Experimental Performance Evaluation of 500W mini Wind mill
Mr. P. D.Haridas,
Industrial Training Institute (Girls)
Solapur, Maharashtra
pradipdharidas@yahoo.com
Prof. N.N. Shinde*
*Co-ordinator, Department of Energy Technology,
Shivaji University, Kolhapur
energyunishivaji@gmail.com
ABSTRACT
Wind energy has proven a best alternative to
fossil fuel based energy and is environmental friendly
also. In India, a small family of having 4/5 persons
consumes about 1.5 Kw electricity per day. Hence
there is a huge potential for mini wind mills &
necessity of developing horizontal axis wind turbine
machine of capacity of 200 watts to 1500 watts, which
can run on average wind velocity of 2 to 3 m/s.
Authors has made an attempt to resolve this problem.
This paper deals with the design, manufacture and
testing of HAWM of 500 W for performance
evaluation for domestic application. The rotor blades
are aerodynamically designed and are made up of
FRP weighing 500 gm. each. The Permanent Magnet
Generator is having 16 poles. The machine is
dynamically balanced before fitting on pole at roof top
for testing. During performance evaluation it is
observed that the machine runs on 2.7 m/s, against the
design cut in wind speed of 3.5 m/s.
During field experiments, it has been
observed that, small horizontal axis wind turbine
reached maximum 957 RPM and developed 19.2
amperes current during the continuous testing period
of 180 hours as per code of standards. This prototype
has potential for commercializing the product for
domestic application.
KEY WORDS
– Renewable energy, horizontal axis wind machine,
aerodynamic design of rotor blades, PMG for HAWT,
Performance curves
978-1-4673-6150-7/13/$31.00 ©2013 IEEE
Mr. Atul A. Sagade,
Solar thermal research laboratory,
New Satara College of engineering & Management
(Polytechnic),
Korti-Pandharpur - 413304,
Maharashtra, India
atulsagade@gmail.com
Mr. Satish Aher
Amrutvahini College of engineering,
Sangamner-422608, Maharashtra, India
Satish1910@gmail.com
INTRODUCTION
This project envisions the design and
appropriate implementation of 500W electricity
producing wind turbine. The turbine will ideally be
designed for implementation in remote communities to
power individual house’s electrical needs or to be fed
directly into a local energy grid. The aim of the project is
to design a wind energy converter comprising of a rotor
system, and a generator that will successfully produce
the specified electrical power. As wind turbines are not
new technology the project will be aimed at proving and
optimizing a system based on existing technology to
achieve the desired power output. Considerations are
taken in designing the turbine with an effective post life
recycling scheme in mind so that there will be minimum
wastage of resources once the turbine is made redundant.
In the last one decade, wind power has emerged
as the biggest renewable energy source in the world.
Presently wind power alone is generating almost 26,000
MW capacities globally and the estimated potential of
wind power within India itself is 45,000 MW. In May
2005, India surpassed Denmark and attained 4th position
in the world after Germany, Spain and US in wind power
generation capacity. The Grid-connected wind power
generation capacity has now crossed 5,300 MW, more
than half of which has been achieved in last two years
alone with a capacity addition of 2,850 MW. Large
commercial Wind Turbines ranging from 300 KW to 2
MW capacities are being installed all over the country
side for supplementing the grid to meet the urban,
industrial and commercial power requirement.
The main aim of this study is
312
 1) To collect the Design data for 0.5 KW
HAWT.
2) To understand the Design methodology.
3) To understand the technology and
manufacturing method.
4) To evaluate the barriers in development
process.
5) To understand the test methodology and
performance evaluation techniques.
6) To design cost effective system with better
efficiency.
LITERATURE SURVEY
SWTs are generally classified as having an output power
of less than 100 kW. The smallest units generate about 50
W, and are often used for educational purposes. The
international standards for SWT design is IEC 61400-1
Ed.3.0 (2005) part-1 and IEC 61400-3 Ed.2.0 (2006). This
equates to a rotor diameter of up to 16 m. Further
classification of SWTs is by the orientation of the rotor
axis, and the aerodynamic principle employed, that is, lift
or drag. Arrays of different design configurations have
been developed. (Manwell, McGowan & Rogers
2002).[1]
The different HAWT and VAWT designs make use
of the aerodynamic principles of drag and lift. Drag and
lift forces on a body immersed in an oncoming fluid flow,
are the forces acting on the body in the directions parallel
and perpendicular to the flow, respectively. Rotors using
aerodynamic lift achieve higher power coefficients than
drag devices. The power coefficient is the ratio of the
extractable mechanical power to the power contained in
the air stream (Hau 2006). Normally, HAWTs utilise
aerodynamic lift, although other drag-type designs exist.
Savonius turbines are dragtype devices, while the
Darrieus design uses lift. [2]
A. Sedaghat , M. Mirhosseini used Blade Element
Momentum theory (BEM) to design a HAWT blade for a
300 kW horizontal axis wind turbine. The airfoil is RISØ-
A1-18, produced by RISØ National Laboratory,
Denmark. Desirable properties of the airfoil developed by
the authors are related to enhancement of aerodynamic
and structure interactions. Authors used parameters wind
tip speed ratio, nominal wind speed and diameter of rotor
for designing the airfoil. BEM has been used for obtaining
maximum lift to drag ratio for each elemental constitution
of the blade. Authors plotted the blade design
distributions versus rotor radius for BEM results and
suggest that the blade shape then can be modified for ease
of manufacturing, structural concerns, and to reduce
costs.[3]
Baku M. Nagai et.al designed and examined prototype
3 kW horizontal upwind type wind turbine generator of
4 m in diameter under real wind conditions. The machine
was designed based on the concept that even small wind
turbines should have a variable pitch control system just
as large wind turbines, especially in Japan where
typhoons occur at least once a year. Authors applied two
control methods the variable pitch angle, and regulation
of the generator field current. The characteristics of the
generator under each rotational speed and field current are
investigated in the laboratory. Authors describe the
performances of the wind turbine in terms of the functions
of wind turbine rotational speed, generated outputs, and
its stability for wind speed changes. The expected
performances of the machine have been confirmed by the
authors under real wind conditions and compared with
numerical simulation results. The wind turbine showed a
power coefficient of 0.257 under the average wind speed
of 7.3 m/s.[4]
John F. Hall, Dongmei Chen explores that Variable Ratio
Gearbox (VRG) can be used in the drive train of a small
to medium-size wind turbine to improve aerodynamic
efficiency. Currently, all commercially-available wind
turbines operate using a fixed-gear ratio between the
turbine rotor and electrical generator. A VRG allows wind
turbines, with a constant-speed generator, to discretely
vary rotor speed and to achieve greater aerodynamic
efficiency. The authors’ previous results demonstrate the
viability of the VRG design. This research quantifies the
gain in efficiency for a VRG-enabled wind turbine based
on wind data from representing all seven wind
classifications. Author’s findings suggest that the VRG
can benefit all wind turbines, irrespective of wind class,
with some wind profiles in the study experiencing gains
greater than 10%.[5]
Onder Ozgener study presents an energy analysis of the
1.5 kW small wind turbine systems (SWTS) with a hub
height of 12 m above ground level with a 3 m rotor
diameter in Turkey. The SWTS was installed at the Solar
Energy Institute of Ege University (latitude 38.24 N,
longitude 27.50 E), Izmir, Turkey. NACA 63-622 profile
type (National Advisory Committee for Aeronautics)
blades of epoxy carbon fiber reinforced plastics were
used. Test results show that when the average wind speed
is 7.5 m/s, 616 W and 76 Hz electricity is produced by the
alternator.[6]
313
Chalmers, B.J. Spooner discussed the development of an bush. Then this hub bush is fitted on the main shaft of the
axial-flux permanent-magnet generator for a gearless generator. This hub bush is screwed with shaft. Generator
wind energy system which aims to demonstrate the is fitted in the nacelle. Complete assembly of slip ring is
feasibility of integrating wind and photovoltaic energy fitted in the nacelle. Cable is drawn through the yawing
converters for the generation of electricity and to achieve system and through the tower by drilling the hole to the
optimum exploitation of the two energy sources. The tower. Yawing system is welded to the nacelle base plate.
design, construction and test results of a 5 kW, 200 A bearing is fitted in the system for yawing. The complete
rev/min permanent-magnet generator, to form a 10 kW assembly of rotor, nacelle with yawing system is then
pilot power plant with a 5 kW photovoltaic array, has fitted on the tower top plate by means of the yawing
been presented by the authors [7] system base plate. Steel strips are welded to the tower
The study of Spooner et.al describes Radial-field, multi from back side for fitting it to the column at the roof of
pole, permanent magnet synchronous machines as direct- the DOT building.
coupled generators for large grid-connected wind SPECIFICATION OF WIND MACHINE
turbines. Power ratings from below 100 kW to more than TO BE MANUFACTURED
1 MW and pole numbers of 100 to 300 may be required.
Following are the specifications of the Small
Authors explained that modular construction reduces the
Wind Turbine machine which to be manufactured
detailed design effort, and the number of drawings and
Number of Blades-3 Blades
tools needed. Module designs are presented by the authors
Generator Type-Permanent Magnet DC
which can be used for a wide range of machine designs.
The arrangement eases assembly of the magnetised parts Generator sp. - 24 Volt, 20 Amp.
and creates a machine with low reactances and high Nacelle size -300mm x200mmx200mm
efficiency. [8] Tail length -700 mm
Hiroyuki Hirahara et.al reported performance of a Rated Power -500 Watts
very small wind turbine system for multi-purposes.. The Voltage -24 Volts
rotor diameter of the turbine is 500 mm. Authors carried Tower type -Tubular
out the tests of the energy output, turbine speed, power Tower material-Mild Steel
coefficient, and torque of turbine for a wide rage of free Tower size -100 mm Diam., 3 m height
stream velocity. The flow around the wind turbine and the Weight -30 kg (without pole)
influence of the turbulence were investigated with a
particle image velocimetry by them. Authors General characteristics of 500 watts small wind turbine
experimentally obtained power coefficient was 0.4 in Cut in wind speed 2.7 m/s
maximum and 0.36 in the rated running condition, Rated wind speed 10 m/s
respectively. The tip speed ratio corresponding to the Cut-out wind speed 15 m/s
optimum driving condition was 2.7. Authors also Rotor situation Up wind
compared results with the other commercial turbines; the Number of blades Three
performance was excellent at a slow turbine speed. It was Blade material FRP
confirmed that the actual flow passed through the blades Rotor diameter 0.55 m
was about 20% slower than the ideal flow. Tip vortex Generator PMDC
shed from the blade tip was also visualized clearly. [9] Rated power 500 Watts
Voltage 24 Volts
TEST SETUP Tower Tubular concrete fitted
Tower Material Mild Steel
Design a SWT assembly including rotor blades, generator
Tower Height 3 metre
and tower using commercially available parts. Small
Height of wind turbine 30 m (Building + pole ht.)
Wind Turbine assembly is assembled . Rotor blades are
from ground
fitted on blade fitting plate by means of nut bolts. This
Yawing system Fitted at top of the pole
blade fitting plate is already fitted to hub plate. Hub plate
System regulation Rotor tilting
is fitted on the hub bush , means all the assembly of rotor
Emergency brake Generator short circuit
blades, blade fitting plates, hub plate is fitted on the hub
Weight 30 Kg without pole

314

INSTALLATION AND COMMISSIONING
The proposed site of installation of the small
wind turbine machine is at the roof of the International
school of Technology, Department of Technology
building of the university. The wind data was studied for
the perfect installation. It was found that the wind speed
over the year ranges from 1 to 15 m/s. This data was
studied already by previous 1 Kw wind machine design
project. So it is easy to find the exact site or location for
the installation. Assembly of the complete machine and
Commissioning of the project is carried out at the roof of
the International school of Technology, Department of
Technology building of the Shivaji University.
Arrangement of Tower fixing, at the particular location
which one is selected for the installation of small wind
turbine machine, the vertical column of 2.5 ft x 2.5 ft x
2.5 ft was available and the tower was fixed parallel to the
previous column by constructing the other column having
size 2.5 ft x 1 ft x 2.5 ft, around the tower. Also the tower
is hinged and welded by the heavy angles, to the previous
column steel bars. Both the foundation and fixing is done
to avoid the vibrations at the time of the heavy wind
speed.
EXPERIMENTAL DATA & CALCULATIONS
Prototype of 500W wind mill has been tested
under no load & full load conditions. This paper
represents the results for full load conditions.
One-dimensional theory considers a moving
stream of air passing through a circular disk (Figure 3.3).
The energy in the moving stream of air is given by the
kinetic energy equation 1
Ek = ½ mVwind2 -------------------------------- (1)
Where
E k = kinetic energy of the air stream (J)
m = mass of the air (kg)
v wind = velocity of the air (m/s)
The power in this air stream is given by equation
2 and 3 energy per unit time
P = E k / t = ½ mVwind2 / t --------------------- (2)
= ½ m/t Vwind2 = ½ m Vwind2 (W) ---------- (3)
Where m& is the mass flow rate of the air
stream, and is given by equation 4
m = ρ A rotor ν wind (Kg/s) ---------------------- (4)
Thus the power of a moving stream of air, with density ρ
and velocity v, that flows through a disk of area A is given
by equation 5
P = ½ ρ A rotor ν wind 3 ------------------------- (5)
This expression gives the power available in a
moving stream of air, but the power that can be extracted
from this moving stream is what is required. Thus we can
consider a ratio, known as the power coefficient, between
the power in the wind, and the power of the rotor is given
by equation 6
Cp = Rotor Power / Wind Power ----------- (6)
In theory, the maximum possible rotor power
coefficient is given by the Betz Limit, CP = 16/27 = 0.593
(Manwell, McGowan & Rogers 2002). In practice,
however, further inefficiencies cause a decrease in the
maximum achievable output power:
• Rotation of the wake after the wind has passed
through the rotor
• The number of blades used, and the losses at the
blade tips
• Non-zero aerodynamic drag, as assumed by the
1D theory
• Electrical losses, such as heat loss through the
transmission cabling or inefficiency of the slip
rings
So the power output of the SWT can be
summarized by equation 7
P = Cp X η X ρ A rotor νwind3------------- (7)
Where
CP = power coefficient of the blades
η = efficiency of the turbine, considering all mechanical
and electrical losses
To be able to achieve the design output of 500
W, it is necessary to determine the rotor power
coefficient, estimate the overall turbine efficiency,
evaluate the air density and wind speed at the target
location, and specify a rotor diameter. Sections 3.4 and
3.5 will look at the target location, and the required wind
parameters will be identified. Section 3.6 will consider the
SWT turbine design in detail, and the specifications of the
device will be determined.
Table 1 show experimental data collected at
dept. of technology, Shivaji University, Kolhapur
Table 1:- experimental data collected
315
 Speed Speed
Sr Wind Cur Sr Wind Cur
of Volt Actual Th. of Volt Actual Th.
. Spee rent Efficiency . Spee rent Efficiency
Turbi age Power Power Turbi age Power Power
N d (am (%) N d (am (%)
ne (V) (W) (W) ne (V) (W) (W)
o. (m/s) p) o. (m/s) p)
(rpm) (rpm)
1 1.2 72 20.5 0.7 14.35 1.07 7.46 42 2 105 20.7 1.7 35.19 4.96 14.09
2 1.9 122 21.2 1.5 31.8 4.25 13.37 43 2.5 130 20.8 2.3 47.84 9.68 20.24
3 0.9 65 21 0.5 10.5 0.45 4.30 44 2.6 130 20.8 2.3 47.84 10.89 22.77
4 0.7 52 21.2 0.2 4.24 0.21 5.01 45 1.5 82 20.5 1.2 24.6 2.09 8.50
5 0.6 52 21.3 0.19 4.047 0.13 3.30 46 1.2 82 20.5 1.2 24.6 1.07 4.35
6 1.7 90 21.5 1.2 25.8 3.04 11.80 47 3.9 204 20.9 3.9 81.51 36.77 45.12
7 1.5 75 21.1 1 21.1 2.09 9.91 48 2.1 130 20.9 2.5 52.25 5.74 10.98
8 2 110 21.2 1.7 36.04 4.96 13.76 49 2.9 152 21 3 63 15.12 24.00
9 2.5 130 21.1 3.4 71.74 9.68 13.50 50 1.6 105 21 1.5 31.5 2.53 8.06
10 1.2 79 21 0.7 14.7 1.07 7.28 51 3.8 182 21.1 3.6 75.96 34.02 44.78
11 0.5 60 20.7 0.17 3.519 0.07 2.20 52 4.7 241 21.1 4.8 101.28 64.37 42.55
12 1.4 75 20.8 1 20.8 1.70 8.17 53 4 235 21.2 4.6 97.52 39.68 40.68
13 4.4 279 21.1 5.3 111.83 52.81 47.22 54 3.5 212 21.1 4.2 88.62 26.58 29.99
14 2.3 145 21.1 3.1 65.41 7.54 11.53 55 3.7 215 21.1 4.2 88.62 31.40 35.43
15 4.5 270 21.2 5.3 112.36 56.49 50.28 56 4 242 21.2 4.7 99.64 39.68 39.82
16 3 192 21 3.7 77.7 16.74 21.54 57 3.3 198 21 3.8 79.8 22.28 27.92
17 3.7 195 21.3 3.4 72.42 31.40 43.36 58 2 126 20.8 2.2 45.76 4.96 10.83
18 2.7 142 21.1 2.2 46.42 12.20 26.28 59 3.4 178 20.8 3.2 66.56 24.36 36.61
19 2.9 171 21.2 3.1 65.72 15.12 23.00 60 4 235 20.9 4.5 94.05 39.68 42.19
20 4.6 295 21.4 5.9 126.26 60.34 47.79 61 5.7 447 21.5 8.6 184.9 114.81 43.09
21 5.4 342 21.7 6.5 141.05 97.62 45.21 62 4.3 381 21.4 7.5 160.5 49.29 30.71
22 4.6 280 21.7 5.5 119.35 60.34 50.56 63 1.5 106 20.9 1.2 25.08 2.09 8.34
23 0.8 71 21.1 0.5 10.55 0.31 3.00 64 2 120 20.9 2 41.8 4.96 11.86
24 1.1 78 21.2 0.6 12.72 0.82 6.48 65 3.6 223 21.2 4.2 89.04 28.92 32.48
25 1.2 78 21.2 0.6 12.72 1.071 8.42 66 3.7 223 21.2 4.2 89.04 31.40 35.27
26 3.4 190 21.2 3.8 80.56 24.36 30.24 67 2.8 202 21.3 3.9 83.07 13.61 16.38
27 0.9 75 20.7 0.5 10.35 0.45 4.36 68 0.9 105 21.5 1.1 23.65 0.45 1.91
28 0.5 42 20.5 0.1 2.05 0.07 3.78 69 4.3 262 21.4 5.2 111.28 49.29 44.29
29 2.7 151 20.5 2.9 59.45 12.20 20.52 70 3.4 212 21.5 3.9 83.85 24.36 29.06
30 1.6 97 20.6 1.2 24.72 2.53 10.27 71 1.7 127 21.5 2.1 45.15 3.04 6.74
31 3.9 203 21.3 3.7 78.81 36.77 46.66 72 5.6 462 21.7 9.4 203.98 108.88 53.37
32 4 261 21.4 4.3 92.02 39.68 43.12 73 4.6 325 22.2 6.4 142.08 60.34 42.47
33 2.2 132 21.4 2 42.8 6.60 15.42 74 4.7 325 22.2 6.4 142.08 64.37 45.30
34 4.5 281 21.6 5.6 120.96 56.49 46.70 75 3.4 241 22.3 4.8 107.04 24.36 22.76
35 4 269 21.7 5.1 110.67 39.68 35.85 76 3.6 250 22.3 4.9 109.27 28.92 26.47
36 1.1 60 20.9 0.5 10.45 0.82 7.89 77 4 307 22.5 5.9 132.75 39.68 29.89
37 2 95 20.9 0.6 12.54 4.96 39.55 78 3.2 262 22.4 5 112 20.31 18.13
38 1.6 70 20.8 0.3 6.24 2.53 40.69 79 2.7 168 22.3 3 66.9 12.20 18.24
39 0.9 55 20.7 0.4 8.28 0.45 5.45 80 4.4 302 22.3 5.9 131.57 52.81 40.14
40 0.7 48 20.5 0.3 6.15 0.21 3.45 81 2.5 182 22.4 3.1 69.44 9.68 13.95
41 1.9 101 20.7 1.7 35.19 4.25 12.08 82 5.3 381 22.4 7.6 170.24 92.30 54.21

316
RESULTS & DISCUSSION:
Variation of turbine speed with current

10
Variation of speed of turbine with Wind velocity
500

8
Speed of Turbine(RPM)

400
6

Current (A)
300
4

200
2

100 0

0 100 200 300 400 500

0
0 1 2 3 4 5 6 Turbine Speed (RPM)
Wind Speed(m/s)

Fig.3 Current Vs RPM

Fig.1 Wind Speed Vs RPM Graph shows Current Vs RPM . RPM is
plotted along X- axis and Current along Y-axis. As
the Turbine speed increases linearly from 0 to
Fig. 1 shows variation of turbine speed with
600rpm the current increases from 0 to 10 Amperes.
wind speed. It is common phenomenon that as wind
speed increases speed of rotation of turbine enhances.
With the system described it is possible to generate PERFORMANCE COMPARISON
sufficient amount of electrical energy.
Variation of Therotical power with wind speed
120

100
Variation of Current produced with wind velocity
Therotical Power (W)

10 80

60
Current (ampere)

8
40

6
20

4 0

0 1 2 3 4 5 6
2
Wind Speed (m/s)

0
0 1
Fig.2 Wind Speed Vs Current
Graph shows Wind Speed Vs Current. Wind
Speed is plotted along X- axis and Current along Y-
axis. As the wind speed increases linearly from 0 to 6
m/s the current increases from 0 to 10 Amperes.
Fig.4 Wind speed Vs theoretical Power
2 3 4 5 6
Graph shows Wind Speed Vs Theoretical
Wind Velocity (m/s)
power. Wind Speed is plotted along X- axis and
Theoretical power along Y-axis. As the wind speed
increases linearly, from 0 to 6 m/s the power
increases from 0 to 120 Watts.

317
 cut in speeds. The mounting plates, power
Variation of power with wind speed transmission, coupling, shaft bearings are designed
200
based on regular practices of ASME, ASTM and BIS
standards.
While tested as per guideline procedures of IEC
150 61400-12-1 standards for performance
Actual Power (W)

characterization, it is found that the small wind

100
machine manufactured and developed has resulted
with one of the best average performance among
available small wind turbines. Though it was
50 designed for 10-14m/s rated speed the actual
maximum efficiency is observed at 8-10m/s wind
0
velocities. The machine has started at the cut in speed
of 2.7m/s. Due to limitations of wind velocities at
0 1 2 3 4 5 6 site, it is not possible to calculate the performance at
Wind Speed (m/s) higher wind speeds above 12m/s. The lower cut in
wind speed and maximum efficiency at lower wind
speed than designed rated speed could be because of
Fig. 5 Wind speed Vs actual Power selection of aerofoil section NACA 4415, light
weight rotor blades, bearing and tail vane selection
Graph shows Wind Speed Vs Actual power. and also low rpm high permanent magnet strength
Wind Speed is plotted along X- axis and Actual generator used during the testing. The performance
power along Y-axis. As the wind speed increases testing at higher wind speed is required, since
linearly, from 0 to 6 m/s the power increases from 0 maximum rotor blade tip rpm observed is at 957 rpm.
to 200 Watts. The further wind speed testing requires safety
measures.

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