Helical gears are well suitable at high speed whereas spur gear cannot withstand
high speed.
o They pick of the load gradually.
o Helical teeth have a greater breaking strength.
o Gradual transfer of load in the helical gear results in quieter running, lower
dynamic load, and higher permissible speeds.
Because of these advantages helical gear are always used.
6.2 DESIGN CONSIDERATION
The design consideration usually includes
1. The horse power
2. The speed of driving gear and the driven gear or the velocity ratio.
3. The center distance between the shafts.
In the design of the gear drive, there are several requirements that must be followed. The
following are the important ones.
a. The gear teeth should have sufficient strength to withstand static load such
as that high starting torque or under the dynamic loading during the
running conditions.
b. The teeth should have good wear characteristics so that their life will be
satisfactory.
c. The material used should be economical.
d. Lubrication agreement.
6.3 DESIGN CRITERIA
The turbine is to be coupled to a generator producing electricity. As the rotational speed
of turbine shaft is very low, a step up must be before the coupling of the generator,
keeping in view the unavailable of metric standards, we are designing gear box according
to AGMA standards.
64
6.4 STEP UP RATIO:
Rpm of low speed shaft = 300
Rpm of high speed shaft = 1500
Step up ratio = 1500/300 = 5
Assume,
m = o.25 or 6.35mm
N
p
= 29 tooth
Pd = = 4 teeth/in
6.5 PITCH CIRCLE DIAMETER
6.6 PITCH LINE VELOCITY
6.7 TANGENTIAL LOAD
65
6.8 GEOMETRY FACTOR
For Pinion
J
p
= 0.38
For Gear
J
g
= 0.46
6.9 INDUCING STRESSES
For Pinion
Where,
V is in m/s
66
Gear#1 Gear#2 Gear#3 Gear#4
Pressure Angle 20 20 20 20
RPM 1500 670 670 300
Teeth Number 18 40 27 60
Diameteral Pitch 8.467 8.467 8.467 8.467
Bore Diameter 1.839 4.45 2.915 6.812
Module 3 3 3 3
Addendum 0.118 0.118 0.118 0.118
Dedendum 0.137 0.137 0.137 0.137
Whole Depth 0.255 0.255 0.255 0.255
Working Depth 0.236 0.236 0.236 0.236
Tooth Thickness 0.186 0.186 0.186 0.186
Clearance 0.019 0.019 0.019 0.019
Pitch Diameter 2.126 4.724 3.189 7.086
Outside Diameter 2.362 4.96 3.425 7.323
Base Diameter 1.998 4.439 2.997 6.659
Root Diameter 1.853 4.451 2.916 6.813
Circular Pitch 0.371 0.371 0.371 0.371
Bore Diameter 1.834 2.319 2.397 2.397
Size(m3) 0.154 0.66 1.25 733
Weight(gm) 538 2.5 1.11 5400
Max. Length 2.352 4.948 3.422 185.7mm
Max. Width 2.329 4.948 3.416 185.7mm
Max. height 0.197 0.375 0.375 29.36mm
Table 8: Gear Characteristics
67
SHAFT DESIGN
68
7. SHAFT DESIGNING
7.1 SHAFT CONNECTED TO ROTOR (HUB):
7.1.1 Material selected:
AISI 4340 (alloy steel)
7.1.2 Force on Hub
Force on Hub = 3(weight of blade) + weight of Hub (including bolt)
7.1.3 Bending Moment:
B.M = M = 1.2510
3
Nm
7.1.4 Torque:
7.1.5 Tangential Force:
7.1.6 Radial Force:
69
7.1.7 Thrust Force:
7.1.8 Horizontal Bending Moment:
Bending Moment at R
1
:
Bending Moment at A:
7.1.9 Vertical Bending Moment:
Net Vertical Bending moment:
70
Bending Moment at R
1:
Bending Moment at A:
7.1.10 Resultant Bending Moment:
Hence, by the above calculations, we get:
M = 690.5lb-in
T = 386.8lb-in
F
a
= 189.11 lb
K
b
= 1.5
K
t
= 1
71
Here,
Kt = combined shock and fatigue (torsion)
Km = combined shock and fatigue (bending)
= column acting factor
And
Hence,
d = 10 mm
72
Design of Coupling
73
8. COUPLING DESIGN
8.1 FLEXIBLE COUPLING
We have selected Flexible Coupling of the company ASN 125 Duetche .
The reason behind this is to allow vibrations and certain small misalignments, ASN 125
Deutche comes with built in Dampinf system. That absorbs shock efficiently.
Diameter of shaft = d = 20.3 inches
taking number of bolts = n = 4
Diameter of bolts =
Since, thickness of bush = 5mm
d
1
= 10.075+2.5mm(threading)
=12.5mm
d
2
=12.5+(22.5)+(25)
=27mm
D=2d
1
+d
2
=67.6mm
74
Generator Selection
75
9. GENERATOR SELECTION
As mentioned earlier in the theory section, the alternator or generator must be both
properly sized to match your swept area, and produce the right type and voltage of power
to match your application. Unfortunately, there are no commercial or surplus products
than can be easily matched to a set of blades for building a wind turbine. It's more
practical to build your own alternator than to try and adapt a commercial unit that was
designed for a completely different purpose. PM converted induction motors, DC
generators, DC brushless PM motors, vehicle alternators, and induction motors are
options but are marginal performers at best.
9.1 ASYNCHRONOUS - INDUCTION GENERATOR
This is the oldest employed technology and uses a standard "squirrel cage" induction
motor directly connected to the grid. The generator is connected to the turbine through a
gearbox. The machines cannot supply their own excitation current, which needs to be
supplied from the grid, or supplied separately through capacitors. Induction generators
are usually only used with fixed speed, stall regulated turbines. The induction generator
cannot provide fault ride-through, reactive power or voltage control, frequency regulation
or power control, but it does contribute to the power system inertia in the same manner as
a standard industrial induction motor.
[22] Fig 16: Asynchronous- Induction Generator
76
9.2 SYNCHRONOUS - UNSYNCHRONIZED
With this option the generator uses either permanent magnets or a standard excitation
system. The generator is direct connected to the turbine and allows variable speed
operation over a wide range, thereby optimising energy extraction. As the generator
frequency will not necessarily be the same as the grid frequency, a four quadrant power
converter is used to interface the generator to the grid. This system can provide reactive
power, voltage and frequency regulation and, with recent developments, fault ride-
through. Power ramp regulation is also being provided with machines of this type.
9.3 SYNCHRONOUS - SYNCHRONIZED
There is a fourth generator option currently available, although very few in-service units
exist. The generator is connected to the turbine by means of a variable speed gearbox. In
theory this arrangement will overcome the reactive power, voltage, frequency regulation,
fault ride-through and inertia concerns that accompany the three main system types.
However at this time the ability of the variable gearbox to provide robust speed
regulation under all operating and grid conditions has not been totally proven.
77
Now we have multiple options, i.e.
1. Asynchronous - Induction Generator
2. Synchronous Unsynchronized
3. Synchronous Synchronized
The third option Synchronous Synchronized requires complex gearing mechanism so
we are not using it.
9.4 OPTION NO. 1
For Asynchronous Induction Generator, Gear Box is required to provide necessary
constant rpm for the generator. Gear box is designed as mentioned in previous section
and with respect to our condition we can select:
Type Asynchronous Induction PMG
Power 500 watts
Speed 1500 rpm
Frequency 50 Hz
No. of pole
4
Phase 3
Casing Squirrel cage Water Proof
Available
Vendors
Vestas, WTG Technologies etc
78
9.5 OPTION NO. 2
We prefer the 2
nd
type i.e. Synchronous Unsynchronized. The reason behind this
selection consists on a number of advantages.
- Suitable for Wind turbine as allows variable speed input
- Reduce overall weight of Nacelle
- Gear Box not required reducing weight, vibration and noise
- Do no require excitation from grid.
- Fluctuation can be regulated by electronic circuit
Type Synchronous PMG
Power 500 watts
Speed Variable
Frequency 50 Hz
No. of pole
4
Phase 3
Casing Squirrel cage Water Proof
Available
Vendors
Vestas, WTG Technologies etc
79
10. YAW MECHANISM
10.1 YAW MECHANISM
The wind turbine is said to have a yaw error, if the rotor is not perpendicular to the wind.
A yaw error implies that a lower share of the energy in the wind will be running through
the rotor area. (The share will drop to the cosine of the yaw error, for those of you who
know math).
If this were the only thing that happened, then yaw control would be an excellent way of
controlling the power input to the wind turbine rotor. That part of the rotor which is
closest to the source direction of the wind, however, will be subject to a larger force
(bending torque) than the rest of the rotor. On the one hand, this means that the rotor will
have a tendency to yaw against the wind automatically, regardless of whether we are
dealing with an upwind or a downwind turbine. On the other hand, it means that the
blades will be bending back and forth in a flap wise direction for each turn of the rotor.
Tower selected is high strength steel with 30 meter height.
[23] Fig 17 : Yaw Mechanism
80
11. BREAKING AND SHUTDOWN SYSTEM
11.1 BRAKE:
Micro wind turbines are often employed with disc brakes system with a capacity of
slowing down moving components from a range of ( )rpm to (rpm) without damaging the
system. We have installed disc brake system for ensuring sufficient braking force in cases
of vigorous wind speed situations, primarily used asbestos lined brake shoes along cast
iron drum.
We have selected the following configuration for the braking system:
Material Advance Polymer, Asbestos
lining, Aluminum Alloy
Type Drum brake
Performance rating High
Preferable usage Micro wind turbines
Available companies/vendors Sunnec, DK Inc
11.2 SHUTDOWN SYSTEMS:
This is a manual control that completely shuts the wind generator down. It is not allowed
to spin at all, and should be able to survive extremely violent winds in this condition. It
can be electrical or mechanical.
Electrical Shutdown: With permanent magnet alternator machines, simply shorting the
main AC power output leads together should effectively shut down the wind turbine. The
problem is that when the machine is spinning at high RPMs during a windstorm, the
shutdown may be either impossible electrically (the turbine is performing too
inefficiently for shorting the output to have any effect), or too damaging to the alternator
(the heat produced in the stator coils by shutdown at high speeds turns the coils into
molten slag.) Our normal method is to simply wait for a space between high wind gusts
to short the mill with a switch.
Mechanical Shutdown: These systems physically break the wind generator, or force it out
of the wind by turning the tail parallel to the blades. Generally, a cable is attached to a
hinged tail, with a small hand winch located at the bottom of the tower for the operator.
81
12. COMPLETE DESIGN
Complete Description of Turbine Design
Radius of Blade 1.77 m
Airfoil RAF - 6
Number of Blade 3
Cut in speed 3 m/s
Cut out speed 13 m/s
Tower Height 30 m
Transmission Gear Box / Direct Shaft
Generator Asynchronous Induction/Synchronous PMG
Rated Power 500W
82
12. ECONOMICAL ANALYSIS
It is necessary to know the Life Cycle Cost of project before analyzing Economics.
Economic advantage of clean energy and renewable sources come after certain payback
time.
For Wind Turbine, initial cost is definitely higher but after certain time it gives
continuous profit as annual maintenance cost is negligible and there is no fuel cost in it.
We have taken a case study of a home with consumption of 500 watts with a grid
connection of local transmission versus wind turbine. The break even is as follows:
Month
Domestic
Grid
Connection
Wind
Energy
0 17000 45000
1 18500 45200
2 20000 45400
3 21500 45600
4 23000 45800
5 24500 46000
6 26000 46200
7 27500 46400
8 29000 46600
9 30500 46800
10 32000 47000
11 33500 47200
12 35000 47400
13 36500 47600
14 38000 47800
15 39500 48000
16 41000 48200
17 42500 48400
18 44000 48600
19 45500 48800
20 47000 49000
21 48500 49200
22 50000 49400
23 51500 49600
24 53000 49800
25 54500 50000
26 56000 50200
27 57500 50400
28 59000 50600
29 60500 50800
30 62000 51000
Table 9: Case Study Comparison of Domestic Grid Connection Vs Wind Energy
83
From above data of case study Break Even was calculated.
21.1 RESULT:
The graph shows the payback time is in 22
nd
month i.e. we will get continuous profit after
22 months. Within two years, all of our investment will be regain in terms of saving
monthly bill expenses as wind turbine has very low annual cost. Wind turbine needs a
little maintenance which is very low as compared to bill of local power producer
Thus we can say that its break even is 22 month which is less than 2 years and it totally
profitable decision to utilize this economical and ecological technology.
Domestic Vs Wind Cost
0
10000
20000
30000
40000
50000
60000
70000
1 2 3 4 5 6 7 8 910111213141516171819202122232425262728293031
Months
C
o
s
t
Local Grid
Transmission
Charges
Wind Energy
Charges
Fig 18: Comparison of Domestic Grid Connection Vs Wind Energy
84
13. REFERENCES
1 [1] Danish wind Association. (www.windpower.org)
2 [2] RM Dutch & Co.
3 [3], [4], [5] HSW Website.
4 [ 6 ], [7] & [8] PMD (Pakistan Meteorological department)
5 [ 9 ] UNDP/GEF Wind Energy Project (WEP)
6 [ 10] AEDB Reports & Pakistan Meteorological Department
7 [11] Courtesy Zorlu Wind Farm Jhimpir
8 [12] Ford Logistics & Co.
9 [13] ISUZU Heavy Machinery
10 [14] AEDB (Alternate Energy Development Board)
11 [15] NACA Journals
12 [16], [19] Royal Airforce RAF Airfoil Journals
13 [17], [18] Profili 2
14 [20], [21] MATLAB CODE
15 [22] WTG technologies website
16 [23] E Machine Shop Journals
17 WindRose Consultancy www.windroseone.com
18 Fundamentals of Renewable Energy Processes By A. V da Rosa Stanford.
19 Mayura Botejue BSc(Hons) C.Eng Consultant - Wind Power
20 IEP Conference on Wind Energy Harnessing
21 Zorlu Energi Wind Farm Jhimpir Pakistan