(SAVONIUS) VERTICAL AXIS WIND MILL

DESIGN AND FABRICATION OF

(SAVONIUS) VERTICAL AXIS WIND MILL

Submitted in partial fulfillment of the requirements for the degree of

Bachelor of Engineering

By

Vade Abhay R. 200356

Iyer Anand B. 200316

Yadav Dinesh R. 200361

Khan Sahir Z. 200321

Under the guidance of

Prof.Nilaj Deshmukh (Internal)

Department of Mechanical Engineering

Fr. C. Rodrigues Institute of Technology

Sector – 9A, Vashi, Navi Mumbai – 400 703

UNIVERSITY OF MUMBAI

May, 2007

Certificate of Approval

Project Entitled: DESIGN AND FABRICATION OF WIND MILL

Submitted by:

Vade Abhay R. 200356

Iyer Anand B. 200316

Yadav Dinesh R. 200361

Khan Sahir Z. 200321

In partial fulfillment of the degree of Bachelor of Engineering in “Mechanical

Engineering” is approved.

Guides: Examiners:

______________________ 1. Internal: _________________

2. External: _________________

ACKNOWLEDGEMENT

We take this opportunity to express our sincere gratitude towards Prof. Nilaj Deshmukh,

of Mechanical Department, Fr. C. Rodrigues Institute of Technology for his valuable

guidance, encouragement and help during the course of this project. His remarks and

suggestions gave us direction and made us understand the subject better.

We are thankful to K.P. Rajesh, Workshop in charge and Moreshwar Kor, Machine tool

Instructor, work shop, Fr. C. Rodrigues Institute of Technology who was the constant

source of inspiration and guidance to us. His valuable knowledge and experience helped

us get through all the difficulties in our project.

We would like to thank concerned authority of central library of Fr. C. Rodrigues

Institute of Technology for providing us with the various literature material required for

our project work.

We would also like to thank the staff of Mechanical Dept. of Fr. C. Rodrigues Institute of

Technology for their assistance.

Finally, before ending, we would like to express our true gratitude to all those involved

directly or indirectly in our project.

Vade Abhay R. 200356

Iyer Anand B. 200316

Yadav Dinesh R. 200361

Khan Sahir Z. 200321

ABSTRACT

Through the next several decades, renewable energy technologies, thanks to their

continually improving performance and cost, and growing recognition of their

Environmental, economic and social values, will grow increasingly competitive with

Traditional energy technologies, so that by the middle of the 21st century, renewable

Energy, in its various forms, should be supplying half of the world’s energy needs."

We has selected this as our final year project so as to begin thinking towards

power generation through clean sources such as wind. Power generation in our country is

very low at present. Industrially developed states like, Maharashtra is suffering through

major power shortages, and this is a signal of major crises. Even in cities like Mumbai

peoples are suffering from power cuts.

We knew that this project does not reflect any new discovery; but our intention is

that residential societies should install such wind mills on the terrace to tackle with the

power cuts and become independent unto certain amount.

So we have begun it with our college. As our college is near a creek thus good location

for a wind mill.

In this project wind turbine charges a 12 volt battery and runs various 12 volt

appliances. We have fabricated the small scale wind turbine on the basis of design

calculations and made changes in design to track it with manufacturing constraints.

Chapter 1

Introduction

Through the next several decades, renewable energy technologies, thanks to their

continually improving performance and cost, and growing recognition of their

Environmental, economic and social values, will grow increasingly competitive with

Traditional energy technologies, so that by the middle of the 21st century, renewable

Energy, in its various forms, should be supplying half of the world’s energy needs."

The cost of wind-generated electric power has dropped substantially. Since 2004,

according to some sources, the price in the United States is now lower than the cost of

fuel-generated electric power, even without taking externalities into account. In 2005,

wind energy cost one-fifth as much as it did in the late 1990s, and that downward trend is

expected to continue as larger multi-megawatt turbines are mass-produced. Wind power

is growing quickly, at about 38%, up from 25% growth in 2002. Wind power is the

fastest growing form of electricity generation on a percentage basis.

Wind energy conversion systems convert the power in the wind to rotational shaft power

and to electricity by coupling a generator to the unit.  Wind “turbines” is wind electric

power units, and are used throughout the world. Commercial wind turbines range from a

few hundred watts to about 20 kilowatts for rural applications.  Units designed for grid

connection are available in the range of 20 kilowatts to over one megawatt. Where annual

average wind speeds exceed about 5 meters per second, residential and village-scale wind

turbines can provide electricity at costs competitive with or below those of diesel

generators, and can be used in stand-alone applications not requiring a local power

distribution system. [3].

1.1 Aim of the project

Our aim was to build wind turbine which charges a 12 volt battery and runs various

12 volt appliances. By building this project we want drive the attention of peoples

towards power generation through renewable sources so as to tackle problem of power in

our country which is suffering from power shortages. With the help of such project

various sections like residential, industrial, commercial etc. can become independent

from supply of power from electricity board unto certain extent.

1.2 Problem description

In this project the main aspect is how the wind energy is utilized in effective way for

power development by running generator. For this a system is to be made which will

convert the wind force in rotational motion of generator.

The system usually contains rotor blades on which wind strikes and which converts this

force of the wind into rotational motion of the shaft which is connected to the shaft of the

generator.

Also for holding this system a rigid structure is to be building which not only hold this

system but also save it from damage. For holding this rigid structure a very strong base is

to be developed which should be able to hold this complete system under various wind

conditions.

Developed wind mill can effectively work in areas of low wind speed.

Chapter 2

Literature survey

The knowledge of availability of required components and their working is essential for

implementation of the project. This chapter provides information about the wind mill

theory and types which is important for designing of wind mill.

Vertical-axis wind turbines (VAWT) are a type of wind turbine where the

main rotor shaft runs vertically. VAWTs work somewhat like a classical

water wheel in which water arrives at a right angle (perpendicular) to the

rotational axis (shaft) of the water wheel. Vertical-axis wind turbines fall

into two major categories: Darrieus turbines and Savonius turbines.

Savonius Turbine

invented in Finland, the Savonius turbine is S-shaped if viewed from above.

This drag-type VAWT turns relatively slowly, but can produce a high

torque. It is useful for grinding grain, pumping water and other works that

need high torque, but if this kind of turbine connected with

electric generator, it only can

produce a little electricity

Turbine

The commonest VAWT is a Savonius VAWT which is an

extended version of an anemometer (wind speed measuring

tool). VAWTs can offer up to 15% efficiency and they work

equally well no matter which direction the wind is coming from.

2.1 Introduction

We all know about non conventional energy resources these are the sources of energy

which are abundant on our earth but we have a doubt why we call this as non-

conventional energy sources because they are also going to be depleted at the end of our

planet therefore why not to call them as omnivore sources of energy but left it we will

call as people calls so there are many non conventional energy sources like solar energy,

wind energy, air energy etc.

Wind power is a renewable resource, which means using it will not deplete the earth's

supply of fossil fuels. It also is a clean energy source, and operation does not produce

carbon dioxide, sulfur dioxide, mercury, particulates, or any other type of air pollution, as

do conventional fossil fuel power sources.

The development of wind turbines has made a significant contribution to human

achievement and technological advancement throughout history. With an ever-increasing

demand for limited energy resources, and global concern about pollution and

environmental damage arising from fossil fuels, wind turbines may begin to assert an

ever-increasing role during the next century and beyond. [1]

2.2 Theory

Air current turbines work, in principle, much like windmills, but driven by flowing air

rather than air. They can be installed in the hilly places with high air current velocities, or

in a few places with fast enough continuous ocean currents, to take out energy from these

huge volumes of flowing air. These flows have the major advantage of being an energy

resource, which is mostly as predictable as the tides that cause them, unlike wind or wave

energy, which respond to the more random quirks of the weather system. It is also

beneficial to reduce the costly power cables, which carry current to coastal areas as they

can be benefited directly by supplying power.

Wind energy is abundant, renewable, widely distributed, cleans, and mitigates the

greenhouse effect if it is used to replace fossil fuel derived electricity.

Now a day most of the country used Thermal energy and Fossil energy for generating

electricity but raw material used for such energy is limited hence in future and in present

scenario also Windmill have its own importance. [1]

Working of wind mill

Fig, 2.1 working of wind mill [2]The working of wind mill is very simple as the air comes in the structure the working

blades rotates which is connected to main rotor shaft by the supporting arms the main

rotor is coupled to a generator from where we can get the output.

The power in the wind can be extracted by allowing it to blow past moving wings that

exert torque on a rotor. The amount of power transferred is directly proportional to the

density of the air, the area swept out by the rotor, and the cube of the wind speed.

The mass flow of air that travels through the swept area of a wind turbine varies with the

wind speed and air density. As an example, on a cool 15°C (59°F) day at sea level, air

density is about 1.22 kilograms per cubic meter (it gets less dense with higher humidity).

An 8 m/s breeze blowing through a 100 meter diameter rotor would move about

76,000 kilograms of air per second through the swept area.

The kinetic energy of a given mass varies with the square of its velocity. Because the

mass flow increases linearly with the wind speed, the wind energy available to a wind

turbine increases as the cube of the wind speed. The power of the example breeze above

through the example rotor would be about 2.5 megawatts.

As the wind turbine extracts energy from the air flow, the air is slowed down, which

causes it to spread out and diverts it around the wind turbine to some extent. [2].

Advantages and disadvantages of wind mill

It has many advantages they can be categorizing as:

Economical advantages

Earns tradable emission credits

Scalable power cost

No fuel costs

Inexpensive

Local transmission

Competitive capital costs

Green pricing

Ecological advantages

Global climate change has become a catalyst for the social and political demand for

sustainable energy sources. This combined with the high cost of extending electricity

grids to rural areas and the decreasing price of stand-alone power systems is a significant

incentive to the rise of locally generated energy.

The windmill communities large and small, to generate electricity without emitting

greenhouse gases of any kind or impacting the local marine environment. Unlike

conventional barrage systems, the windmill relies on ocean currents rather than air

amplitude to generate electricity. The array of slow moving turbines allows air and fish to

flow freely and safely through the structure. Larger marine mammals will be prevented

from contact with the rotary foils by a protective fence, and further protected by a backup

auto-breaking system controlled by sonar sensors. [2].

Disadvantages of wind mill

There are less disadvantages as compared to advantages one of the disadvantage is that

for its installation high current zone is required then its initial cost is high about 3 to 3.5

crore. There are chances of breaking of mill during severe weather conditions like in case

of tsunami. [2].

2.3 Types

Windmills can be classified same like windmills they can be classified on the basis of

axis of rotation they are: -

Horizontal axis wind mill

Vertical axis wind mill

Horizontal axis wind mill

Fig.2.2 Horizontal axis wind mill [1].

Its design consist of a main rotor shaft which is driven by hydrofoil blades which rotate

due to incoming air in turbine duct then this rotor shaft is coupled to generator in an

coupling chamber .the generator is kept above air level in an machinery enclosure from

there we can get the output the & utilize it for various purpose.

All existing HAWTs (or Horizontal Axis Wind Turbine) have the main rotor shaft and

generator at the top of a tower, and must be pointed into the wind by some means. Small

turbines are pointed by a simple wind vane, while large turbines generally use a wind

sensor coupled with a servomotor. Most have a gearbox too, which turns the slow

rotation of the blades into a quicker rotation that is more suitable for generating

electricity. Since a tower produces turbulence behind it, the turbine is usually pointed

upwind of the tower. Turbine blades are made stiff to prevent the blades from being

pushed into the tower by high winds. Additionally, the blades are placed a considerable

distance in front of the tower and are sometimes tilted up a small amount.

Downwind machines have been built, despite the problem of turbulence, because they

don't need an additional mechanism for keeping them in line with the wind, and because

in high winds, the blades can be allowed to bend which reduces their swept area and thus

their wind resistance. Because turbulence leads to fatigue failures and reliability is so

important, most HAWTs are upwind machines.

Vertical axis wind mill

Fig 2.3 Darrieus-design vawt [1].

The vertical axis windmill consists of twin axial flow rotors of 15m to 20m in diameter,

each driving a generator via a gearbox much like a hydroelectric turbine or a wind

turbine. The twin power units of each system are mounted on wing-like extensions either

side of a tubular steel monopile some 3m in diameter, which is set into a hole, drilled into

the seabed.

Vertical axis turbines (or VAWTs) have the main rotor shaft running vertically. The main

advantages of this arrangement are that the generator and/or gearbox can be placed at the

bottom, on or near the ground, so the tower doesn't need to support it, and the fact that the

turbine doesn't need to be pointed into the wind.

Drawbacks are usually the pulsating torque produced during each revolution, and the

difficulty of mounting vertical axis turbines on towers. This means they must operate in

the slower, more turbulent air flow near the ground, with lower energy extraction

efficiency. [1].

In vertical axis windmills the turbine is positioned so that it rotates along a vertical axis. Changes in wind direction don't tend to effect such a windmill because unlike horizontal axis windmills they don't have to point into the wind for maximum efficiency.

If the wind turns round (as it does sometimes when it is blustery) a normal windmill will slowly come to a stop and then turn the other way, with subsequent loss of power during this period. A vertical axis windmill wont really notice any difference and will continue to produce power without stopping.

We will take the following steps...

1. Build as big a frame as possible. Since the swept area of the blades is

the most important factor for generating power, I want to start with

a big frame for the blades.

2. Find high quality bearings / shaft and mount them to the frame. This is

important because the bearings can be one source of inefficeincy and

reduce the power output. 

3. Make the blade as big and efficient as possible because this

determines how much power we can steal from the wind. Also,

choose a blade style that fits your needs; fast and scary

4. Then we put it all together and let it spin without an dynamo attached.

Analyze the characteristics of the wind turbine in action. We need to

know how many revolutions per minute (RPMs) the turbine will spin

at for a given wind speed. The RPM value at an average wind speed

gives us an idea of how to build the dynamo to fit the turbine. Figure

out what the tip speed ratio (TSR) is so we can calculate the

revolution per minute RPMs at any wind speed.

Build an dynamo that matches the RPM and TSR rating of the turbine. Make

sure the cut-in speed is low enough that it will generate electricity at the

right voltage. And, make sure the dynamo generates the most power at the

RPM range that the wind in your area will spin it at. 

Chapter 3

Objectives and Benefits of project

3.1 Objectives

Our main objective is the build a wind mill in such a way that cost of the wind mill is

easily affordable by common people. So that common people get attracted towards such a

clean source of energy which will give a source of business to the industries which works

as the needs of common people. Due to this many companies will move towards

manufacturing of such wind mill which will reduce cost of wind mill. Thus it will reduce

cost of the power produced by the wind mill.

3.2 Benefits

Following are the benefits of the wind mill

Clean source of energy.

No fuel costs

Inexpensive

Local transmission

Green pricing

Using of small wind turbine will make residential societies independent from

other sources of power.

Running cost is low. [2].

CHAPTER NO

DIFFERENCE BETWEEN HORIZONTAL AXIS AND

VERTICAL AXIS WIND MILL

Wind units can be divided into two major types, horizontal axis and vertical

axis machines. Horizontal machines some times known as HAWT

(Horizontal Axis Wind Turbines) are the traditional conventional design,

they consist of a rotor with one to twenty blades driving a generator or a

pump either directly or through a gearbox, chain or belt system. A tail vane

or fantail is required to direct the machine into the wind. They are usually

more efficient than vertical axis units known as VAWT (Vertical Axis Wind

Turbines). Savonius and Darius are two designs of vertical axis machines.

This type of unit is often not situated on a tower and does not have to be

directed into the wind. Materials and construction are usually cheaper than

horizontal axis machines.

A simple unit can be made by attaching two halves of vertically split oil

barrel to a vertical axis this produces a low speed high torque unit that can

be used for pumping water and through a gearing mechanism, generating

electricity. This design also has the advantage of an aerodynamic effect

called the "magnus principal”, suction is formed by the air moving over the

convex face of the rotor. This means that there is force acting on the face of

the rotor pulling it into the wind. 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.

Chapter 4

Design calculations

Designing of wind mill

Before going to actual designing we must consider following points

Suitable site

Types of wind mill

Aerodynamics design

Overall design of wind mill

Suitable site

While selection of suitable site we must keep a note that it must be placed where

plenty of air flows without obstructions i.e. at a certain elevated height.

Types of wind mill

From different types of wind mill the multiback flow is selected. As we have

sufficient speedy air and also losses for this type of wind mill is minimum.

Aerodynamics design

While studying on the design of wind mill we come to conclusion that blade should

be kept in a certain angle to still away the momentum from the approaching wind.

Thus the wind come horizontally hits the blade which is kept at fixed angle.

Overall design of wind mill

Designs of the components as follows,

4.1 Power capacity

Calculation of Wind Energy and Power

Force = mass x acceleration F = ma (Typical Unit -Newton’s)

Energy = Work (W) = Force (F) x Distance (d) (Typical unit – Joules)

Power = P = W / time (t) (Typical unit –Watts)

Power = Torque (Q) x Rotational Speed (Ω)

Kinetic Energy in the Wind

Kinetic Energy = Work = ½MV2

Where:

M= mass of moving object

V = velocity of moving object

Mass of moving air

M = density (ρ) x volume (Area x distance)

= ρ x A x d

= (kg/m3) (m2) (m)

= kg

= 1 x 0.2826x 0.585

= 0.165 kg

Dia 600mm

585mm

Power in the Wind

Power = Work / t

= Kinetic Energy / t

= ½MV2 / t

= ½(ρ x A x d) V2/t

= ½ρAV2 (d/t) (d/t = Distance/time = velocity)

= ½ρAV3

Power in the Wind = ½ρAV3

V = 2 meters (m) per second (s) m/s

ρ = 1.0 kg/m3

Selecting Rotor diameter, D = 0.6 m.

Rotor radius (Length of blade), R = 0.3 m

A = (∏/4) x D2 = (∏/4) x (0.6)2 = 0.283m2

Power in the Wind = ½ρAV3

Units = (kg/m3) x (m2) x (m3/s3)

= (kg-m)/s2 x m/s

= ½ x1 x 0.283 x 22 N-m/s

= 0.566Watt

Wind Turbine actual Power available considering losses and efficiency: -

Power in the Wind = 0.5 x ρ x A x V3 x Cp x Ng x Nb [1].

Where:

P = power in watts

ρ = air density

A = rotor swept area, exposed to the wind (0.351 m2)

Cp = Coefficient of performance (Cp is the percentage of power in the

wind that is converted into mechanical energy, 0.59 {Betz limit} is the

maximum theoretically, 0.35 practically)

V = wind speed in meters/sec (2 m/s)

Ng = generator efficiency (practically 75%)

Nb = gearbox & bearings efficiency (Assuming 75%).

Hence,

P = 0.5 x 1 x 0.35 x (2)3 x 0.35 x 0.75 = 0.367 Watts

POWER CAPACITY = 0.37 Watts

SAE 1040 SAE (SOCIETY OF AUTOMOBILE ENGINEERING)

10 =Plain carbon steel

40 = 0.4 % of carbon

Following stresses are normally adopted in shaft design

Maxm shear stress = 70 N/mm2

Maxm bending stress = 100 N/mm2

Power = 2 П N T/ 60

0.367 = 2 П x 180 T/ 60

T= 0.0194 N-m

T= 19.42 N-mm

T = 3.14/16 x fs x Ds3

19.42 = 3.14/16 x fs x 203

Fs induced = 0.012 N/ mm2

Fs allowable = 70 N/ mm2

As induced stress is less than allowable the design of shaft dia is safe

The horizontal channel is subjected to bending stress

Stress given by => M/I = fb / y

In above equation first we will find the

moment of inertia about x and y

Axis and take the minimum moment of

inertia considering the channel of

ISLC 75 x 40 size.

l = 40

t = 5

B = 75 b = 65

We know the channel is subject to axial

compressive load

From Rankines formula

Wc = ( fc x A )

1+ a (L/k xx )

Wc = ( 100 x 775 )

1+ 1/7500 (685/1.78 x 5 )

Wc = 61676 N

DESIGN OF C-SECTION

Material: - M.S.

The horizontal channel is subjected to bending stress

Stress given by => M/I = fb / y

In above equation first we will find the

moment of inertia about x and y

Axis and take the minimum moment of

inertia considering the channel of

ISLC 75 x 40 size.

l = 40

t = 5

B = 75 b = 65

We know

the channel is

subject to

axial

compressive load

In column section the maximum bending moment occurs at

channel of section

M = W x L/4 simply supported beam

W

Ra Rb

685 mm

M = 490 x 685/4

M = 83912.5 N-mm

We know

fb = M/Z

Z = t (l x b + (b2/6))

Z = 5 (40 x 65 + (652/6))

Z = 3304 mm3

Now check bending stress induced in C section

fb induced = M/Z

fb induced = 83912.5 /3304 = 25.39 N / mm2

As induced stress value is less than allowable stress value design is safe.

fb = Permissble bending stress = 170 N / mm²

fb induced < fb allowable

Hence our design is

safe.

DESIGN OF WELDED JOINT :

The welded joint is subjected to pure bending moment . so it should be design for

bending stress. We know minimum area of weld or throat area

A = 0.707 x s x l

Where s = size of weld

l = length of weld

A = 0.707 x 5 x ( 75 + 40 + 35 + 58 +35 )

A = 0.707 x 5 x 243

A = 859 mm2

Bending strength of parallel fillet weld

P = A x fb fb = 80 N / mm2

M =83912.5

we know fb = M /Z

Z = BH3 – bh3

----------------------

6H

40 x 753 – 35 x 583

Z = -----------------------------------

6 x 75

Z = 209824

Calculating induce stress developed in welded joint

fb induced = 83912.5 / 209824

= 0.39 N /mm 2

As induce stress is less then allowable stress the design is safe.

DESIGN OF JOINT NUT AND BOLTS TYPE Here the bolt will be double sheared as shown below in the figure --- Arm guide way arm

Shear armResisting area = ( π / 4 x d2) x 2

P . fs = --------------- 2 x π / 4 x d2

490 . fs = ---------------

2 x π / 4 x 102

fs = 3.12 N/ mm2

As induce stress is less then allowable stress the design is safe

As we know

N pulley D dynamo =

N dynamo D pulley

180 15 = 3000 X

x = 15 x 3000 180

x = 250 mm

Dia of shaft pulley = 250 mm

As out put rpm of system is sufficient to develop electricity from dynamo so our transmission design is safe & efficient.

CHAPTER NO

MANUFACTURING PROCESS

The following are the various manufacturing process used in

mechanical engineering.

1) Primary Shaping Process :

The process used for the preliminary shaping of the machine

component is known as primary shaping process.

2) Machine Process :

The process used for giving final shape to the machine

component, according to planned dimensions is known as machining

process. The common operation drilling, boring etc.

3) Surface Finishing Process :

The process used to provide a good shape surface finish for the

machine components are known as surface finishing processes. The

common operation used for the process are polishing, buffing, lapping

etc.

4) Joining Process :

The process used for joining machine components are known as

joining process. The common operation used for this process are

soldering, brazing, welding etc.

5) Process Affecting Change In Properties :

These are intended to import specific properties to material e.g.

heat treatment, hot working, cold rolling etc.

WELDED JOINTS :

Definition :

A welded joint is a permanent joint, which is obtained by the

fusion of the edges of the two parts, to be joined together, with or

without the application of pressure and a filler material.

Welding is intensively used in fabrication as an alternative

method for casting or forging and as a replacement for bolted and

reverted joints. It is also used as a repair medium.

Advantages :

1) The welded structures are usually lighter than riveted structures.

2) The welded joints provide maximum efficiency which to impossible

innervated joints.

3) Alteration and addition can be easily made.

4) As the welded structure is smooth in appearance, it is good looking.

5) In welded structures, tension members are not weakened.

6) In a welded joint has high strength often more than parent metal.

Disadvantages :

1) Since there is uneven heating and cooling during fabrication

therefore the members may get distorted as additional stresses may

develop.

2) It requires a highly skilled labour and supervision.

3) No provision for expansion and contraction in the frame, therefore

there is possibility of cracks.

4) The inspection of welding work is difficult than riveting work.

V - BELT AND ROPE DRIVERS :

V - belt is mostly used in factories and workshops where a great

amount of power is to be transmitted from one pulley to another then

the two pulleys are very near to each other.

The V - belt are made of fabric and cords moulded in rubber and

covered in fabric and rubber. The power is transmitted by the wedging

action between the belt and the v - groove in the pulley as sheave.

Advantages :

1) The drive is positive.

2) Since the v - belts are made endless and there is no joint cable,

therefore the drive is smooth.

3) It provides larger life, 3 to 5 years.

4) It can be easily installed and removed.

5) The operation of the belt and pulley is quiet.

6) The belt have the ability to cushion the shack when the machines

are started.

7) The wedging action gives high value of limiting friction therefore

power transmitted by v - belts is more than flat belts for the same

coefficient of friction, are of contact and allowable tension.

Disadvantages :

1) The v - belt drive connect be used with large centre distances

because of larger weight, for unit length.

2) The v - belt are not so durable as flat.

3) The construction of pulleys for v - belts is more complicated than

pulleys of flat belt.

4) Since the v - belts are subjected to certain amount of creep,

therefore not suitable for constant speed applications.

5) The belt life is greatly influenced with temperature changes, improper belt tension and mismatching of belt lengths.

COMPONENT: FRAME CHANNEL

MATERIAL:- M.S. CHANNEL

MATERIAL SPECIFICATION:-I.S.L.C. 40X.75X5

SR. NO

DESCRIPTION OF OPERATION

MACHINE USED

CUTTING MEASUREMENT TIME

1 Cutting the channel in to length as per dwg

Gas cutting machine

Gas cutter Steel rule 15min.

2 Cutting the channel in to length as per dwg

Gas cutting machine

Gas cutter Steel rule 15min.

3 Filing operation can be performed on cutting side and bring it in

Bench vice File Try square 15 min.

perpendicular C.S.

4 Weld the channels to the required size as per the drawing

Electric arc welding machine

------- Try square 20 min

5 Drilling the frame at required points as per the drawing.

Radial drill machine

Twist drill Vernier calliper 10 min.

NAME OF THE PART – SHAFT

MATERIAL – BRIGHT STEEL

QUANTITY – 1

SR.NO. DETAIL

OPER.

M/C.

USED

TOOL

USED

ACCES MEA.INST.

1. Marking on

shaft

- - - Scale

2. Cutting as

per dwg

Power

hack saw

Hock saw

blade

Jig &

fixtures

Scale

3. Facing both

side of shaft

Lathe

machine

Single

point

cutting

tool

Chuck Vernier

caliper

4. Turning as - - - -

per dwg size

5. Filling on

both end

Flat file Vice -

NAME OF THE PART – SHEET METAL CURVE BLADE

MATERIAL – BRIGHT STEEL

QUANTITY – 3

SR.NO. OPERATION MACHINE TOOL/GAUGE TIME

1. Cut M.S. Sheet of 3mm thickness of required dimensions.

Hand lever cutting machine

Steel rule 1.00

2. It is bent at its edges to fit another bent edge.

Hand press Bending dies 0.30

3. Weld all blade as per dwg

Arc welding mc

Chisel and hammer

0.45

4. All the panels are ----------- Soft hammer 0.45

tested for proper welding

5. It is coated with red oxide and then after painted

Air compressor Red oxide and green paint

0.45

COMPONENT: PULLEY

MATERIAL:- C.I

QUANTITY : - 1

SR. NO

DESCRIPTION OF OPERATION

MACHINE USED

CUTTING MEASUREMENT TIME

1 Take standard pulley as per design

------ ---------- ------------- ---------

2 Face both side of hub portion

Lathe

machine

Single

point

cutting

tool

Vernier caliper 15 min.

3 Hold it in three jaw chuck & bore inner dia as per shaft size

Lathe

machine

Single

point

cutting

tool

Vernier caliper 20 min.

4 Drilling the hub at required points as per the drawing

Radial drill machine

Twist drill

Vernier calliper 10 min.

5 Tap the hub at drill area.

Hand tap set

Tap Vernier calliper 10 min.

Chapter 7

Testing and Results

Readings:

Using 12 Volts generator and rated power.

SR no.

Wind speedm/s

Speed of shaftrpm

VoltageV

1 1 to 1.5 82 to 90 3.2

2 1.5 to 2.5 109 to 121 3.9

3 2.5 to 3.5 189 to 201 4.8

4 3.5 to 4.5 271 to 320 6.2

5 4.5 to 5.5 328 to 353 8.8

6 5.5 to 6.5 390 to 396 9.2

7 6.5 to 7 400 to 409 12

Power curve:

We have taken 12 readings in an interval of 5 minutes each so the readings taken during the 1hour span are as follow;

Intervals of 5

minutes

Wind speedm/s

Voltagevolts

CurrentAmpere

Powerwatts

1 4.1 6.3 2.1 13.32 4.6 9.1 2.7 24.53 4.9 9.2 2.6 23.94 5.3 9.3 2.7 25.15 5.9 9.4 2.8 26.46 6.8 10.9 2.9 31.67 6.2 9.1 2.6 23.78 7.2 11.8 2.9 34.39 6.9 11.3 2.8 31.710 7.3 11.8 2.9 34.311 7.1 11.7 2.9 33.912 6.8 11.3 2.9 32.8

Average 6.1 10.1 2.8 28.3

Average Power obtained = 28.3 watts

Fig.7.1 Power curve

= (28.3/1000) Kw

= 0.02828 Kw

Annual power obtainable = 0.02828 x (365 x 24) = 247.8 Kw-hr

No. of units in 24 hours = (power in kilowatts) x 24 [9].

=0.02828 x 24

=0.68 Kw in 24 hours.

Cost of one unit = 4 Rs. [9]

Therefore, Cost of 0.68 units = 2.72 Rs.

Thus in a day 0.68 Kwhr of power is produced.

If the complete capacity of the wind mill is utilized with Generator rating of 200Watts then,

Consider 30% losses,Power = 200 x 0.7 =140 Watts = 0.14 Kw

Annual power obtainable = 0.14 x (365 x 24) = 1226.4 Kwhr [9].

No. of units in 24 hours = (power in kilowatts) x 24 [9]. = 0.14 x 24 = 3.36 Kw in 24hours.

Cost of 3.36 units = 13.44 Rs.

Thus in a day 3.36 Kwhr of power is produced.

Result:

Parameters 36 Watts rated Generator

200 Watts rated Generator

Power obtained 0.02828 Kw 0.14 KwAnnual power 247.8 Kw-hr 1226.4 Kwhr

obtainableNo. of units in 24 hours 0.68 Kwhr 3.36 KwhrCost of obtained units 2.72 Rs 13.44 Rs

From the readings and observations it is clear that the power increases with wind speed and Rotor diameter.

For testing we had used the generator of rated power 36 watts but the generator unto rated power 200watts can be installed for utilizing the complete power capacity of the wind mill.

This power can be used for running the various 12volts household appliances like mixer, juicer

Tube lights of rated power up to 36watts, small fans, charging of cell phones etc.

Chapter 8

Specification of wind mill

Operating data

Rotor diameter & height 585 mm x 600 mmPower capacity ≈225wCut in wind speed 1m/sRated wind speed 5m/sCut out wind speed 7m/s

Rotor

Blade 3 layer, vertical axis Swept area 1.33m2

Rotational speed 82rpm /480rpmRotor material mild steel

Generator

Type 12 volts, D.C. motorRated output 36wattsRotational speed 50rpm/500rpm

transmission system

Type 1 stage (2 pulley)Ratio 25:1Type of cooling air cooled

Tower

Type c section, mild steel

Chapter 9

Cost estimation

Material cost:

Material Specification QuantityCost(Rs.)

Turbine blade 600 mm dia 3 3500

shaft 20 mm dia 1 390

Pedestal bearing P204 2 600

frame 75 x 40 x 4 mm C section

1 4000

pulley 250 mm 1 350

dynamo 6 watt 1 300

blower 1/8 hp 1 2200

Total Material cost = 11040 Rs.

Machining cost:

Machine used Total operation time

Cost/hr(‘Rs.’)

Total cost

(‘Rs.’)welding 3 Hrs 150 450

Drilling 1 Hrs. 100 100

Sheet searing 4 hrs 50 200

750

Total Machining cost = 750 Rs.

Miscellaneous cost = 500 Rs.

Total cost = Total Material cost + Total Machining cost + Miscellaneous cost

Total cost = 11040 + 750 + 500 = 12290

Chapter 10

Conclusion

10.1 Summary

During working on this project we came to know about the various renewable sources of energy and there importance in power production in the world. We came to know that importance of the power through wind mills. In future, further development in the direction of wind energy will make the power cheaper. India stands fifth in rank of power produced by wind energy.

The building of this project has helped us to develop good amount of confidence as we were able to tackle very interesting problems like,

1. Transmission system for converting the wind force in to rotational speed of shaft.

2. Mechanism to rotate the head assembly so as to access the use of wind from any direction, which increases the efficiency of the system.

It also gave us opportunity to realize ourselves as we were subjected to different problems and were compelled to take self decisions which really develops our problem tackling skills.

10.2 Payback period

For 0.37 watts rated Generator

In a day 8.88 units of power is obtained

Cost of 1 units = 2.72 Rs.

In one years,

Amount obtained in 1 years = (365) x 2.72 x 8.88 = 8816 Rs. Pre year

Considering 4% of total manufacturing as annual maintenance cost,

Annual Maintenance Cost = 0.04 x 88160 = 352 Rs.

Amount obtained in 5 years after deduction of maintenance,

= 8816- 352= 8464 Rs. Pre year

Cost of set up = 12290 Rs

Payback period = 12290 / 8464 = 1.45 years

10.3 Future works

The project can be continued further for improvement in it working.

Future developments can be done are as follows,

1. The power producing capacity can be increased by installing higher rated generator.Maximum rated power of 200 watts generator can be used and will cost approximately 1500 Rs.

2. The capacity can be increased by increasing the rotor diameter.For various rotor diameters following are the power capacities at maximum wind speed of 12 m/s,

a. Rotor diameter = 2 mPower capacity = 534 wattsApproximate total cost = 4500 Rs.

b. Rotor diameter = 3 mPower capacity = 1201 wattsApproximate total cost = 6000 Rs.

c. . Rotor diameter = 4 m, Power capacity = 2136 watts

Approximate total cost = 8000 Rs.

This is the maximum size of the rotor which is suitable for our college terrace wind conditions. Above rotor diameter of 4 m requires higher average velocity for efficient working.

3. The power capacity can be increased by increasing the number of wind mills.Our college terrace is suitable for installing up to 5 numbers of same types of wind mills. For this higher capacity of storage system has to be installed.

Power capacity of 5 wind mills = 225 x 5 ≈ 1125 watts.

Considering 30% losses,

Power = 1125 x 0.7 =787.5 Watts = 0.7875 Kw

Annual power obtainable = 0.7875 x (365 x 24) = 6898.5 Kwhr

No. of units in 24 hours = (power in kilowatts) x 24 = 0.7875 x 24 = 18.9 Kw in 24hours.

Cost of 18.9 units = 75.6 Rs.

Thus in a day 18.9 Kwhr of power is produced an 75.6 Rs can saved. This will also reduce the payback period.

4. The control of speed of the rotor shaft through Micro-controller

5. Braking systems for avoiding damage to system due to higher wind velocity

6. Storage system can be installed like 12 volt battery.A storage system of capacity up to 40 watts or 40 KVA can be used for storing the power in our fabricated system.The storage capacity can be used for increasing the standby reserve capacity.

7. Stabilizer for avoiding the damage to storage system.

CHAPTER NO

REFERENCES

[1] Website: www.wikipedia.com.

[2] Website: www.powertechnology.com.

[3] Website: www.howstuffwork.com .

[4] Dr. Eric Eggleston, “Sources of Energy”, 2nd Edition, 2001.

[5] R.S Khurmi, J.K Gupta, “Machine Design”

[6] K.L.Kumar, “Fluid Mechanics”, 8th Edition, 2005.

[7] S.Ramamrutham, R.Narayanan, “Strength of Materials”, 6th Edition, 2002.

[8] P.S.G, “Design data Book”, 2nd compiled Edition, 2006.

[9] Domkundwar, “Power plant engineering”, 5th Edition, 2003.

HOW IS ELECTRICITY MEASURED?

Electricity is measured in units of power called watts. It was named to honor James Watt,

the inventor of the steam engine. One watt is a very small amount of power. It would

require nearly 750 watts to equal one horsepower. A kilowatt represents 1,000 watts. A

kilowatt-hour (kWh) is equal to the energy of 1,000 watts working for one hour. The

amount of electricity a power plant generates or a customer uses over a period of time is

measured in kilowatthours (kWh). Kilowatthours are determined by multiplying the

number of kW's required by the number of hours of use. For example, if you use a 40-

watt light bulb 5 hours a day, you have used 200 watts of power, or .2 kilowatthours of

electrical energy..