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Certified that this is a bonafide record of the dissertation work entitled, ROWTHU. HEMANTH KUMAR bearing PIN. No: 10276-EE-020 submitted to the faculty of Electrical and Electronics Engineering, in partial fulfillment of the requirements for the DIPLOMA with specialization in ELECTRICAL AND ELECTRONICS ENGINEERING from MADANAPALLE INSTITUTE OF TECHNOLOGY AND SCIENCE,
MADANAPALLE.
We extend our special thanks to the principal DR. K. SREENIVASA REDDY, and the management, who supported us in all aspects of the project. At last, but the most important I would like to thank my family, for their unconditional support, inspiration and love.
With gratitude Mr. R. Hemanth Kumar (10276-EE-020) 3 DIPLOMA IN ELECTRICAL ENGINEERING, MITS, MADANAPALLE
ABSTRACT
Rising sea levels and escalating pollution levels has generated worldwide interest and has given rise to new wind turbines designs. Wind turbines mainly are of two types: vertical axis(VAWT) and horizontal axis(HAWT). HAWT are the most common type of wind turbines built across the world. VAWT is a type of wind turbine which have two or three blades and in which the main rotor shaft runs vertically. They are however less frequently used as they are not as effective as HAWT. The main difference between the VAWT and HAWT is the position of blades. In HAWT, blades are on the top, spinning in the air and are most commonly seen while in VAWT, generator is mounted at the base of the tower and blades are wrapped around the shaft. The main advantage of VAWT over HAWT is it's insensitivity to wind turbines and therefore can be mounted closer to the ground making it effective for home and residential purpose. Vertical-axis wind turbines (VAWTs) are a type of wind turbine where the main rotor shaft is set vertically and the main components are located at the base of the turbine. Among the advantages of this arrangement are that generators and gearboxes can be placed close to the ground, which makes these components easier to service and repair, and that VAWTs do not need to be pointed into the wind. Major drawbacks for the early designs (Savonius, Darrieus and giromill) included the pulsatory torque that can be produced during each revolution and the huge bending moments on the blades. Later designs solved the torque issue by using the helical twist of the blades almost similar to Gorlov's water turbines. A VAWT tipped sideways, with the axis perpendicular to the wind streamlines, functions similarly. A more general term that includes this option is "transverse axis wind turbine". For example, the original Darrieus patent, includes both options. Drag-type VAWTs, such as the Savonius rotor, typically operate at lower tipspeed ratios than lift-based VAWTs such as Darrieus rotors and cycloturbines. A unique, mixed Darrieus - Savonius VAWT type has recently been developed and patented. The main benefits obtained are improved performance at lower wind speeds and a lower r.p.m. regime at higher wind speeds resulting in a silent turbine suitable for residential environments. 8 DIPLOMA IN ELECTRICAL ENGINEERING, MITS, MADANAPALLE
Chapter 1: Introduction
1.1 Project Background
The fluid mechanics department in DIT Bolton Street were approached by a company called Br Toinne Teoranta with a design for a vertical axis wind turbine (VAWT). The company had completed the preliminary design of the turbine but had not carried out any testing to determine its performance. It was decided that the mechanical testing of this VAWT design would be undertaken as an undergraduate final year project. On accepting the project, videos of an early version of the turbine operating in a wind tunnel were provided by the company to show the principle of operation of the turbine. These videos were carefully analysed in order to gain an understanding of the challenges that were ahead for the project. The company also provided the relevant CAD files for the unique turbine blades, which would allow the blades to be manufactured in accordance with the companys design. The following dissertation was compiled to document the approach used in testing the Br Toinne Teoranta turbine design along with the testing methodologies which were devised for analysing the turbines performance.
Figure 2 (Project Time Plan) 1.4.Types of VAWTS: There are two types of Vertical Axis Wind Turbines.
Chapter 2: Background
2.1 Introduction
The following chapter contains a literature review which was carried out in the areas of energy, wind energy, wind turbine fundamentals and the development of vertical axis wind turbines. Before any work could be done on designing the vertical axis wind turbine test rig, a good understanding of the history of wind energy was obtained. In the following chapter, the history and the development of the wind turbine is discussed, from its early conception in the form of the windmill to the modern day electricity generating devices with which the world is now so familiar. The area of aerodynamics is explored in this chapter, pointing out the various characteristics of aerofoils and the concepts behind aerofoil performance. This is a crucial area as the turbine being tested in this project is a lift type device which has an aerofoil cross section. The development of the VAWT was investigated, along with the various different rotor designs which have been developed over the years. In this chapter the different rotor design are discussed in order to gain an understanding of the performance expected from the unique VAWT rotor design presented by Br Toinne Teoranta.
Figure 3 (Graph showing energy consumption pattern (in million tonnes oil equivalent))
Wind Energy has been used since several years to power homes, sail boats, pump water from wells or heating and cooling homes and offices. Today with the ever increase in the demand for fossil fuels and with the prices soaring all time high numerous resources have been invested in the wind energy. Wind energy has its own advantages and disadvantages. While on one side it is renewable source of energy and cause less air and water pollution, on the other hand it also dirupts the ecological balance as it poses threat to wildlife. Also, Wind energy can not be produced everywhere since you need strength of wind to produce energy from it. Today less than 5% of total world energy demands are met by wind energy and in the years to come this figure is going to be much higher. This article covers the topic of "How Wind Turbines Work" and basic understanding of the generation of electricity through out wind turbines.
Figure 4: (Wind-sourced electricity in Ireland 2000-2009. Source: Eir Grid & SEAI EPSSU ) 2.3.1 Benefits of Wind Energy Wind energy is classed as a renewable source of energy and has certain benefits associated with it when compared with other non-renewable processes used to produce power. A common theme amongst renewable energies is that they can be described as clean energy sources. A clean energy source does not produce any emissions like nitrogen oxide, sulphur dioxide, mercury and carbon dioxide, which pollute the air. This means that not only can wind energy provide the world with extra capacity for creating electricity; it can do so without producing any extra emissions. When a country has got a well established system for producing electricity using wind energy in place, it can then start to decrease the demand on electricity produced in power plants, hence decreasing the amount of fossil fuels which will be consumed on a daily basis. The development and progression of wind energy as a source of electricity has benefits on a domestic level also. As the wind energy industry grows, there will be a diversification in the market whereby the majority of the worlds electricity will no longer be coming from power plants burning fossil fuels. This means that when there are dramatic increases in the price of oil and other fossil fuels around the world, the cost of electricity for customers will not be as dramatically affected. In an ideal situation, 100% of the energy supplied to a customer would be from a wind energy source and electricity prices would not be affected at all by the cost of fossil fuels. [5]
through the turbine, A is the swept area of the turbine (the area which the blades or rotor sweeps through), and is the wind speed. 17 DIPLOMA IN ELECTRICAL ENGINEERING, MITS, MADANAPALLE
Where
efficiency and performance of a wind turbine is usually displayed using power curves. Figure 5 below shows plots of power coefficient versus tip speed ratio for various different wind turbine types. The theoretical maximum power coefficient is known as the Betz limit and is 0.59 for an ideal wind turbine. This Betz efficiency is marked as the ideal efficiency of propeller-type turbine in Figure 5 below. [7]
Figure 6 (Drag-type rotor) 2) Lift turbines In a lift type turbine like the ones shown in Figure 7 below the force generated by the wind acts perpendicular to the direction that the wind is blowing. It should also be noted that in a lift type turbine, the maximum speed of the blade is not limited to the speed at which the wind is blowing as in drag type turbines. This means that lift type turbines can have much larger tip speed ratios than their drag type counterparts. In order to fully understand exactly how lift type turbines operate, an investigation must be done into the area of aerodynamics and aerofoil technology.
Figure 7 (Left: Darreius type lift turbine, Right: Propeller type lift turbine)
Figure 12 (Savonius Rotor)[10] The Savonius rotor uses drag as its driving force. It has been used as a rotor for water current turbines to good effect. The Savonius rotor has various advantages associated with it, such as the simplicity of its design and the ease with which it can be manufactured. This makes the Savonius rotor an interesting, economical possibility for converting wind energy to electricity in underdeveloped areas of the world.
Figure 13 (Gorlov helical rotor) A company form the UK called quietrevolution has developed a helical VAWT shown in Figure 14 called the Q5, which is designed to be used in urban areas where the turbine will be operating close to the general public. The helical design eliminates vibration in the turbine, so it can be attached onto buildings without causing any detectable shaking of the building. The company also says that the helical design eliminates any noise from the turbine and provides it with a robust structure. [12] 27 DIPLOMA IN ELECTRICAL ENGINEERING, MITS, MADANAPALLE
Figure 14 (Helical VAWT from Quietrevolution)[12] 2.6.5 VAWT Case study There have been a few reasonably successful attempts at creating large scale VAWTs in the past, for example a VAWT called the Eole shown in Figure 15, which was built in 1986 by an American company called FloWind. The Eole was a 96m tall Darrieus turbine which as the largest VAWT ever built had a maximum power output of 3.8MW. During its five year lifetime the Eole produced 12GWh of electricity, reaching power levels of around 2.7MW. Failure of the bottom bearing in the Eole resulted in the turbine being shut down. The existence of this multimegawatt Darrieus type VAWT shows that it is realistic to believe that the VAWT could someday be just as popular as the HAWT. [7]
Figure 15 (The Eole 3.8MW VAWT) 28 DIPLOMA IN ELECTRICAL ENGINEERING, MITS, MADANAPALLE
Figure 17 (Wind tunnel dimensions) The other factor which limited the size of the turbine was the capacity of the machines which would be used to manufacture the blades. After looking at the possible manufacturing techniques 32 DIPLOMA IN ELECTRICAL ENGINEERING, MITS, MADANAPALLE
3.6.3 Final Blade The Standard Tessellation Language (STL) file for the blade was imported into a software package called catalyst in order to prepare it to be sent to the Dimension machine. This file contains the data required by the Dimension machine to manufacture the blades. The catalyst programme calculates the required support material to be added to the model as shown in Figure 21. This support material is required so that the machine can print out parts of the blade which are not sitting on the base of the machines build area. The orientation of the blade is essential to minimizing the amount of support material required. Several orientations were investigated to see which used the smallest amount of support material. The catalyst software then calculated the 37 DIPLOMA IN ELECTRICAL ENGINEERING, MITS, MADANAPALLE
3.7 Summary
Before the investigation into the rotor manufacture began, the wind tunnel in DIT Bolton Street was measured in order to determine the maximum size VAWT which could be tested accurately. The wind tunnel had a cross section of 0.5m by 0.5m so the rotor diameter was immediately limited to within these dimensions. The next area which was investigated was the manufacturing methods available for the manufacture of the blades in DIT Bolton Street. The 3D printing machines available were limited to a maximum dimension of 200mm. This 200mm was then considered the maximum diameter for the turbine blades. The CAD files for the turbine blades presented by Br Toinne Teoranta were carefully analysed and scaled down to the 200mm limit discussed above.
Parts: 1. Rotor 2. Axle 3. Bearings 4. Metalsheet 5. 9V Motor 6. Clamp type Supporting 7. Guy Wire 8. Upper Hub 9. Lower Hub
40 DIPLOMA IN ELECTRICAL ENGINEERING, MITS, MADANAPALLE
2) Axle: An axle is a central shaft for a rotating wheel or gear. On wheeled vehicles, the axle may be fixed to the wheels, rotating with them, or fixed to its surroundings, with the wheels rotating around the axle. In the former case, bearings or bushings are provided at the mounting points where the axle is supported. In the latter case, a bearing or bushing sits inside the hole in the wheel to allow the wheel or gear to rotate around the axle. Sometimes, especially on bicycles, the latter type is referred to as a spindle. On cars and trucks, several senses of the word "Tandem axle" co-occur in casual usage, referring to the shaft itself, its housing, or simply any transverse pair of wheels. The shaft itself rotates with the wheel, being either bolted or splined in fixed relation to it, and is called an "axle" or "axle shaft". However, it is equally true that the housing around it (typically a casting) is also called an "axle" (or "axle housing"). An even broader (somewhat figurative) sense of the word refers to every transverse pair of wheels, whether they are connected to each other or not. Thus even transverse pairs of wheels in an independent suspension are usually called "an axle"
Bearings
A Ball bearing is a type of rolling-element bearing that uses balls to maintain the separation between the bearing races. The purpose of a ballock bearing is to reduce rotational friction and support radial and axial loads. It achieves this by using at least two races to contain the balls and transmit the loads through the balls. In most applications, one race is stationary and the other is attached to the rotating assembly (e.g., a hub or shaft). As one of the bearing races rotates it causes the balls to rotate as well. Because the balls are rolling they have a much lower coefficient of friction than if two flat surfaces were sliding against each other. 4) Metal Sheet:
Metal Sheets Metal sheets used for designing the blades. Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking, and can be cut and bent into a variety of different shapes. Countless everyday objects are constructed of the 42 DIPLOMA IN ELECTRICAL ENGINEERING, MITS, MADANAPALLE
9V DC Motor In electricity generation, an electric generator is a device that converts mechanical energy to electrical energy. A generator forces electric charge (usually carried by electrons) to flow through an external electrical circuit. The source of mechanical energy may be a reciprocating or turbine steam engine, water falling through a turbine or waterwheel, an internal combustion engine, a wind turbine, a hand crank, compressed air, or any other source of mechanical energy. The reverse conversion of electrical energy into mechanical energy is done by an electric motor, and motors and generators have many similarities. Many motors can be mechanically driven to generate electricity and frequently make acceptable generators.
Guywire A guy-wire or guy-rope, also known as simply a guy, is a tensioned cable designed to add stability to a free-standing structure. They are used commonly on ship masts, radio masts, wind turbines, utility poles, and tents. One end of the cable is attached to the structure, and the other is anchored to the ground at a distance from the structure's base. The tension in the diagonal guy-wire, combined with the compressional strength of the structure, allows the structure to withstand lateral loads such as wind or the weight of cantilevered structures. They are often installed radially, at equal angles about the structure, in trios and quads. This allows the tension of each guy-wire to offset the others. For example, antenna masts are often held up by three guy-wires at 120 angles. Structures with lateral loads, such as electrical utility poles, may require only a single guy-wire to offset the lateral pull of the electrical wires. Conductive guy cables for radio antenna masts may disturb the radiation pattern of the antenna, so their electrical characteristics must be included in the design. 7) Hub: The rotor hub is a welded construction made of steel. It houses the pitch mechanism and the pitch bearing. The hub connects to the rotor and blade assembly to the generator shaft.
Chapter 5. Conclusion
5.1 Conclusion
The aim of this project was to carry out performance tests on an innovative vertical axis wind turbine (VAWT) designed by Br Toinne Teoranta. Overall the project was a great success and all of the original objectives set out were achieved. The objectives set out at the start of the project were as follows 1. Carry out research into the area of wind energy and develop an understanding for the fundamentals of wind power generation. 2. Manufacture the turbine blades designed by Br Toinne Teoranta to a high standard. 3. Design a testing methodology to obtain performance curves for the turbine. 4. Design and fabricate a suitable test rig for the wind tunnel testing. 5. Carry out wind tunnel testing on the VAWT. 6. Analyse the results obtained from the wind tunnel testing. 7. Present the findings from testing in report form. Before work commenced on the project, a good understanding of the importance of sustainable energy was obtained. It was clear from this research that in order to meet the global energy demand, sustainable energy sources such as wind must be utilised. It was also clear that there was a need to conduct more research into the area of vertical axis wind turbine technology. Vertical axis wind turbines are more favourable than horizontal axis turbines in many applications, making any research and development carried out in the area both relevant and beneficial. This project offered a good opportunity to gain experience in the area of turbine blade manufacture. The 3D CAD files from the designer had to be interpreted and understood so that the correct approach to manufacture could be taken. Several small design modifications had to be made to the turbine blades designed by the manufacturer and components had to be designed to mount the blades to the central shaft of the turbine. Experience was also gained in the area of
Chapter 6. References
1. Jha, Ph.D., A.R. (2010). Wind turbine technology. Boca Raton, FL: CRC Press. 2. US Patent 1835018 3. Amina El Kasmi, Christian Masson, An extended k-epsilon model for turbulent flow through horizontal-axis wind turbines, Journal of Wind Engineering and Industrial Aerodynamics, Volume 96, Issue 1, January 2008, Pages 103-122, retrieved 2010-04-26 4. Sandra Eriksson, Hans Bernhoff, Mats Leijon, (June 2008), "Evaluation of different turbine concepts for wind power", Renewable and Sustainable Energy Reviews 12 (5): 1419-1434, doi:10.1016/j.rser.2006.05.017., ISSN 1364-0321, retrieved 2010-04-26 5. Chiras, D. (2010). Wind power basics: a green energy guide. Gabriola Island, BC, Canada: New Society Pub. 6. Fish hold the key to better wind farms 7. Steven Peace, Another Approach to Wind, retrieved 2010-04-26 8. Kathy Svitil, Wind-turbine placement produces tenfold power increase, researchers say, retrieved 2012-07-31 9. Jha, Ph.D., A.R. (2010). Wind turbine technology. Boca Raton, FL: CRC Press. 10. Chiras, D. (2010). Wind power basics: a green energy guide. Gabriola Island, BC, Canada: New Society Pub. 11. http://en.wikipedia.org/wiki/Vertical_axis_wind_turbine 12. http://www.sciencedaily.com/releases/2012/07/120730204607.htm