The University of Edinburgh Sustainable Energy Group Design Project 3 Design of a Helical Vertical Axis Wind Turbine March 2016 CERNIAUSKAS, Gabrielis 51311429 DAMAS, Pedro 51338039 FEUK, Henrik 51309329 MARTIN, Michal 51336695 NEGUS, Rory s1419599 Abstract This report outlines the process of designing and constructing a vertical axis wind turbine (VAWT). The main body of the report will focus on the design approach, calculations and dimensions, whilst the prototype build process and test results will be provided in the appendix.Table of Contents Abstract Introduction to the Problem Approaches to the Design. Horizontal Axis Wind Turbine aaa ee Vertical Axis Wind Turbine Prof eck Phat ccc rats tate atacnitmtarimsateactactmieermi AD) Turbine Dimension Calculations 2 Tower and Gravity Stand Design. Force on Rotor Calculation... Force on Cylindrical Tower Calculation. ‘Tower and Gravity Stand Specifications Blade Design. 24 Aerodynamics of Vertical Axis Wind TUrbine......eneneneinsiasesennninennisninnnnnnnenennee dt Dynamic Stall and Velocity Vectors .. 23 Selection of Aerafoil Profile 24 Pitch Angle and Blade Shape Generator / Central Mounting Mechanism 29 Central Mounting Mechanism Material Selection. 33 Finite Element Analysis on Central Hub. 36 Generator Design. Getic aT pe cease rere nartecmeracerectnac te screener rcesi SO) Design oh Generston scarce ces gree eee tact ease caesar Choice of Magnets... Initial Design of Rotor and Stator. 40 Final Design of Rotor and Stator. 43 Alar Ch Tg Seer terc sears ranraae ance AM Final Construction of Generator 46 Charging Circuit Introduction ... Rectification Stage Voltage regulation stage... Final Circuit Design. 49 Procurement of Parts...Bill of Materials... ‘Manufacturing Methods... Proposed Prototype Assembly. 53 Proposal for Mass Production..... CAD Models. Drawings References Appendices...Introduction to the Problem Over the last few decades, the importance of renewable energies has increased alongside with the concem regarding the depletion of fossil fuels and the harmful effect of their combustion that leads to the destruction of the ozone layer. Currently, according to the British Department of Energy and Climate Change, in 2015 about 25.3% of the energy produced came from renewable energy sources, out of which roughly 11.7% corresponds to onshore (4.85 TWh) and offshore (3.57 TWh) wind power. ill! — ron 2013 21a 201s Figure 1: Renewable electricity generation (left) Share of electricity regeneration from renewables (right) (1. The last twenty years have seen an exponential growth in the generation of electricity from wind power, having produced a global power capacity of 432.4 GW in 2015. This indicates that wind power electricity generation is a growing market that presents alternative and environmental friendly solutions to the increasing energy demand. Advantages of wind power include being abundant, clean, not having direct harmful effects to the atmosphere, occupies smaller portions of land and does not need much maintenance. On the other, besides being dependent on the intermittence of wind, this energy source is claimed to produce visual and audible pollution to the environment due to the size of the turbines used in wind farms and the sound produced by the blades. Moreover, biologists claim that large wind turbines interfere with local animal species by damaging their natural habitat. Nonetheless, as this technology was developed, different designs have been invented, being generically divided into two main types: VAWT and HAWT.Figure 2: Comparison of VAWT and HAWT. Vertical axis wind turbines (VAWTs), opposed to horizontal axis wind turbines (HAWTS), consist of a vertical structure with a given number of blades free to rotate around a vertical central axis. These are less commonly seen than the three bladed HAWTs widely used in a vast range of applications and sizes. Nonetheless, they operate under the same principle of energy conversion from linear wind speed, to rotational blade speed and finally the production of electricity by the coil cutting magnetic field of the generator. This report will focus on the Helical Darrieus VAWT, after a detailed comparison between the vast range of possibilities, by designing and planning the manufacture of each component. The turbine being designed proposes to conduct a feasibility study for an engineering company. It has to be portable and have a rated power of 100W, being able to charge 12V lead acid batteries under 13 m/s wind speeds. However, the design has to allow the batteries to charge with lower wind speeds. After the design stages, the goal is to manufacture the prototype of the turbine and run tests. Lastly, an adjustable gravity stand also has to be designed, allowing the turbine to be supported at a 2m hub height for low wind speeds and 1.5m for stronger winds.Approaches to the Design To begin with, the wind turbine type was chosen by evaluating general advantages and disadvantages of several types of VAWT and HAWT from design and manufacturing point of view. Preliminary CAD models were made for all types of wind turbines to better understand possible design difficulties. Discussed points are summarised below. Horizontal Axis Wind Turbine Figure 3: Preliminary design CAD models of HAUT. Advantages High efficiency - blades always move perpendicular to the wind, receiving power through the whole rotation, unlike vertical axis. Most are self-starting Smaller rotor size for same power - less materials needed. Disadvantages Not ideal for use near ground/turbulent winds. Require additional yaw control to turn the blades towards the wind. Generator must be installed at the head of the turbine - this may require additional costs in building a stronger tower. Slip rings needed. Gearbox likely to be required. Blades shape is more complex. Vertical Axis Wind Turbine For vertical axis machines, several designs and their combinations were considered.Savor S Advantages: ‘+ Not affected by wind direction - makes the design of the wind turbine ideal for areas with turbulent flow. ‘= Can generate electricity in strong winds without being damaged, © Very quiet. + Easyto make. ‘= Generator in line with the shaft. Disadvantages: + Low efficiency - around 15% * Cannot rotate faster than the speed of the wind— maximum tip speed ratio (TSR) of 1 + Turns slowly and generates high torque - difficulties with generators which require high RPM. + Robust blades. ‘+ Cheaper and easier to build than standard Darrieus. + Works well in turbulent flows. + Vane could be used in cycloturbine design to mechanically orient the pitch of the blades for maximum efficiency - helps in self-starting. + Noneed for gearbox. ‘+ Generator in line with the shaft. Disadvantages: + Not asefficient as Darrieus. ‘+ Requires strong winds (or a motor) to start rotating, ‘+ Cansstruggle to maintain a steady state of rotation. + Cycloturbine is more complex, heavy and expensive to build. In order to choose the wind turbine type which would have the most advantages over the other types, a decision matrix was created.Toble 1: Decsion matrix Efficiency 8 4 3 s & Number of parts generator 8 6 3 Aesthetics 5 6 5 Sensitivity to turbulence 6 5 8 Tendency to start spinning 8 3 7 Portability 6 6 6 Cost of manufacture 5 8 7 Complexity of blades/design overall 3 7 6 Total Score 336 Ba 332 The weighted score for a specific wind turbine design and criteria is the criteria weight multiplied by the score the wind turbine design received. The total score for a wind turbine design is, the sum of all of the weighted scores, ‘After considering possible designs, the vertical Giromill Darrieus type was chosen for designing the 100W portable wind turbine, as it had the greatest total score. Error! Reference source not found. the decision matrix and the criteria used. With primary analysis and research in Giromill Darrieus type VAWT, several combinations showed in figures below were considered. Savonius type VAWT to be mounted on top of Giromill Darrieus was considered, in order to avoid common self-starting problems.Figure 4: Giromil Dartieus vertical wind turbine Flgure §: Giromill Darrieus with Savonius vertical wind turbine Figure 6: Gomi Darvieus with alternative Savonius vertical wind turbine Height of the turbine blades was primarily estimated to be 0.5m with an approximate diameter of 0.8m. It was decided, if possible, to aim for self-starting Giromill Darrieus without a Savonius type VAWT (Figure 4) on top of it, mostly because of different TSR required for both of these types. Savonius wind turbines operate at a TSR of 1 and would therefore require a clutch mechanism which would disconnect it from the rest of the turbine when Giromill is started and TSR increases to 3-4. ‘The selection of aerofoil assures that, theoretically, the turbine is self-starting, however if additional starting problems are encountered, the team will design a small Savonius type wind turbine to assist with the start-up. If the addition of a Savonius is needed, the final design would look similar to the one shown in Figure 45. Further refinement of the vertical Giromill Darrieus design will be pursued in the section: Turbine Dimension Calculations.Project Plan The initial project plan was created on 16" of November 2015, providing an overview of the timescale of the project and deadline for each objective. The plan can be seen in Figure 7 overleaf. The plan shown is very similar to the original project plan, with only a few alterations throughout the project. Keeping to the manufacturing schedule was not possible due to delays in component delivery, particularly the resin and silicon required to manufacture the blades, which, as of writing this, is 3 weeks delayed. Additionally, generator, and central hub parts which were ordered on the 1" of March have yet to been delivered. Due to the unreliable lead times when ordering through the university, itis hard to estimate when the components will actually arrive, and ifit is even possible to complete the wind turbine build by the end of the academic semester. The project plan was, however, successful in keeping the group on schedule for the design and report aspects of the project, with minimal adaptations required. 10Pra Fak Stet De AGN iy | faite s ines Q i é¢ it a un a 7 aon @ 1 tn it 2 um ia a Ahite wo 4 atcnpatiy an ut gpm iy An Lae at 2 ate w 2 ae “4 22 ani a 22 catia we wa ‘rin ag 2h natu, 26 oud 2 tats wa wad 221 Suita 585 oa 0 aha oH wat 21 narctv esate wot nat at wr BaD am wa wat a wt ten m6 a a sen im bat UE WBE NT Mm 3 wot msn aI iat im na Fa wr mena Fi se mst a oe We eT Nanteamgrans im a 2 enn tepaana puma im 2 2 wma me (aM STSIBLETN) @ a B Mongrcrtcam ME STEN Mm BS 2 Eymetonroaie WS eH Mm a 3 gma aoe sie tm 2 oD u WE BEN maT st ‘ eg Sa TINE a ‘We aH 5 3 lS a a WE mes 4s 8 see os a u ms as t : te Bo S maiynran om , = vce dep at marr a 2 at we 1 a hep a a wie alms 06 a ia se aoe } = 1 Oftauiendmin EA « ss a paime an « I nna an « a Faget: Pret Pan aTurbine Dimension Calculations In order to justify turbine size approximations stated previously, further analysis was carried out. From the very beginning, blade manufacturing process was considered to be a limiting factor as it involves 3D printing a real size blade, using it for making a mould and casting blades from glass fibre. The 3D printer limited the length of the blade to 0.25m, however, after discussion with technicians at the workshop, it was decided that half of the blade (symmetry line at 2 mid-span point) could be printed and used to create a mould for a single blade. Such an approach set the maximum length of the blade (height of the turbine) to be 0.5m. ‘Also, based on further research and lecture notes, C, for the Giromill Darrieus turbine was taken to be 0.28 and generator and electrical systems efficiency (generator) Was estimated to be 60%. Wind speed of 13m/s and air density of 1.225kg/m? was used to estimate the size of the 100W VAWT. ‘The size of the wind turbine is governed by equation (1): a 2 P =X PXAX Cgenerator X Cp XV “) Where: P - power (W) pair density (kg/m?) A- frontal area of wind turbine (m’) G,- coefficient of performance v- wind speed (m/s) generator ~ efficiency of the generator and electrical systems. Solving for frontal wind turbine area: 2xP. generator % PX Cy X09 2) 0.442m? 12Table 2: Turbine see calculations Giromill Darrius Sizing Frontal Height Blade area of Tip Omega, Centrifugal Generator needed turbine Speed w Torque acceleration Cp efficiency m*2___(m)_ Diameter TSR (mm/s) _ (rad/s) RPM (Nm) _(mv/(s*2)) 0.28 os oat oa] 3 39 1763 16839 5.67 687.71 0.28 os oa} a2] 22] 3395.27 336.78 © 284 1375.42 0.28 os aaa} a3] 47] 3 3952.90 $05.16 1.89 © 2063.13 0.28 os aaa} a4 tai], 3397053 67355 142 2750.84 0.28 as o4ae] 04s] =e] «3 397835 757.75 126 «= 30849 028 os aaa] os] 3 38 8817 Balg4 113 Basa The table above was made to evaluate how parameters of the wind turbine vary with varying dimensions. Values for turbine height were used to calculate diameter, angular frequency, RPM, torque and centrifugal acceleration. Height of the wind turbine was chosen to be 0.45m as it gives an optimum combination of all these parameters; consequently the diameter was found to be: 0.442 0.45 982 m @) ‘As shown by studies of VAWT aerodynamics (section: Selection of Aerofoil Profile), TSR of 3 was found to give the maximum power coefficient for a chosen blade profile. Due to the relatively low TSR of Darrieus turbines, a design using 4 blades was chosen, giving a tip speed of 39m/s. Tip speed = wind speed x TSR = 13 x3 = 39 m/s. “) The angular frequency is then: (Blade Tip speed) _ 2x39 diameter 0983 er) 79.35 radians/s RPM: +60 _ 7925460 oe 2x) fem RPM (6) Torque. 13Power output _ 100 < 75.35 = 126m 0 Centrifugal acceleration at blades: + diameter _ 79.35? «0.982 2 = 3094.69 m/s? (3) 14Tower and Gravity Stand Design The gravity based stand was designed with an adjustable hub height for the turbine. It can support the turbine hub at 2.0 m above ground during light wind operation (around 12 m/s) and at 1.5m height during high wind speeds of up to 22m/s. The gravity stand and tower will be made of steel as it is easy to weld together. Additionally, steel’s higher density compared to other structural materials will help lower the centre of mass and increase the mass of the structure. Without a tower, gravity stand and central shaft for the generator, the total mass of the wind turbine is about 15.83 ke, The shaft, which is in not rotating during operation, will be connected to the tower column by two steel pins Figure & Adjustable Height Mechanism with Stee! Pins The wind turbine’s shaft has a diameter of 25 mm, therefore the tower's central pipe must have an inner diameter of slightly more than 25 mm. The height adjustment will be done by moving, the shaft up and down relative to the tower tube. The height of the turbine hub will be secured using the pin mechanism shown above. {As stated, stee! tubing will be used in the manufacture of the tower and gravity stand. Steel density can vary between 7,750 and 8,050 kg/m’ [2]. For the purpose of the gravity stand and tower design, the density of steel is assumed to be 8,050 kg/m’, The steel tubing, which will be used for the tower will have an inner diameter of 26 mm and a thickness of 3 mm which gives it a mass per meter of approximately be 2.20 kg. The tower stee! 1stube will be 1.15 m long, and its lower end point will be 0.55 m from the ground during operation. This design will be developed further below. The gravity stand will consist of four steel tubes in order to form a square area between the ground contact points of the support tubes. If three steel tubes were used, the tubes would need to be longer, assuming constant angle to the central tower tube, in order to give the same support as a 4 support configuration would. The outer diameter of the 4 gravity stand tubes will be 18 mm with a thickness of 2.5 mm, which gives it a mass of 0.98 kg per meter. Force on Rotor Calculation 1 F = 5X (air density) x Cy x (area of turbine) x (wind speed)? © Air density=1.225kg/m3 * Gp the power coefficient is 0.28 © Area of turbine = 0.442 m2 © Wind Speed = 22 m/s © The force on the rotor is thus 36.69 N. Force on Cylindrical Tower Calculation It is assumed that the force can be approximated as uniformly distributed along the tower colurnn’s height. 1 3% (air density) x C x (column outer diameter) x (column height) x (wind speed)? Air density = 1.225ke/m* © Area of turbine = 0.442 m? Wind Speed = 22 m/s ‘© Outer diameter of column = 47 mm. © Colum height = 1.25 m + Cy, the drag coefficient is more difficult to find, To find a good approximation of the drag coefficient, the Reynolds number of the flow against the tower column must be known. 18Re=— v Where v is the maximum wind speed of 22 m/s, v is the kinematic viscosity. Which is 1.514x10° m?/s at 20° Celsius. L is the length of the beam, which is 1.5 m. Using these values, Re is found to be 6.8x10%, At this Re number, the drag coefficient for the tower column is 1.1 [3]. The force on the cylinder shaped tower is therefore: 22.99 N at wind speeds of 22 m/s. Moment calculations will be done at the bottom of the wind turbine to ensure that the gravity stand can keep the wind turbine upright under wind speeds of up to 22 m/s. Tower and Gravity Stand Specifications Balance of moments Astana 2 Fy 1.5Frotor + 0.75Frower Figure 9: The balonce of Moments Using basic balancing of moments, the smallest lever arm which will be able to keep the wind turbine upright at 22 m/s is half of dawns (0.59 m). dsons is the smallest distance between two opposite facing lever arms’ end points. itis worth noting that the lever arm distance will vary as the wind direction changes when using only 4 support tubes. If a circular contact with the ground was chosen, the lever arm distance would be constant. 7A thirty percent margin will be used for the lever arm, to make operation at high wind speeds safer. The lever arm distance, with the thirty percent safety margin will be half of 0.76 m. The gravity stand tubes will be connected to the tower column 0.1 m from the bottom of the tower column, By using a solver, the length of each gravity stand beams was found to be 0.80 meters, the angle between the support beams and the tower column to keep tower column 0.55 m above the ground was found to be 46.9° and the total mass of the structure was calculated to be 21.3 kg vt bean —=—— Figure 10: Top View of Gravity tond ‘As one can see in the figure above, the 0.76 divided by 2 meters is the smallest possible “lever arm”, which occurs when the wind is 45° to the stand beams. The largest possible “lever arm” is 1.08 m divided by 2 If one were to increase the angle further then 46.9° between the tower column and the gravity stand tubes, the hub height would not be able to go as far as 2 m, but the wind turbine could remain upright at higher wind speeds. With the design proposed the support beams can be folded up along the tower tube and have the folded structure be the length of the tower column of 1.05 m, as the gravity stand tubes do not extend past the column, 18Figure 11: Foldable Gravity Stand Mechanism ‘Strong mounting of the support tubes to the central tower column is vital in order to provide a long lasting wind turbine platform. The mounting mechanism is shown below. Figure 12: eunting Mechanism For prototyping purposes, the rackets will be bolted onto the tower column, which will in tum have the support tubes pinned to them. However, for mass production purposes the rackets would. be welded to the tower and the supporting tubes’ pins would be inserted by interference fitting. The structure will be painted to give it some corrosion resistance. 19Figure 13: Folding Mechanism Figure 13 shows the folding mechanism of the gravity stand. The black ring can slide along the tower column to allow changes in the angle of the support tubes to the central tower column. The black ring is able to lock in position using screw fasteners, so that the support tubes do not move during operation. The wind turbine is detachable from the stand. Additionally, the gravity stand can be folded so thatiit takes up very little space in storage. FE analysis was conducted on the tower and gravity stand, The results of this analysis showed that stresses were well within the suitable limits. 20Blade Design Aerodynamics of Vertical Axis Wind Turbine One of the main advantages of vertical axis wind turbine is that it does not have to be turned to the direction of the wind, therefore it can operate near the ground where flow is more turbulent. As aresult of the design, wing profiles are facing the direction of the wind with relatively high angles of attack which vary as a function of the azimuth angle of the turbine and as a function of TSR. The latter was proved by Ertem, S. and influences attack angles less with higher TSR [4]. Relation to TSR is explained by looking at velocity vectors on aerofoil travelling in a VAWT. With increasing rotational speed, blade speed increases and with constant wind speed, angle of ‘speed of air flow’ to zero lift line decreases and magnitude increases (Figure 14).. wind speed blade speed. —— speed of air __ flow angle of attack _troutetne a Figure 14: Velocity vectors for rotating blade (5) Relation to azimuth angles is explained by analysing calculated and experimentally obtained values of angle of attack in Figure 16. In Figure 15, reference frame for azimuth angles with respect to direction of wind is explained. 21~~ PRPEEEM : a oY \ oo 100 28 ‘ ae Ms 4 ses Figure 15: Azimuth angles with respect to wind In Figure 16, geometric angle of attack, obtained by Geurts, B. at all (6], for linear analysis and it is compared to mid-span data from simulating rotating blade with the chord length of 15cm. Although, exact data for every profile varies, generally in the latter part of the graph, from 170° to 360° azimuth angle, the angle of attack stays in a range from -2° to -4 because of dynamic stall explained below. Static stall angles, depending on a specific aerofoil, are also marked and going to be discussed in the section below. 20) fips as ener anhacreafoell oacrl d aal Aegie of Attack, « decd & 0 135 180 225 270 318 360 405 450 405 ‘Azimuth, y [deg] Figure 16: The angle of attack variation as a function of azimuth (6) Consequently, because of attack angles in region of 0 - 170° azimuth, the following instantaneous force coefficients for a single blade were obtained by Geurts, B. [6]. 22Tangential Force Coefficient adil Force Coefficient 0% 4500 135. 180. 228-270 318 360 ‘Azimuth position [*] Figure 17: Instantaneous radio! and tangential force coefficient of one single blade (6) Dynamic Stall and Velocity Vectors Rotation of the turbine about vertical axis causes disturbance in the flow which might change predicted power performance curves for steady-flow conditions. This phenomena, called dynamic stall, was further investigated by Bronchier [7] for VAWT with NACA 0018 profile blades at the tip speed ratio of 2.14 (Figure 18), which is close to TSR of proposed VAWT design. om mats wena ri ht ee = ——— pieces Figure 18: Schematic diagram of disturbed flow and velocity vectors for rotating VAWT [7] In the diagram on the left, two main vortexes can be seen; the first one (clockwise) is created by the leading edge of the blade coming towards position 1, The second one (anti-clockwise) 23originates when blade starts travelling downwards, following the direction of the wind by the trailing edge of the blade, These vortices join together and create a wake area behind the tower in the direction of flow. Consequently, because of the direction of the lift forces, represented on the right of Figure 18, as well as dynamic stall, the vast majority of wind power is extracted by the blades travelling towards the wind (1"" quarter of the circle) and are in laminar flow region in the upwind direction. Blades in the 4"” quarter of the circle contribute the least to extraction of the wind power. Also, because of dynamic stall, drag on these blades is decreased; this results in higher power coefficient than predicted by steady-flow simulations. Knowing that 1* quarter of the circle contributes most to the wind power extraction, average instantaneous angle of attack for range 30° ~ 90° azimuth angle (increasing force coefficient region in Figure 17) was found by analysing vector directions of apparent wind. The value for this. range is 16.6° and is later used to found optimum pitch angle for specific blade profile. Apparent Wind Angle versus Azimuth Angle Azimuth Angle, ("1 Apparent Wind Angle, ["] Figure 19: Azimuth angle vs apparent wind angle Selection of Aerofoil Profile With this basic information, aerofoil profile can be selected and the optimum pitch angle can be determined. Based on experience from similar projects, two symmetrical profiles were analysed to pick the best one for this VAWT. Computational Fluid Dynamics (CFD) simulation were run on straight blades with NACA 0018 and NACA 0024 profiles at angles varying in the range from 0° to 20 Reynolds number at TSR of 3 and the wind speed of 13m/s (39m/s flow speed) was calculated to be 440 000, figures below show pressure and velocity profiles around NACA 0018 blade. This set of data was not used for comparison, however numerically found lift and drag 24coefficient plots for azimuth angles from 0° to 30° (Figure 22) were used to compare 0018 and 0024 profiles. Figure 20: Pressure distribution NACA 0018 coefficient Figure 21: Velocty profile NACA 0018 NACA 0018 vs 0024 Re=420 000 toe “*-Lift coeff NACA 0025 Drag coeff NACA 0025 #-Lift coeff NACA 0018 + Drag coeff NACA 0018 Attack angle, [*] Figure 22: iftand drag coefficients for NACA 0018 and 0024 25To justify results from SolidWorks Flow Simulation software, data was compared to experimental values for NACA 0018 by Sheidahi, R. €. [8] and the difference between the data was found to be less than 7% which proves reliability of the simulation. Experimental data for 0024 profile was not found. Simulation shows that NACA 0018 stalls at around 10° attack angle but it is not clear if 0024 profile stalls at the same point, this would require further investigation. By comparing lift coefficient curves in Figure 22, NACA 0018 was decided to be a better profile for proposed design VAWT. However, further research also shown, that VAWT with symmetrical blade profiles struggle to self-start and, as explained by Kirke and Lazauskas (9] (Figure 23), consequence in negative power coefficient at low TSR. In order to avoid this problem, the design team decided to go with unsymmetrical NACA 4415 profile which ensures self-starting of the VAWT and gives the same power coefficient (at TSR of 3) as symmetrical profiles. Tip speed ratio Figure 23: Camber influence on power coefficient. Symmetrical 0015 profile vs unsymmetrical 4415 (9) Lift and drag coefficient values for NACA 4415 profile, shown in the Figure 24, are for Reynolds number of 500 000 which is close to our investigated case. 26NACA 4415 Re=500 000 Lift coeff NACA 441s coefficient Drag coeff NACA 4ai5 Attack angle, [*] Figure 24: Lift and drag coefficients for NACA 4445 [10] With the further research into the blockage ratio, the chord length of 150mm was chosen based on El-Samanoudy, M. [11] tested VAWT operating at 13 m/s. Chord length was linearly scaled down while keeping the same rotor diameter to chord length ratio. However, to manufacture these ‘on blades, half of the real size model had to be 3D printed which was later used to produce si mould and to cast glass fibre blades. 3D printer was a limiting factor and therefore chord length had to be decreased to 140mm. The blade dimensions are summarised in Figure 25. NACA 4415 Length, [mm] =F » : — 3 = a oO = = Figure 25: NACA 4415 profile Pitch Angle and Blade Shape Specifically for NACA 4415 profile, the optimum pitch angle was calculated. As it can be seen from Figure 24, stall angle for this profile is 14° and therefore blades in the 1* quarter (Figure 18) of a7the rotating wind turbine are desired to have instantaneous attack angle slightly smaller than stall angle for maximum performance. Also, because this is an asymmetrical profile, its zero lift angle is - a With average instantaneous attack angle of attack being 16.6” (Section: Aerodynamics of vertical axis wind turbine), pitch angle should be 6.6" for blade to operate at stall angle, however as average is used and desired region is lower than 14°, the pitch angle was chosen to be 10°, giving the angle of attack to be 10.6” on average (1). Calculations are explained below, refer to Figure 26. Average attack angle ~ (zero-lift angle) ~ (stall angle) 16.6" (-4°)~ (14" itch angle 16, pitch angle chosen to be 10°, apparent wind ~ cas | | contre of VAWT Figure 26: Pitch angle analysis Although creating higher blockage ratio, helical shape blades were decided to be used in the proposed design. Blade curves around the vertical axis and distributes aerofoil sections more evenly throughout the blade circle contributing to more balanced forces on all four blades. Helical shape designs also give lower noise and vibration as well as smoother torque curves. 28Generator / Central Mounting Mechanism Central Mounting Mechanism The central mounting mechanism serves two main functions: to support the turbine blades and house the generator. One of the major benefits of a VAWT turbine is that the generator can operate as part of the mounting mechanism, minimising the number of parts required. The following design criteria were outlined to improve the efficiency of design and construction: ‘= Simplify design ‘+ Minimise moving parts in contact with one another © Cheap to manufacture + Easy to assemble/disassemble Initial conceptions of the VAWT, such as the one shown in Figure 27, did not account for the generator. Figure 27: CAD model in earl design stages ‘An initial concept for the central mounting mechanism is shown below in Figure 28. The sketch outlines the main characteristics The generator stator containing the copper coils is mounted directly onto the shaft using a series of circlips. By attaching the stator directly to the shaft, there was no need to use slip rings in order to transmit the electrical current generated by the turbine, and the wires were able to be fed 29directly down the shaft. This both simplified the generator design and made the overall turbine more aesthetically pleasing, ‘A bearing connected to the rotor will provide both rotational freedom and axial support by preventing contact between any rotating and stationary components. The rotor plates are connected by a series of bolts, spaced by aluminium tubing. Stator (Copper Cots) Bottom Rotor Plate ite ‘Top Rotor Pate Figure 28: Initial sketch of central hub Points 1-4 show positions where the support arms for the blades will be mounted. By mounting the arms directly onto the hub, factors such as transmission losses could be minimised. The support arms were designed to be as simple as possible, from a single sheet of material. Initially it was conceived that the easiest way of joining the support arms would be to weld them to each rotor plate. This proved problematic due to the possibility in material variation and the necessity to for removal during prototyping. A CAD model, complete with blades, is shown in Figure 29 for a design where the arms would be welded to the nacelle. 30oN om Figure 29 CAD concept of hub and blades Figure 30 shows how the support arms will be attached to the rotor by bolts. As the radius of the turbine is 495mm, it was important to minimise the radii of the rotor plates in order to reduce production costs. This would result in extremely long support arms, which would have to be extremely long and stiff to support the weight of the blades. Figure 30: Secondary hub design ‘A CAD model for the final design is shown in Figure 31. All dimensions and technical drawings are provided in the drawings section. a1\ Figure 31: Fina! hub design Figure 32 shows an alternate design for the hub that uses roller bearings between the stator and rotor plates. However, the design was not used due to these bearings not providing sufficient axial support, and the possibility of failure under the loading from the rotor plates. In addition to this, this concept shows the shaft going through both rotor plates, whereas it would be preferable for it to only go through one. S Figure 32: Alternate hub design using roller bearings 32Material Selection Table 2 outlines the material selection process. Any process described as ‘machining’ refers to a common subtraction process whereby material is removed, e.g., cutting, drilling, lathing etc. Table 2: Material selection chart ‘Component | Material Manufacturing | Advantages Disadvantages Processes Rotor ‘Aluminium Laser Cutting, | Lightweight, Ductile, (egy) (12) | Manual Resistanttocorcosion | May be dificult to Machining. weld, (ENC Machining, Lower yield stress Welding than most structural metals Low Carbon Steel | Laser Cutting | Extremelystrong, | Heavy, (5275) (231 Manual cheap May interfere Machining, with magnetic ‘CNC Machining, ‘fx, welding May be dificult to machine Tiylen6/6[14] | Laser Cutting, | Lightweiaht, ess durable than Manual Cheap, other materials, Machining, Rapié manufacturing, | Prone to wear Automated No magnetic Machining, Interference, Injection High strength and Moulding, Impact resistance, earusion (Good theemal and chemical resistance, [Good machinabilty Polyetherimide | Laser Culling | Can implement Prone to stress us} Manual carbon fibre cracking, Machining, reinforcement. Chemical Automated High mechanical resistance is not Machining, strength, a5 good as other Injection Good thermal polymers (reacts Moulding, resistance, with ehierine), Extrusion Good machinabilty | Relatively expensive for polymer Shae “Aluminium Manual Ughtweight, Ductile, 33(HAMAS) 12) | Machining, Resistant tocorresion | May be difficult to ‘CNC Machining, machine, Welding Lower yield stress ‘than most structural metals, May be dificult to weld Castiron ($6600) | Manual ‘Cheap, Heavy, Us) Machining, very strong (high | Prone to corrosion CNC Machining, | tensile, compressive | (rust), Welding and yield strengths), Not prone to fracture “oy Steal (EHDET) | Manual Earemelyavong, | Heavy, Machining, Cheap, May be dificult to CNC Machining, | Easy to weld machine Welding SupportArms | Aluminium Manual Ughtweleht Ductile, (H1ajuas) (12) | Machining, Resistant tocorresion | May be dificult to ‘ENC Machining, machine, Lower yield stress ‘than most structural metals Gstiron (SG4a00) | Manual Cheap, Fea, tas) Machining, very strong (nigh | Prone to corrosion CNC Machining, | tensile, compressive | (rust), and yield strengths), Not prone to fracture Blades (Carbon Fibre ‘Compression Ughtweight, Brite, Reinforced moulding, Reid Expensive Polymer ‘vacuum bagging, Filament winding Glass Fibre Handlaving High Tensile and ew shear Reinforced (followed by Compressive strength, Polymer(E-gass} | epoxymatrix), | Strengths, Brittle, Spray-laying ‘Strength canbe Epony takes along (followed by controlled by layering | time to set ‘epoxy matrix), | Fibres, Filamentwinding, | Cheap, Easy to form, Lightweight Nylon6/6[14] | Injection Tahtweieht ess durable than 34Moulding ‘cheap, Rapid manufacturing, No magnetic Interference, High strength ane impact resistance, [Good thermal and chemical resistance other materials, Prone to wear Polyetherimide us} Laser Cutting, Manual Machining, Automated Machining, Injection Moulding, Extrusion ‘Can implement carbon fibre reinforcement. High mechanical strength, Good thermal [Good machinabilty Prone to stress cracking, Chemical resistance is not a5 good as other polymers (reacts ‘with chlorine), Relatively expensive fora polymer Staines Steel (903/316) (17) High yield stresses, cheap, Resistant tocarrosion All finalised choices are given in the bill of materials. 35Finite Element Analysis on Central Hub ‘When considering aluminium as a material, it was important to ensure that cyclically loaded components would not fail under fatigue stress over time. Figure 33 outlines the decrease in yield strength of steel and aluminium over many cycles. soo = 1045 steel a E 400] oo EB = = = 09 5 = 2 t ; og a g & 5 0 lo vw Ww Ww 1 1 10" Number of eycles, Ny Figure 33: Decrease im strength of cyclically loaded materia During prototyping it is expected that the VAWT will experience approximately one million revolutions, and therefore it must be ensured any cyclically loaded components are able to withstand a decrease in yield strength of up to 50%. The nature of the hub design means only the shaft and bearing are subject to cyclic loading, and so only those components will be subject to fatigue loading FE analysis was performed upon the blade support arms and the central shaft to ensure they would be able to withstand the centrifugal forces present during operation. The FE analysis results for the support arms are shown in Figure 34. Figure 34: FEA results of centrifugal forces acting on support arm. 36The yield stresses caused by the centrifugal forces are minimal, and so it was decided aluminium would be used for the support arms. The aluminium would be machined using manual methods in order to reduce cost. The final cross section of the flat bar used is 3.2mm x 19mm, The shaft would be subject to a bending moment caused by the wind acting upon the turbine, in addition to centrifugal forces caused by the rotation of the rotor. It was desired that the shaft be made from aluminium in order to reduce weight and cost, therefore brief FE analysis was carried out to determine suitable dimensions, shown in Figure 35. In the subsection, “Force on rotor Calculation” to the section, “Tower and Gravity Stand Design”, the force on the rotor was calculated to be 36.69 N. The same force is applied to the shaft, of the wind turbine. Se % mene Figure 35: Comparison of stresses acting on shaft of wall thickness 1.6mm (left) and 3.2mm (right) The first shaft has a 1.6mm wall thickness. The stresses present greatly exceed the yield stress of aluminium. However, the second shaft has a wall thickness of 3.2mm, and has a much lower stress distribution. These images show a shaft Im in length, whereas the actual turbine will use a shaft length closer to 0.25m. During operation, the blades will be subjected to significant centrifugal forces, resulting in a bending moment across the span of the blade. In order to determine the optimal joining position for the support arms, and subsequently reduce this moment, FE analysis was performed several times on the blade whilst varying the mounting point. The mounting points were initially modelled 22.5mm from either end of the blade. Subsequent FE analysis is carried out with the mounting point 2.5mm further towards the centre for each iteration. Minimum stresses are present when the mounting point is one quarter in from. the edge (112.5mm), shown in the fifth image in Figure 36. 37se re Figure 36: Analysis of blade mounting postion Basic hand calculations on the placement of the support beams were first conducted on a straight beam member to get an idea of the optimal position of the support points. It was found that in order to make the bending moment at the centre point of the beam zero, the support points had to be one quarter of the total length of the beam away from each end point. FE analysis was then used to verify this conclusion, 38Generator Design Generator Type The initial task in the design of the generator was to decide what type of generator to implement. Three types of generators were considered and contrasted: permanent magnet, induced field and coreless axial flux generators. The permanent magnet with iron core design eliminates the need for field excitation and slip rings, however produces a high starting torque [28]. This torque could prove problematic in our design due to the low wind speeds encountered at the altitudes which small wind turbines operate. Additionally, vertical axis turbines are known for typically having a low torque as it starts up. Axial flux coreless generators are often used when low starting torque is required and can work with large air gaps [18]. It was therefore decided to build an axial flux generator due to its suitability to implementation in small wind turbines. (Info from week 1 lecture) Design of Generator The coreless axial flux design was adopted using two rotor plates and a single stator. Each rotor blade contained 12 magnets and the stator was made up of 9 coils with 3 coils per phase. The choice of 9 coils and 12 magnets per rotor was deduced using the expressions: = 120fuom 20 3p 705 ‘Where p represents the number of pole pairs, fromthe nominal frequency, naam the rotational speed in revolutions per minute, and Q the number of coils. Once the number of coils were found the corresponding number of magnets per rotor was deduced using Table (3). Table 3: Pole Pairs Combination % 6 a a a i 2a However, the size of the rotor and stator depended largely on the size of magnets selected. 39Choice of Magnets Due to the small-scale of this project it was desired for the generator to remain compact. This influenced the choice to use neodymium magnets in contrast to ferrite, due to neodymium producing a significantly greater magnetic field strength per unit size. The price limit on this project further constrained the range of magnets available. The magnets purchased were N52 neodymium magnets with dimensions: 25x8x2mm. In order to determine whether the strength of these magnets would be sufficient for the intended purpose, finite element analysis simulations were run in FEMM with an estimated airgap of mm and a coil thickness of 6mm. Figure 37 displays the simulation which obtained a magnetic field strength of 0.33T at the centre point between ‘opposing magnet faces. Figure 37: Simulation of magnetic field strength Initial Design of Rotor and Stator Using these magnet dimensions, the rotor and stator plates were designed. The spacing of ‘magnets largely determined the dimensions of the rotor plates as the optimum ratio of the inner to ‘outer radius of the magnets (as seen in Figure 38, represented by Ri and Ro respectively) was 1: V3 [29]. This resulted in an inner radius of 35mm and an outer radius of 60mm, thus @ minimum rotor diameter of 120mm. Furthermore, the coil size also depended upon magnet dimensions Ry and R, as illustrated in Figure (38). 40Figure 38: Original rotor and stator concepts [29] Original rotor and stator concept designs were sketched as shown in Figures 39 and 40. Additional area was allowed behind magnets in case additional supporting material was required to keep magnets secure during high rotational speeds. Figure 29: Original rotor sketch 41Figure 40: Original stator sketch The choice was made to use trapezius shaped coils as they best-utilised the space on a Circular rotor disk allowing for a compact design. Rectangular magnets were used alongside as they were suitable to be implemented with trapezius coils. Figure 41 illustrates the path traced when a magnet would pass over a coil, with fs represen ig the magnet length. Cena pot ck on Figure 41: Magnet path over a coil (20) The number of turns per coil was calculated using the equation: 2, Ne = = re a ageghe 42k Pmax 7 T55 42‘Where, és the induced voltage, q the number of coils per phase, kuthe winding coefficient, mae the maximum flux per pole, n the RPM at cut-in and p the number of pole pairs. This number of ‘turns per coil was found to be 40 using a cut in speed of 7ms" Final Design of Rotor and Stator The final design of both rotor plates and stator are illustrated in Figures 43, 44 and 45. —— ree_Diameter_1=210 (Ciele_Diametor_2=25 ~— Ratial_Diamator_1=9 Linear 1-35, Radial_Dlameter_2=11 Figure 42: Lower rotor plate (210 > Rodi iameter_1=210, Linear 49185 — +4 LUnear_3=185 Lunear.t=70 —! Figure 43: Upper rotor plate 43Circle_Diameter_1=135 Figure 44: The stator The rotor diameter in the final design was larger than the original sketched design (210mm. comparison to 140mm). This additional size resulted as it was decided that the blades of the turbine were to be directly connected to the rotor. Further differences occurred between initial concept and final design. Originally, both rotor plates were identical, however upon final design only the bottom plate required a hole for the shaft, both plates required 16 bolt holes for the connection of the blades and the bottom plate required an additional 4 bolt holes in order to attach a bearing. Manufacturing Stator ‘Awinding mechanism was first constructed in order to produce coils faster, more consistent and with a higher accuracy to the intended design. This mechanism was created by first sketching the trapezius shape of the inside of a coll on a block of wood, placing a 6mm spacer on this block and. ‘adding another block on top. These blocks were connected by inserting nails through both in the position of the four corners of the trapezius, and spacers removed to leave 6mm of nails between the two blocks. This gap between the blocks set the maximum thickness of the coils. Copper wire, of 0.85mm diameter, was wound round these nails, with 40 turns per coil. Nine coils were made, held together using string and electrical tape, and then connected in a star configuration by soldering as shown in the Figure 45, 44Figure 45: Three phose star formation of the collsin the generator [20] The diameter of the coil configuration resulted approximately 10mm larger than initial estimates. This variation occurred as a thicker coil wire was used than originally planned to ensure that the level of current could be handled without risk of overloading the wires. Figure 46 shows the completed coils connected in a star configuration. x Figure 46: The completed coils In order to reduce manufacturing time, a mould for casting the stator was sourced externally by using a pastry tin as shown in figure 47. 45,Figure 47: Pastry tn as stator mould To cast the stator a thin layer of fiberglass sheet is placed in the mould to reinforce the stator. The coils are correctly positioned and the epoxy resin poured in to cover them. A second layer of fibre glass sheet is placed over the coils and covered in epoxy and the resin is left to set Final Construction of Generator Magnets were glued in position on the rotor disks and the generator assembly completed by connecting the rotor plates and stator. The rotor plates were bolted together and a bearing connected to the lower plate with the bearing and stator attached to the central shaft. The final construction of the generator is illustrated in Figure (48). lerator and central hub design 46Charging Circuit Introduction The battery charging circuit comprised of two primary stages: rectification and voltage regulation. The battery being charged in this case is a 12V lead acid Leisure type battery. This battery requires a minimum of 13.4V in order to begin charging. Figure 49 shows the charging curve of the battery. Stage 1: Vorage Stage Curent ops; Stage 3: Votage foes content — olchage sess sloneredta fot reno Vpeak — Whenconenevts of cha lev Figure 49: Charging curve forthe battery (21) Rectification Stage ‘The generator output, connected in star configuration, produces a 3-phase AC voltage. However, @ DC voltage is required in order to charge the battery. This is the primary function of the rectifier: to convert AC to DC voltage. For this application a 3-phase bridge rectifier was used, which comprises of six diodes as shown in the figure: BD, D: Dy Vo Vp o——— Va Load Dy Ds De Figure $0: 3:phase bridge rectifier (21) 47Figure 51 illustrates rectification: converting 3 AC signals into a single signal which approximates OC. Figure 512 Rectfication of signals (23) Voltage regulation stage Once the 3 phase AC signal has been converted to DC, the voltage must be regulated to ensure a safe range for the charging of the battery. A charge controller is an essential component in this, Circuit as it monitors the battery voltage and switches the battery on or off depending on whether the battery is fully charged or has reached a pre-set level of discharge. The battery charging circuit, adopted in the case focused around the LM317 IC. The LM317 device is an adjustable three- terminal positive-voltage regulator capable of supplying more than 5A over an output-voltage range of 1.25V to 37V. It requires only two external resistors to set the output voltage [22]. The functional block diagram of the LM317 chip is given in Figure 52. Wa, Output Figure 52: L317 ep (22) The flexibility of the LM317 allows it to be configured to take on many different functions in DC power applications [22]. The chip can readily be adapted to a battery charging device (as illustrated 48in Figure $3) through the simple use of a potential divider to determine voltage and a series resistor which limits the current output of the LM31?, minimizing damage to the battery cell. TMst7 an —Npur—ourpur i Ra 24ka Figure 53: Battery charging device (22) Final Circuit Design A final circuit was designed using the 3-phase bridge rectifier in combination with the LM317 battery charging circuit and additional circuitry. Figure 54: Final circuit design Additional safety circuitry was added to prevent damage to the battery during charging. This, involved including a relay and an additional “dump load” resistor so that the current could be switched/redirected from charging the battery to this load. A capacitor was also included in order to smooth the AC ripples from the rectified signal as well as an additional diode to ensure that the direction of current flow was not reversed, 49‘The output voltage of the LM317 can be manually set using the variable resistor R2. For this circuit layout, the relation between input and output voltage is: Where Ver is the reference voltage with a typical value of 1.25V for the LM317 chip. From this, equation, and with the limitation that R2 is 20k variable resistor, it can be observed that the output has a range of 1.25V - 20v. 50Procurement of Parts ‘The following justifies the suppliers used to source the materials for each component, ‘+ The rotor plates and base plate are laser cut from a specialist supplier. This ensures maximum accuracy and reduces the manual machining hours. The total price for two Smm plates is £15.54. Parts sourced from: www.lasermaster.co.uk/ ‘+ Aluminium flat bar for support arms, metalsdu provide necessary dimensions (3.2mm x 19mm) at a competitive price of £5.95 / 4000mm. Parts sourced from: ‘+ metals4u also provide a range of metal tubing, which can be used for the shaft. Aluminium tubing (25.4mm od x 3.2mm wall thickness) was found to be cheaper than steel at £7.11 / 1000mm, however the outer wall thickness would have to be thicker to account for the lower yield stress. In addition to this, the aluminium would be harder to weld. However, these issues are outweighed by the reduction in weight and cost. Parts sourced from: https://www.metals4u.co.uk/.../25.4mm-x-3.2mm=-(-Lod-x. ‘+ The same supplier was also used for the aluminium tubing used to separate the rotor plates, at £2.02 / 1000mm (12.7mm od x 1.6mm wall thickness). Parts sourced from: https://www.metals4u.co.uk/.../12.7mm-x-1 6mm-{-12-0d-x-../p972 ‘+ The neodymium magnets for the rotor were sourced from firstamagnets. They provided a comprehensive and competitive service. By ordering in bulk with other groups, the total cost for the magnets was greatly reduced. ‘+ The bearing, bolts, nuts and washers were all sourced from eBay. This was due to the relative cheapness of the components in smalll quantities whereas more specialised suppliers tend only to distribute in bulk quantities. ‘+ Other materials such as silicon, copper wire, fibreglass and epoxy are all supplied by the workshop for our purposes. s1Billof Materials Theil of materials a comprehensive lt of 2 pts unites, mata and at estimations or tea potty. The BoM provides conc yt detailed information about every necessary component. awe ef nctris ‘This Bl of Materials outlines all materials fr the prototype VAWT assemblyManufacturing Methods Proposed Prototype Assembly Outline for prototype VAWT assembly: 1. Stator 2. Blades a b. « 4, 3. Rotor a b. Manufacture/acquire mould. In order to reduce manufacturing time, a mould may be sourced externally by using a pastry tin. (Estimated time: 2 hours) The coils are made. This will be done by wrapping the copper wire around a wooden mould or a series of nails correctly positioned in a piece of wood. The coils will then be correctly aligned in a three phase orientation, soldered and a (Estimated time: 4 hours) A thin layer of fiberglass sheet is placed in the mould to reinforce the stator. The coils are correctly positioned and the epoxy resin poured in to cover them. A second layer of fibre glass sheet is placed over the coils and covered in epoxy. The resin is left to set. (Estimated time: 72 hours) 3D print 0.5 blade profile (PLA/ABS). (Estimated time: 13 hours) Produce full silicone mould from blade profile. (Estimated time: 24 hours) Fiberglass is layered in the mould, and epoxy resin is poured in. The blade is allowed to set. The silicone mould is then repurposed so that the process can be repeated three times to produce 4 blades of equal dimensions. (Estimated time: 288 hours) Bolt holes to attach the support arms are machined in each blade (Estimated time: 30 mins) Rotor components to be laser cut are sent to Laser Master. (Estimated time: 48 hours, supplier estimate) Magnets are epoxied to rotor plates (Estimated time: 20 mins 4. Support Arms Aluminium bar is cut to correct length for support arms. (Estimated time: 30 mins) Manufacture die for bending of aluminium arms. (Estimated time: 1 hour) Machine bolt holes in aluminium arms. (Estimated time: 30 mins) ‘The arms are bent using a wire bender to produce the correct geometry. (Estimated time: 1 hour) 535. Shaft a. Shaft is machined to size. (Estimated time: 5 mins) b. Grooves for stator circlips are machined using lathe. (Estimated time: 30 mins) ¢. The shaft is welded to the baseplate. (Estimated time: 30 mins) 6. Final Assembly a. Final finishing of any components is carried out. (Estimated time: 2 hours) b. The VAWT is assembled. (Estimated time: 30 mins) 7. Estimated Manufacturing Time: 458 hours 25 mins Proposal for Mass Production The proposed mass production of the VAWT will be very similar to the prototype, however, more rapid processes will be incorporated, 1. Stator a. Apermanent mould/ series of moulds are produced for the stator body, b. The winding process for the coils is automated, producing coils far faster than would be possible by hand The coils are mounted correctly in the mould following reinforcing fibreglass sheets. The epoxy is poured in and allowed to set. The epoxy is cured in a carefully monitored oven in order to speed up curing time. 4. A compression bushing is fitted inside the shaft slot, this will be used on the permanent model instead of circlips in order to reduce manufacturing time and improve reliability. a. Permanent, two plate split moulds of the entire blade are produced, allowing the blade to be made as a single component. b. Fibreglass is laid in the moulds ©. Epoxy is rapidly injected into the moulds and the mould is baked to allow the blade to cure. a. The central disks for the rotor are laser cut. b. The appropriate bolt holes are countersunk in order to allow the bolts to lie flush with the rotor plates and reduce the diameter of the rotor plates. 4, Support Arms 34a. The aluminium bar is cut to size by an automated process to ensure accuracy. b. The bar is then bent around a die in order to achieve the required geometry. Shaft . Minimal machining has to be carried out on the shaft, as no circlips will be used, Nacelle a. Previously unmentioned, the nacelle would provide a protective cover for the central hub. b. Using a suitable polymer such as ABS, the nacelle will be made via injection moulding. Gravity Stand/Tripod a. The various tubing diameters for the gravity stand are machined to size. b, The brackets are bought in from an external supplier to reduce lead time on manufacturing, Final Assembly 38CAD Models igure 56: Gravity stand folding mechanism. Figure 57: Exemplfcation of the folded stand. 38Figure 58: View of the rotor in perspective Figure 59: View of the turbine in perspective 97Figure 60: View ofthe turbine from the top Figure 61: View of the turbine from the side (1). 58gure 62; View of the turbine from the side (2) Figure 63: View of the turbine from below. 39Drawings Drawings to show the final dimensions of some parts. Even though the drawing frame includes important information such as the weight, scale, tolerance, date and author, it occupies space in this report and decreases the size of the actual drawing relative to the page size, ‘thus changing the actual scale. Moreover, since tolerances were considered in important parts such as the laser cut plates and so was the weight, no information was lost in this process. Moreover, being such a simple design with many standards parts, it was decided that the only parts worth doing technical drawings were the top and bottom rotor plates. Figure 64: Technical drawing of the top rotor plate 6020 ia ai t 25 StS oS ORT om 5 qs Ee " & “e “ . ee Figure 65: Technical drawing of the bottom rotor plateReferences [1] British Department of Energy and Climate Change, "DUKES Renewables 2015,” National Statistics, London, 2015. [2] “Repair Engineering,” [Online]. 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Latoufis, “Axial Flux Permanent Magnet Generator Design for Low Cost Manufacturing of ‘Small Wind Turbines,” Multi-Science Publishing Company, Essex, 2012. [21] E. Macpherson, “Power Electronics and Machines Lecture 9,” The University of Edinburgh, Edinburgh, 2016. [22] T. instruments, LM317 3-Terminal Adjustable Regulator, Austin: Tl, 1997. [23] “Airfoil examples,” [Online]. Available: https://en.wikipedia.org/ wiki/Airfoilt/media/File:Wing_profile_nomenclature.svg. [Accessed 20 03 2016). 63Appendices This sections comprises the project plan, engineering drawings, calculations and any other additional detailed information that is useful (some will be added after the submission),