DESIGNANDFABRICATIONOFSAVONIUSVERTICALAXIS

WINDTURBINE
AProjectreportsubmittedinpartialfulfillmentoftherequirementforthe
awardofdegreeofBACHELOROFTECHNOLOGY
IN
MECHANICALENGINEERING
SubmittedBy
SATISHCHANDRABALINENI07241A0356
SIVARAMAKRISHNA.R07241A0360
B.SRIRAMKUMAR07241A0364
G.VIJAYKUMAR07241A0368
UndertheGuidanceof

Dr.ADAPARAMARAO
Prof&Dean,CounselingandCareerGuidence

DepartmentofMechanicalEngineering,
GOKARAJURANGARAJUINSTITUEOFENGINEERINGAND
TECHNOLOGY
(AffiliatedtoJawaharlalNehruTechnologicalUniversity)
2007-2011

ABSTRACT
We know that there is enough wind globally to satisfy much, or even most,
of humanity's energy requirements if it could be harvested effectively and
on a large scale. Vertical axis wind turbines (VAWTs), which may be as
efficient as current horizontal axis systems, might be
and

significantly cheaper to build

practical, simpler

maintain than horizontal axis wind

turbines (HAWTs).They also have other inherent advantages, such as they

are always facing the wind, which might make them a significant player in
our quest for cheaper, cleaner renewable sources of electricity. VAWTs
might

even critical in mitigating grid interconnect stability and reliability

issue currently facing electricity producers and suppliers. Additionally,

cheap VAWTs may provide an alternative to the rain forest destruction for
the growing of bio-fuel crops.
Vertical-axis wind turbines (VAWTs) 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 we attempt to design and fabricate a
Savonius Vertical Axis Wind Turbine.

TableofContents
INTRODUCTION..4
SCOPE OF PROJECT ....................................................................................8
LITERATURE REVIEW..9
POWER AND SOURCE ...............................................................................10
CHARACTERISTICS ..11
REQUIREMENTS OF PLACING ................................................................13
VERTICAL AXIS WIND TURBINE..15
GENERAL THEORY....................................................................................17
TYPES OF VERTICAL AXIS WIND TURBINE........................................20
MATERIALS USED IN WIND TURBINES ...............................................27
DESIGN OF WIND TURBINE ....................................................................30
SPECIFICATIONS OF WIND TURBINE ...................................................33
FABRICATION TECHNIQUES ..................................................................34
CALCULATIONS.............................................................................................
APPLICATIONS OF WIND ENERGY............................................................
CONCLUSION AND FUTURE DEVELOPMENTS
BIBILOGRAPHY

INTRODUCTION
If the efficiency of a wind turbine is increased, then more power can be
generated thus decreasing the need for expensive power generators that
cause pollution. This would also reduce the cost of power for the common
people. The wind is literally there for the taking and doesn't cost any money.
Power can be generated and stored by a wind turbine with little or no
pollution. If the efficiency of the common wind turbine is improved and
widespread, the common people can cut back on their power costs
immensely.
Ever since the Seventh Century people have been utilizing the wind to make
their lives easier. The whole concept of windmills originated in Persia. The
Persians originally used the wind to irrigate farm land, crush grain and
milling. This is probably where the term windmill came from.
Since the widespread use of windmills in Europe, during the Twelfth
Century, some areas such as the Netherlands have prospered from creating
vast wind farms.
The first windmills, however, were not very reliable or energy efficient.
Only half the sail rotation was utilized. They were usually slow and had a
low tip speed ratio but were useful for torque.
Since its creation, man has constantly tried to improve the windmill. As a
result, over the years, the number of blades on windmills has decreased.
Most modern windmills have 5-6 blades while past windmills have had 4~8
blades. Past windmill also had to be manually directed into the wind, while
modern windmills can be automatically turned into the wind. The sail design
and materials used to create them have also changed over the years.

In most cases the altitude of the rotor is directly proportional to its

efficiency. As a matter of fact, a modern wind turbine should be at least
twenty feet above and three hundred feet away from an obstruction, though it
is even more ideal for it to be thirty feet above and five hundred feet away
from any obstruction.
Different locations have various wind speeds. Some places, such as the
British Isles, have few inhabitants because of high wind speeds, yet they are
ideal for wind generation. Did you know that the world's largest wind farm is
located in California, and the total wind power generated there exceeds
1,400 megawatts of electricity? (A typical nuclear power plant generates
1,000 megawatts.)
Some geographic features such as mountains also have an influence upon
wind. Mountains can create mountain breezes at night, because of the cooler
air flowing down the mountain and being heated by the warmer valley air
causing a convection current. Valleys are affected in much the same way. In
the daytime, the cooler air is above the valleys and the hot air is above the
mountains. The hot air above the mountain rises above the valleys and cools,
thus creating a convection current in the opposite direction and creating a
valley wind. The oceans create convection currents, as well as they
mountains or valleys. In the day, the hotter air is above the same and the
cooler air is above the ocean. The air heats up over the sand and rises above
the ocean and then cools, creating the convection current. At night, the
cooler air is above the sand and the warmer air is above the ocean, so the air
heats up over the ocean and cools over the sand. As you can clearly see, the
time of day also affects the wind.
We know that for windmills to operate there must be wind, but how do they
work? Actually there are two types of windmills -- the horizontal axis
windmills and the vertical axis windmills. The horizontal axis windmills
5

have a horizontal rotor much like the classic Dutch four-arm windmill. The
horizontal axis windmills primarily rely on lift from the wind. As stated in
Bernoulli's Principle, "a fluid will travel from an area of higher pressure to
an area of lower pressure." It also states, "as the velocity of a fluid increases,
its density decreases." Based upon this principle, horizontal axis windmill
blades have been designed much like the wings of an airplane, with a curved
top. This design increases the velocity of the air on top of the blade thus
decreasing its density and causing the air on the bottom of the blade to go
towards the top ... creating lift. The blades are angled on the axis as to utilize
the lift in the rotation. The blades on modern wind turbines are designed for
maximum lift and minimal drag.
Vertical axis windmills, such as the Durries (built in 1930) use drag instead
of lift. Drag is resistance to the wind, like a brick wall. The blades on vertical
axis windmills are designed to give resistance to the wind and are as a result
pushed by the wind. Windmills, both vertical and horizontal axis, have many
uses. Some of them are: hydraulic pump, motor, air pump, oil pump,
churning, creating friction, heat director, electric generator, Freon pump, and
can also be used as a centrifugal pump.
There are many types of windmills, such as: the tower mill, sock mill, sail
windmill, water pump, spring mill, multi-blade, Darrieus, savonis, cycloturbine, and the classic four-arm windmill. All of the above windmills have
their advantages. Some windmills, like the sail windmill, are relatively slow
moving, have a low tip speed ratio and are not very energy efficient
compared to the cyclo-turbine, but are much cheaper and money is the great
equalizer.
There have been many improvements to the windmill over the years.
Windmills have been equipped with air breaks, to control speed in strong
winds. Some vertical axis windmills have even been equipped with hinged
6

blades to avoid the stresses at high wind speeds. Some windmills, like the
cyclo-turbine, have been equipped with a vane that senses wind direction and
causes the rotor to rotate into the wind. Wind turbine generators have been
equipped with gearboxes to control [shaft] speeds. Wind turbines have also
been equipped with generators which convert shaft power into electrical
power. Many of the sails on windmills have also been replaced with
propeller-like airfoils. Some windmills can also stall in the wind to control
wind speed. But above all of these improvements, the most important
improvement to the windmill was made in 1745 when the fantail was
invented. The fantail automatically rotates the sails into the wind.
Most wind turbines start to generate power at 11 m/s and shut down at
speeds near 32m/s. Another variable of the windmill's efficiency is its swept
area. The swept area of a disk--shaped wind wheel is calculated as: Area
equals pi times diameter squared divided by four (pi equals 3.14).
Another variable in the productivity of a windmill is the wind speed. The
wind speed is measured by an anemometer.
Another necessity for a windmill is the tower. There are many types of
towers. Some towers have guy wire to support them and others don't. The
towers without guy wires are called freestanding towers. Something to take
into consideration about a tower is that it must support the weight of the
windmill along with the weight of the tower. Towers are also subject to drag.
Scientists estimate that, by the 21st Century, ten percent of the world's
electricity will come from windmills.

SCOPE OF THE PROJECT

To utilize the available wind resources and to reduce the usage of non
renewable energy resources. Wind energy is by far the fastest-growing
renewable energy resource. The wind energy industry so far has been
supported by market incentives backed by government policies fostering
sustainable energy resources.
Large-scale wind facilities approaching the output rating of conventional
power plants, control of the power quality is required to reduce the adverse
effects on their integration into the network. These wind turbines can be used
to provide constant lighting. In most cities, bridges are a faster route for
everyday commute and in need of constant lighting makes this an efficient
way to produce natural energy.

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 by 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 = mv2.
Amount of Air passing is given by
m = AV

..(1)

Where
m = mass of air transversing
A=area swept by the rotating blades of wind mill type generator
= Density of air
V= velocity of air
Substituting this value of the mass in expression of K.E.
= AV.V2 watts
= AV3 watts ..

(2)

Second equation tells us that the power available is proportional to air

density (1.225 kg/m3) & is proportional to the intercept area. Since the
area is normally circular of diameter D in horizontal axis aero turbines,
then,
A = D2

(Sq. m)

4
Put this quantity in equation second then
Available wind power Pa = D2 V3

watt

8
10

CHARACTERISTICS & SPECIFICATIONS OF

WIND TURBINES
Wind Speed
This is very important to the productivity of a windmill. The wind turbine
only generates power with the wind. The wind rotates the axis (horizontal or
vertical) and causes the shaft on the generator to sweep past the magnetic
coils creating an electric current.

Blade Length
This is important because the length of the blade is directly proportional to
the swept area. Larger blades have a greater swept area and thus catch more
wind with each revolution. Because of this, they may also have more torque.

Base Height
The height of the base affects the windmill immensely. The higher a
windmill is, the more productive it will be due to the fact that as the altitude
increases so does the winds speed.

Base Design
Some base is stronger than others. Base is important in the construction of
the windmill because not only do they have to support the windmill, but they
must also be subject to their own weight and the drag of the wind. If a weak
tower is subject to these elements, then it will surely collapse. Therefore, the
base must be identical so as to insure a fair comparison.

11

BLOCK DIAGRAM OF WIND POWER

GENERATION

WIND

WIND TURBINE

WIND

AC ALTERNATOR

ENERGY STORAGE

LOAD UTILIZATION

12

REQUIREMENTS FOR PLACING

Site Selection considerations

The power available in the wind increases rapidly with the speed; hence
wind energy conversion machines should be located preferable in areas
where the winds are strong & persistent. The following point should be
considered while selecting site for Wind Energy Conversion System
(WECS).

High annual average wind speed

The wind velocity is the critical parameter. The power in the wind Pw,
through a given X section area for a uniform wind Velocity is
Pw = KV3

(K is constant)

It is evident, because of the cubic dependence on wind velocity that

small increases in V markedly affect the power in the wind
e.g. doubling V, increases Pw by a factor of 8.

Availability of wind V(t) curve at the proposed site

This important curve determines the maximum energy in the wind and
hence is the principle initially controlling factor in predicting the
electrical o/p and hence revenue return of the WECS machines, it is
desirable to have average wind speed V such that
V12-16 km/hr i.e. (3.5 4.5 m/sec).

Wind structures at the proposed site

Wind especially near the ground is turbulent and gusty, & changes
rapidly indirection and in velocity. This departure from homogeneous
flow is collectively referred to as the structure of the wind.

13

Altitude of the proposed site

If affects the air density and thus the power in the wind & hence the
useful WECS electric power o/p.

The winds tends to have higher

velocities at higher altitudes.

Local Ecology

If the surface is bare rock it may mean lower hub heights hence lower
structure cost, if trees or grass or ventation are present. All of which
tends to destructure the wind.

Nearness of site to local center/users

This obvious criterion minimizes transmission line length & hence losses
& costs.

Nature of ground

Ground condition should be such that the foundations for WECs are
secured, ground surface should be stable.

Favorable land cost

Land cost should be favorable as this along with other sitting costs,
enters into the total WECS system cost.

14

VERTICAL AXIS WIND TURBINE

Vertical-axis wind turbines (or VAWTs) have the main rotor shaft arranged
vertically. Key advantages of this arrangement are that the turbine does not
need to be pointed into the wind to be effective. This is an advantage on sites
where the wind direction is highly variable, for example when integrated into
buildings. The key disadvantages include the low rotational speed with the
consequential higher torque and hence higher cost of the drive train, the
inherently lower power coefficient, the 360 degree rotation of the aerofoil
within the wind flow during each cycle and hence the highly dynamic
loading on the blade, the pulsating torque generated by some rotor designs
on the drive train, and the difficulty of modeling the wind flow accurately
and hence the challenges of analyzing and designing the rotor prior to
fabricating a prototype.
CAD MODEL OF VERTICAL AXIS WIND TURBINE

15

With a vertical axis, the generator and gearbox can be placed near the
ground, hence avoiding the need of a tower and improving accessibility for
maintenance. Drawbacks of this configuration include (i) wind speeds are
lower close to the ground, so less wind energy is available for a given size
turbine, and (ii) wind shear is more severe close to the ground, so the rotor
experiences higher loads. Air flow near the ground and other objects can
create turbulent flow, which can introduce problems associated with
vibration, such as noise and bearing wear which may increase the
maintenance or shorten the service life. However, when a turbine is mounted
on a rooftop, the building generally redirects wind over the roof and this can
double the wind speed at the turbine. If the height of the rooftop mounted
turbine tower is approximately 50% of the building height, this is near the
optimum for maximum wind energy and minimum wind turbulence. It
should be borne in mind that wind speeds within the built environment are
generally much lower than at

16

GENERAL THEORY RELATED TO VERTICAL

AXIS WIND TURBINE
The forces and the velocities acting in a Darrieus turbine are depicted in
figure 1. The resultant velocity vector,
undisturbed upstream air velocity,
advancing blade,

, is the vectorial sum of the

, and the velocity vector of the

Thus, the oncoming fluid velocity varies, the maximum is found for
and the minimum is found for

, where is the azimuthal or orbital

blade position. The angle of attack, , is the angle between the oncoming air
speed, W, and the blade's chord. The resultant airflow creates a varying,
positive angle of attack to the blade in the upstream zone of the machine,
switching sign in the downstream zone of the machine.
From geometrical considerations, the resultant airspeed flow and the angle of
attack are calculated as follows:

17

Where

is the tip speed ratio parameter

The resultant aerodynamic force is decomposed either in lift (F_L) drag

(D) components or normal (N) - tangential (T) components. The forces are
considered acting at 1/4 chord from the leading edge (by convention), the
pitching moment is determined to resolve the aerodynamic forces. The
aeronautical terms lift and drag are, strictly speaking, forces across and along
the approaching net relative airflow respectively. The tangential force is
acting along the blade's velocity and, thus, pulling the blade around and the
normal force is acting radially, and, thus, is acting against the bearings. The
lift and the drag force are useful when dealing with the aerodynamic
behavior around each blade, i.e. dynamic stall, boundary layer, etc; while
when dealing with global performance, fatigue loads, etc., it is more
convenient to have a normal-tangential frame. The lift and the drag
coefficients are usually normalized by the dynamic pressure of the relative
airflow, while the normal and the tangential coefficients are usually
normalized by the dynamic pressure of undisturbed upstream fluid velocity.

18

where
A = Surface Area
= Density of air
D= Drag component of aerodynamic force
N=Normal component of aerodynamic force
T=Tangential component of aerodynamic force
FL=Lift component of aerodynamic force
The amount of power, P , which can be absorbed by a wind turbine.

Where Cp is the power coefficient, is the density of the air, A is the swept
area of the turbine, and is the wind speed

19

TYPES OF VERICAL AXIS WIND TURBINES

Darrieus wind turbine
Commonly described as "Eggbeater" turbines, or Darrieus turbines, were
named after the French inventor, Georges Darrieus. They have good
efficiency, but produce large torque ripple and cyclical stress on the tower,
which contributes to poor reliability. They also generally require some
external power source, or an additional Savonius rotor to start turning,
because the starting torque is very low. The torque ripple is reduced by using
three or more blades which results in greater solidity of the rotor. Solidity is
measured by blade area divided by the rotor area. Newer Darrieus type
turbines are not held up by guy-wires but have an external superstructure
connected to the top bearing.
The Darrieus design, the aerofoils are arranged so that they are symmetrical
and have zero rigging angle, that is, the angle that the aerofoils are set
relative to the structure on which they are mounted. This arrangement is
equally effective no matter which direction the wind is blowingin contrast
to the conventional type, which must be rotated to face into the wind.
When the Darrieus rotor is spinning, the aerofoils are moving forward
through the air in a circular path. Relative to the blade, this oncoming
airflow is added vectorially to the wind, so that the resultant airflow creates a
varying small positive angle of attack (AoA) to the blade. This generates a
net force pointing obliquely forwards along a certain 'line-of-action'. This
force can be projected inwards past the turbine axis at a certain distance,
giving a positive torque to the shaft, thus helping it to rotate in the direction
it is already travelling in. The aerodynamic principles which rotate the rotor
are equivalent to that in autogiros, and normal helicopters in autorotation.

20

As the aerofoil moves around the back of the apparatus, the angle of attack
changes to the opposite sign, but the generated force is still obliquely in the
direction of rotation, because the wings are symmetrical and the rigging
angle is zero. The rotor spins at a rate unrelated to the windspeed, and
usually many times faster. The energy arising from the torque and speed may
be extracted and converted into useful power by using an electrical
generator.
The blades of a Darrieus turbine can be canted into a helix, e.g. three blades
and a helical twist of 60 degrees, similar to Gorlov's water turbines
The aeronautical terms lift and drag are, strictly speaking, forces across and
along the approaching net relative airflow respectively, so they are not useful
here. We really want to know the tangential force pulling the blade around,
and the radial force acting against the bearings.
When the rotor is stationary, no net rotational force arises, even if the wind
speed rises quite highthe rotor must already be spinning to generate
torque. Thus the design is not normally self-starting. Under rare conditions,
Darrieus rotors can self-start, so some form of brake is required to hold it
when stopped.

21

Working Model of Darrieus Wind turbine

A Darrieus wind turbine used to generate electricity on the Magdalen

Islands
22

Giromill
A subtype of Darrieus turbine with straight, as opposed to curved,
blades. The cycloturbine variety has variable pitch to reduce the
torque pulsation and is self-starting.The advantages of variable pitch
are: high starting torque; a wide, relatively flat torque curve; a lower
blade speed ratio; a higher coefficient of performance; more efficient
operation in turbulent winds; and a lower blade speed ratio which
lowers blade bending stresses. Straight, V, or curved blades may be
used.
Giromill VAWTs are also self-starting.

A Giromill-type wind turbine

23

Savonius wind turbine

Savonius turbines are one of the simplest turbines. Aerodynamically, they
are drag-type devices, consisting of two or three scoops. Looking down on
the rotor from above, a two-scoop machine would look like an "S" shape in
cross section. Because of the curvature, the scoops experience less drag
when moving against the wind than when moving with the wind. The
differential drag causes the Savonius turbine to spin. Because they are dragtype devices, Savonius turbines extract much less of the wind's power than
other similarly-sized lift-type turbines. Much of the swept area of a Savonius
rotor may be near the ground, if it has a small mount without an extended
post, making the overall energy extraction less effective due to the lower
wind speeds found at lower heights.

Working Methodology of Savonius Wind Turbine

24

ADVANTAGES OF SAVONIUS TURBINES

Savonius turbines are used whenever cost or reliability is much more
important than efficiency. For example, most anemometers are Savonius
turbines, because efficiency is completely irrelevant for that application.
Much larger Savonius turbines have been used to generate electric power on
deep-water buoys, which need small amounts of power and get very little
maintenance. Design is simplified because, unlike with Horizontal Axis
Wind Turbines (HAWTs), no pointing mechanism is required to allow for
shifting wind direction and the turbine is self-starting. Savonius and other
vertical-axis machines are good at pumping water and other high torque, low
rpm applications and are not usually connected to electric power grids. They
can sometimes have long helical scoops, to give smooth torque.
The most ubiquitous application of the Savonius wind turbine is the Flettner
Ventilator which is commonly seen on the roofs of vans and buses and is
used as a cooling device. The ventilator was developed by the German
aircraft engineer Anton Flettner in the 1920s. It uses the Savonius wind
turbine to drive an extractor fan. The vents are still manufactured in the UK
by Flettner Ventilator Limited
Small Savonius wind turbines are sometimes seen used as advertising signs
where the rotation helps to draw attention to the item advertised. They
sometimes feature a simple two-frame animation.

25

Indias Market Overview of Wind Energy

Overview
The development of wind power in India began in the 1990s, and has
significantly increased in the last few years. Although a relative newcomer to
the wind industry compared with Denmark or the US, India has the fifth
largest installed wind power capacity in the world. In 2009-10 India's growth
rate is highest among the other top four countries.
The worldwide installed capacity of wind power reached 157,899 MW by
the end of 2009. USA (35,159 MW), Germany (25,777 MW), Spain (19,149
MW) and China (25,104 MW) are ahead of India in fifth position. The short
gestation periods for installing wind turbines, and the increasing reliability
and performance of wind energy machines has made wind power a favored
choice for capacity addition in India.
India has a vast supply of renewable energy resources. India has one of the
worlds largest programs for deployment of renewable energy products and
systems 3,700 MW from renewable energy sources installed.

26

Materials Usage in Current Wind Turbines

A wide range of materials are used in wind turbines. There are substantial
differences between small and large machines and there are projected
changes in designs that will accommodate the introduction of new material
technologies and manufacturing methods. To arrive at a total, the material
usage is weighted by the estimated market share of the various
manufacturers and machines types. In general the materials used for wind
turbines are Steel, Aluminum, Copper and Reinforced Plastic
In this project we have used Aluminum discs and aluminum
sheets. The following are certain important properties present in the
materials.

PROPERTIES OF MATERIALS USED

Youngs modulus
It is defined as the ratio of stress and strain, where the strain does not have
units. Therefore youngs modulus has the units of stress,N/mm2 , Mpa , Gpa
The value for Aluminum is 70 GPa

Hookes Law
This law states that stress is directly proportional to strain within the elastic
limit.
where E= Youngs Modulus.

Yield Stress
It is the value of stress at which the material continues to deform at constant
load conditions. The value for Aluminum is 20Mpa

Ultimate Stress
It is the maximum stress induced in the specimen & it occurs in the plastic
region. The value for Aluminum is 70Mpa

27

Fracture Stress
As the reduction in cross sectional area continues, the load bearing capacity
of specimen reduces gradually. At a certain stage cross sectional of specimen
is so small that it cannot sustain the load & hence it breaks. The stress at
which the specimen breaks is known as fracture stress. It is generally less
than ultimate stress for ductile materials.

Hardness
It is the measure of resistance to penetration &abrasion, which is a function
of stress required to produce some specified type of failure. It is generally
expressed as a number.

Toughness
The ability of material to absorb energy in the plastic range is known as
toughness. Toughness per unit volume of the material is known as modulus
of toughness.

Poissons ratio
The ratio between lateral strain and longitudinal strain is known as Poissons
ratio. The value for Aluminum is 0.35

28

Principle of Dynamo Operation

The dynamo uses rotating coils of wire and magnetic fields to convert
mechanical rotation into a pulsing direct electric current through Faraday's
law of induction. A dynamo machine consists of a stationary structure, called
the stator, which provides a constant magnetic field, and a set of rotating
windings called the armature which turn within that field. The motion of the
wire within the magnetic field causes the field to push on the electrons in the
metal, creating an electric current in the wire. On small machines the
constant magnetic field may be provided by one or more permanent
magnets; larger machines have the constant magnetic field provided by one
or more electromagnets, which are usually called field coils.
The commutator was needed to produce direct current. When a loop of wire
rotates in a magnetic field, the potential induced in it reverses with each half
turn, generating an alternating current. However, in the early days of electric
experimentation, alternating current generally had no known use. The few
uses for electricity, such as electroplating, used direct current provided by
messy liquid batteries. Dynamos were invented as a replacement for
batteries. The commutator is essentially a rotary switch. It consists of a set of
contacts mounted on the machine's shaft, combined with graphite-block
stationary contacts, called "brushes", because the earliest such fixed contacts
were metal brushes. The commutator reverses the connection of the
windings to the external circuit when the potential reverses, so instead of
alternating current, a pulsing direct current is produced

29

DESIGN OF WIND TURBINE

30

DESIGNING OF VERTICAL AXIS WIND TURBINE

A wind mill is machine for wind energy conversion. A wind turbine
converts the kinetic energy of the winds motion to mechanical energy
transmitted by the shaft. A generator further converts it to electrical
energy. So it is necessary to keep in mind, while designing the
windmills structural part.

Design of blade
Wind turbine blades have on aerofoil type cross section and a variable
pitch. While designing the size of blade it is must to know the weight
and cost of blades. In the project three blade with vertical shaft are used,
it has a height & width of 73cm & 122cm respectively. The angle
between two blades is 600. So if one Blade moves other blades comes in
the position of first blade, so the speed is increases.

Blade Profile
31

Shaft Designing
While designing the shaft of blades it should be properly fitted to the
blade. The shaft should be as possible as less in thickness & light in
weight for the six blade, the shaft used is very thin in size are all
properly fitted. So no problem of slipping & fraction is created, it is
made up of hollow Aluminum which is having very light weight. Length
of shaft & diameter are 18 inches & 2.54cm respectively. And at the top
and bottom ends mild steel of length 1inch each are respectively are
fixed to give strength to the hollow shaft.

Design of Bearing
For the smooth operation of Shaft, bearing mechanism is used. To have
very less friction loss the two ends of shaft are pivoted into the same
dimension bearing. The Bearing has diameter of 2.54cm. Bearing are
generally provided for supporting the shaft and smooth operation of
shaft. We have used ball bearings for the purpose of ease of maintenance

An Electric Dynamo
For generation of electricity from the designed our vertical axis wind turbine,
we chose a Bicycle dynamo which has the capacity to light a bulb of 12 V.
This electric dynamo has the capacity.

32

SPECIFICATIONS OF THE WIND TURBINE

BASE DIMENSIONS
Height

24 inches

Width

21 inches

BLADE DIMENSIONS
Height

18 inches

Diameter

13 inches

Thickness

0.125 inches

Angle

45

Angle b/w blades

60

SHAFT DIMENSIONS
Diameter

2.54cm

Length

18 inches

33

FABRICATION TECHNIQUES

34

VARIOUS OPERATIONS INOVLVED IN FABRICATION

PROCESS

The following were the fabrication techniques involved

1. Gas Cutting
2. Arc Welding
3. Riveting

GAS CUTTING
A cutting torch is used to heat metal to kindling temperature. A stream of
oxygen is then trained on the metal and metal burns in that oxygen and then
flows out of the cut.
For cutting, the set-up is a little different. A cutting torch has a 60- or 90degree angled head with orifices placed around a central jet. The outer jets
are for preheat flames of oxygen and acetylene. The central jet carries only
oxygen for cutting. The use of a number of preheating flames, rather than a
single flame makes it possible to change the direction of the cut as desired
without changing the position of the nozzle or the angle which the torch
makes with the direction of the cut, as well as giving a better preheat balance
[2]

. Manufacturers have developed custom tips for Mapp, propane, and

polypropylene gases to optimize the flames from these alternate fuel gases

35

Gas cutting Torch

The gases used in this process are

1. LPG

2. Helium
Advantages of the Gas Cutting.

Environment friendly (reducing the emission of CO2)

High quality of cut surface

Reduction of man-hours for finishing after cutting

High productivity by high speed cutting.

36

ARC WELDING
Arc welding uses a welding power supply to create an electric arc between
an electrode and the base material to melt the metals at the welding point.
They can use either direct (DC) or alternating (AC) current, and consumable
or non-consumable electrodes. The welding region is sometimes protected
by some type of inert or semi-inert gas, known as a shielding gas, and/or an
evaporating filler material. The process of arc welding is widely used
because of its low capital and running costs
The following gauge lengths of electrodes are used in this process 8,
10&12mm. The number of electrodes used in this fabrication is around 4045 electrodes.

Arc Welding Equipment

37

RIVETING
A rivet is a permanent mechanical fastener. Before being installed a rivet
consists of a smooth cylindrical shaft with a head on one end. The end
opposite the head is called the buck-tail. On installation the rivet is placed in
a punched or pre-drilled hole, and the tail is upset, or bucked (i.e. deformed),
so that it expands to about 1.5 times the original shaft diameter, holding the
rivet in place. To distinguish between the two ends of the rivet, the original
head is called the factory head and the deformed end is called the shop head
or buck-tail.
Because there is effectively a head on each end of an installed rivet, it can
support tension loads (loads parallel to the axis of the shaft); however, it is
much more capable of supporting shear loads (loads perpendicular to the
axis of the shaft). Bolts and screws are better suited for tension applications.

RIVETING EQUIPMENT

38

CALCULATIONS

39

THEORTICAL CALCULATIONS
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, or mv 2.
K.E= mv2. .. (1)
K.E = kinetic energy
mass

m=

v = velocity,
M is equal to its Volume multiplied by its density of air
M = AV

.. (2)

Substituting eqn(2) in eqn(1)

We get,
K E = AV.V2
K E = AV3

watts

= density of air (1.225 kg/m3)

A = D2 /4

(Sq.m)

D = diameter of the blade

A = *(1.22) 2 /4
A = 1.16Sq.m
Available wind power Pa = ( D2 V3)/4

P = 1/8 D2 V3

40

TRAIL 1
FOR VELOCITY 4.5m/s

Pa

= ( D2 V3)/4

Pa

= (*1.225**1.222 *4.53)/4

Pa

= 65.244watt

TRAIL 2
FOR VELOCITY 5.5m/s

Pa

= ( D2 V3)/4

Pa

= (*1.225**1.222 *5.53)/4

Pa

= 119.12watt

TRAIL 3
FOR VELOCITY 7.5m/s

Pa

= ( D2 V3)/4

Pa

= (*1.225**1.222 *7.53)/4

Pa

= 302.06watt

TRAIL 4
FOR VELOCITY 10m/s

Pa

= ( D2 V3)/4

Pa

= (*1.225**1.222 *103)/4

Pa

= 716.00watt

41

APPLICATIONS OF WIND ENERGY

Wind-turbine generators have been built a wide range of power outputs
from kilowatt or so to a few thousand kilowatts, machine of low power
can generate sufficient electricity for space heating & cooling & for
operating domestic appliances.
Low power WEC generators have been used for many years for the
corrosion protection of buried metal pipe lines.
Application of more powerful turbines up to about 50kw, are for
operating irrigation pumps, Navigational signal. Aero generators in the
intermediate power range, roughly 100 to 25 KW can supply electricity
to isolated populations.

ADVANTAGE OF VERTICAL AXIS WIND TURBINE

OVER HORIZONTAL AXIS WIND TURBINE
There are several reasons why we would choose a vertical axis wind turbine
over a horizontal axis windmill.
1. They are mounted lower to the ground making it easy for
maintenance if needed.
2. They start creating electricity at speeds of only 6 mph. And
3. Third, they may be able to be built at locations where taller
structures, such as the horizontal type, can't be.
4. Higher power utilization-- 20% higher than HAWT.
5. Lower noise level--only 27-37 DB, suitable for your living
condition.
6. Safer operation--Spin at slower speeds than horizontal turbines,
decreasing the risk of injuring birds and also decreasing noise
level.
42

7. Simpler installation and maintenance-- besides the traditional

installation site, it can be mounted directly on a rooftop, doing
away with the tower and associated guy lines.
8. Not affected by orientation variationno matter the wind blow
from any orientation, VAWT can work without regard to its
face.
9. Economical

and

practical-Although

one-time

investment

expenses are larger, but you dont have to pay higher tariffs
forever.

Advantages
a) It is a renewable source of energy.
b) Wind power systems are non-polluting so it has no adverse
influence on the environment.
c) Wind energy systems avoid fuel provision and transport.
d) On a small scale up to a few kilowatt system is less costly.
e) On a large scale costs can be competitive conventional
electricity and lower costs could be achieved by mass
production.
f) They are always facing the wind - no need for steering into the
wind.
g) Have greater surface area for energy capture -can be many
times greater.
h) Are more efficient in gusty winds already facing the gust.
i) Can be installed in more locations - on roofs, along highways,
in parking lots.
j) Can be scaled more easily - from mill watts to megawatts.

43

CONCLUSION

&

FUTURE

DEVELOPMENTS

44

CONCLUSION
Our work and the results obtained so far are very encouraging and reinforce
the conviction that vertical axis wind energy conversion systems are
practical and potentially very contributive to the production of clean
renewable electricity from the wind even under less than ideal sitting
conditions. It is hoped that they may be constructed used high-strength, lowweight materials for deployment in more developed nations and settings or
with very low tech local materials and local skills in less developed
countries. The Savonius wind turbine designed is ideal to be located on top
of a bridge or bridges to generate electricity, powered by wind. The elevated
altitude gives it an advantage for more wind opportunity. With the idea on
top of a bridge, it will power up street lights and or commercial use. In most
cities, bridges are a faster route for everyday commute and in need of
constant lighting makes this an efficient way to produce natural energy

FUTURE DEVELOPMENTS
The development of effective alternators and dynamos can be used to
harness wind energy from relatively small winds. The use of materials
like Acrylic Plastic Sheets can be used to develop low cost VWAT

45

BIBLIOGRAPHY
Eggleston, David M. Wind Turbine Engineering Design. Van Nostrand
Reinhold, 1987.
Hunt, Daniel V. Wind power: A Handbook on Wind Energy Conversion
Systems. Van Nostrand Reinhold, 1981.
Kovarik, Tom, Charles Pupher, and John Hurst. Wind Energy. Domus
Books, 1979.
Park, Jack. The Wind Power Book. Cheshire Books, 1981.
Putnam, Palmer Cosslett. Power from the Wind. Van Nostrand Company,

46

PHOTOS

47

BLADE PROFILE

48

CYCLE DYNAMO

49

50