Professional Documents
Culture Documents
2010
MURAT ISLAM
SCHOOL OF
List of Contents 2
List of Tables 5
List of Figures 6
List of Diagrams 9
List of Photographs 10
List of Abbreviations 11
Abstract 12
Declaration 13
Copyright Statement 13
Acknowledgements 14
Chapter 1. INTRODUCTION 15
1.1. Background 15
1.2. Aims and Objectives 15
1.3. Motivations of the thesis 16
1.4. Outline of the Thesis 16
2
2.7. Wheel Size and Economy 27
2.8. Possible VAWT Components 27
3
5.1. Wind Tunnel 70
5.2. Finished components and assembly sequence of the turbine
70
5.3. Experimental Setup 74
5.4. Gathered Data 77
5.4.1. Case 1: Both impellers were freely rotating 77
REFERENCES 91
APPENDIX 93
4
List of Tables
5
List of Figures
6
Figure.15 Hand sketch of a simpler frame concept (3rd) for four
bearings ................................................................................. 41
Figure.16 Hand sketches of simple structure of wind turbine ... 42
Figure.17 Solidworks drawings of simple structure of wind turbine
................................................................................. 43
Figure.18 Hand sketch of used frame of CR-VAMWT .............. 44
Figure.19 3D drawing of the frame, brackets with fixings and
bearings assembly ..................................................................... 45
Figure.20 SPARX Motorcycle alternator with a rectifier ............ 47
Figure.21 ROYAL Enfield 3 wire - 6 volts Alternator ................. 47
Figure.22 a) Coils, b) Magnets, for 3 phase 12 coils AFPM
handmade generator ................................................................. 49
Figure.23 simplified a) 2D, and b) 3D view of 3 phase 12 coils
handmade AFPM machine showing circuit connections ............ 49
Figure.24 Handmade AFPM machine used with a slipring on a
CR-VAMWT ............................................................................... 50
Figure.25 a) Catalogue photo, and b) Solidworks model of a
Printed GPM12 DC Motor .......................................................... 50
Figure.26 Elements of Printed DC Motors [19] ......................... 51
Figure.27 a) Through bore, and b) Face type slip rings ............ 52
Figure.28 a) Catalogue view [20], and b) Solidworks model of
SPB12 through bore signal & power transfer units ..................... 53
Figure.29 a) D series, b) DD series brush holders, and c) through
bore slip ring [20] ....................................................................... 53
Figure.30 a) Savonius, b) 2 bladed H-Type, and c) 3 bladed H-
Type VAWT concepts ................................................................ 54
Figure.31 a) H-Type & Savonius blades 3D drawing, and b) CR-
VAMWT with Darrieus and Savonius Hand sketch .................... 55
7
Figure.32 Centrifugal Tablock Blower Wheels by Hi-Tech
Blowers Inc. [22] ........................................................................ 56
Figure.33 a) Pedestal, and b) Pillow SKF Bearing Blocks ........ 57
Figure.34 Stepped shaft concept ............................................. 58
Figure.35 C shape thin plate connection concept ..................... 58
Figure.36 Advanced C shape cross connection concept .......... 59
Figure.37 Round cup holder concept ....................................... 60
Figure.38 Final frame with fixings and brackets with central
distances ................................................................................. 61
Figure.39 Chosen Aluminium frame profile drawing ................. 62
Figure.40 500mm length 45x45H 10mm slotted aluminium profile
3D CAD drawing ........................................................................ 64
Figure.41 GPM12 Printed DC Motor ........................................ 64
Figure.42 Schematic of the assembly ...................................... 73
Figure.43 Wind generator experimental circuit with 100W light
bulb , ammeter (A), and voltmeter (V) ........................................ 74
Figure.44 Final CAD Design..................................................... 75
Figure.45 a) solid shaft model with bearings, wheels and
generator; b) boundary conditions; c) meshed part .................... 83
Figure.46 Mesh on the wheel models (left) and mesh on the DC
motor models (right) ................................................................... 85
Figure.47 Boundary conditions on meshed bearing place ........ 85
Figure.48 First 10 deformation of mode shapes from top left to
bottom right respectively ............................................................ 86
Figure.49 Golden design of the frame ...................................... 89
8
List of Diagrams
9
List of Photographs
10
List of Abbreviations
11
Abstract
12
Declaration
Copyright Statement
13
Acknowledgements
14
Chapter 1. INTRODUCTION
1.1. Background
After the 19th century the demand for electricity escalated. This
high demand caused development of new electric power
generation facilities such as very large onshore and offshore wind
energy farms, solar power plants, wave power plants and tidal
power plants. The idea behind these large scale generation
facilities is decreasing harmful effects of fossil fuels due to NO x
and COy emissions caused by power plants.
15
1.3. Motivations of the thesis
The high energy demand in the world causes new interest in
different energy areas. Instead of the fossil fuels or non-renewable
energy resources, human realised the necessity of renewable
energies to cleanse the world.
16
Chapter 2. LITERATURE REVIEW
18
causes difficulties in maintaining structural strength and also
static/dynamic control of the blades. [2]
19
Diagram.1 Distribution of yields for installation of SWIFT 1.5
kW turbine
21
Figure.2 Shape and dimensions of buildings and locations of
possible wind turbine mounting points (perspective and plan
views) in the study by Heath et al (2007)
While wind speed goes below 4 m/s large wind turbines may not
produce electricity. Very high inertia of blades and generator
prevents rotation of blades and even though rotation occurs, low
rotational speed causes insufficient production of electricity.
Sometimes across the whole UK, the wind blows below 4 m/s
according to UK Met Office records. However, it is more usual to
see low wind speeds in individual wind sites where ail hours of
wind blow is around 15-20%, while on average 90% of the UK
households are subjected to around one hour low wind speed
conditions per year. And also the summer period has slightly more
ail hours than the winter period. These impacts of low wind speed
amongst areas of the UK are given in Diagram.2 .
22
Diagram.2 Impact of low wind speed events
Drag-type rotors uses drag effect of air stream over surfaces and
others use aerodynamic lift effect rotor which makes use of
aerodynamic lift effect. Low-speed and high-speed rotors are
determined by aerodynamic tip-speed ratio of rotors [5].
Constructional design classification is more common than
aerodynamic function classification due to easy recognition.
Position of wind rotor axis of rotation is the most obvious
characteristic of a wind turbine, so they were classified as vertical
axis and horizontal axis wind turbines. And also wind energy
concentrators are used to focus the air stream into turbine blades
to increase the efficiency.
Vertical axis wind rotors are the first type of wind energy
converters seen in the world. At first they could only use pure
drag-type rotors like the Savonius rotor. Ventilators on rail road
carriages or delivery vans, and anemometer rotors are good
examples of vertical axis of rotation. However, later, French
engineer Darrieus built a blade also using aerodynamic lift known
as the Darrieus rotor. Darrieus rotor blades have a troposkien
shape (i.e. turning rope in Greek) which has vertical axis of
rotation. Due to its complicated shape, manufacturing of Darrieus
rotors are difficult. The benefits of vertical axis wind turbines
(VAWT) can be listed as; its simple design features allows them to
place other components on the ground level, yawing systems are
not needed, functions well in turbulent conditions and constantly
connected to wind without losing power. However, they have low
tip-speed ratios, their self-start ability is weak, and the power
output cannot be controlled by pitching rotor blades. H-rotors
which have straight blades connected to shaft by struts were
24
developed as a variation of Darrieus rotors, and they were made
in the UK, USA and in Germany for commercial use. H-rotors
have better ability of power and speed control than Darrieus
rotors. High manufacturing costs of vertical axis wind turbines
started to decrease but still it is hard to compete with horizontal
axis turbines. However, Darrieus rotors have the potential for
improvement so they might overcome their disadvantages.
The Savonius design is used for small, simple wind rotors like for
driving small water pumps. The low tip-speed ratio and
comparatively low power coefficient of Savonius prevents it being
used as an electricity generating machine. When it is optimized
then its power coefficient approaches 0.25 which still looks low [5].
25
tilt. Also when the engine shuts down airfoils can be closed, so
wind damage can be prevented upon airfoils.
26
Figure.5 Project Nova V shaped vertical axis wind turbine and a
ship next to it
27
at both sides of rotation axis. For a micro wind turbine small sizes
of blower fan blades are considerably suitable.
29
Figure.8 a) RFPM machine, b) AFPM machine
30
Diagram.3 Performance comparison between RFPM and
AFPM machines due to Torque/moment of inertia
33
a) , b)
Once you identify a problem, its easy to fix it. Peter Chaconas
[14]
To be able to say all the targets are finished during the heuristic
method approach, the need must be specified. The statement of
the need is actually the beginning and the most significant part of
the solution to the problem. Without a need statement or
35
providing a complex one, the design can either be restrained too
much or going in a completely wrong and very long way. The
definition of the need for this thesis was defined as; Design and
development of a vertical axis micro wind turbine.
36
3.3. Generation of Concepts
For a design engineer, one of the most important abilities is
creation. There are many methods to be used to generate ideas
such as brain storming which familiar to many people nowadays.
However, to design a machine, we also suggest making hand
sketches of the basic components and try to link them to each
other on the paper. The links can only be improved, if the principle
connection methods are all known.
The best solution is the one that satisfies the requirements with
minimum cost and time consumption. The wind turbine design
was carefully planned as it will be used for further studies, in order
that the design is made with more than enough strength and
without any requirement to have high efficacy from the blades or
the turbine itself. The main consideration was proving the idea of
counter rotating vertical axis wind turbines have better self start
abilities while they produce a similar or greater amount of energy
output than the normal wind turbines which have the same size of
cross sectional area of blades facing the wind flow. Concepts
have been created by selecting individual components due to the
criteria suggested below;
37
3.3.1. Frame Concepts
The frame is the basic component to support the essential parts of
the wind turbine. It must be sturdy enough to compensate the
static forces such as the weight of the wind turbine and tightening
forces due to screws or bolts, and particularly dynamic forces
such as vibrations due to rotating elements and fluctuating thrust
force over the turbine due to blowing wind.
The very first idea of the cross section of the frame was chosen as
it could be a round solid bar to provide better structural strength
and less obstruction effect on the wind flow. Then it was thought
that the strength of the solid bar was unnecessarily high, such that
a round tube was suggested. Taking into account ease of
assembly, it was thought that a square cross section hollow tube
would be better to use. However, after searching deeper with
reference to the frames used for some applications, it was
realised that aluminium profiles with slots are very easy to
assemble and also can be very strong. So that, finally, the cross
section of the frame was selected as a slotted profile. The
generation of the profile of the frame was shown in the following
figures which were taken from websites.
38
While selecting the frame profile, also the shape of the frame was
considered. The idea was suggested by Dr. S. Olutunde Oyadiji
who supervised this dissertation and also sketched the CR-
VAMWT starting idea of this dissertation as shown in Figure.13.
39
less inertia of total rotating elements, so that the self start ability
could have been improved.
40
While creating the sketches, except for making the idea workable,
there were no other objectives. Therefore the sketches include
many unrelated meaningless scribbles purely for the intention to
stimulate the designers mind, and to enable clarity and vision. An
important factor for designers is to take satisfaction and pleasure
in generating new concepts, in order that they feel their final
design be worthy of their clients.
42
The 3D CAD programs enables the designers see their designs
exact dimensions in 3D which makes the feasibility of the machine
clearer. Possible interceptions, assembly difficulties or even
movements of the elements can be seen clearly. And also, saving
these files as pictures creates images in designers minds and
new ideas can be developed by recollecting and combining all of
these images.
43
After the general shape of the wind turbine had been decided,
hand sketch of the real frame which is shown in Figure.18 was
created.
44
Figure.19 3D drawing of the frame, brackets with fixings and
bearings assembly
This concept was chosen as the best one for this thesis because;
it is very easy to adjust for different purpose of studies, such as
assembling it in a different way in an hour without any other
manufacturing process. It has slots to put other bolts and nuts
which enable using other components on the structure such as
guide vanes for wind flow. In addition, the slots could be covered
with plastic caps to lessen the turbulence of the air flow. Moreover
power or signal input/output wires can be put in these covered
slots. The frame is very stable against loads due to its strong
profiles and brackets.
45
3.3.2. Generator Concepts
Generators or alternators are used in all wind turbines to produce
the electricity as DC or AC output. However, batteries can only
store DC current and those results in AC generators or alternators
being used with a rectifier to change the current into DC. In this
thesis, to produce the electricity; motorcycle alternators, bicycle
dynamos, DC electric motors and handmade permanent magnet
alternator concepts were considered.
Apart from current type as DC or AC, the generator type also has
an important effect on generating electricity. AFPM or RFPM
machines should be analysed for their characteristics.
The model ROYAL Enfield 3 wire 6 volts alternator sets for old
models cost about 70 in the market, however, it produce far less
electricity than SPX003 [18].
a) b)
a) b)
a) b)
50
Printed DC motors are a kind of improved AFPM machines. They
are also known as Printed Circuit (PCB) or "Pancake" Motors [19].
Printed DC motors have very thin structure because the wires are
placed on a thin disk and the magnets are relatively small.
51
concept was chosen for being detailed in design in the next
chapter.
a) b)
Face type slipring would have been used in connection with the
generator. Therefore more space would have been saved due to
their thin structure. However, manufacturing difficulties for this
small study governed the use of a through bore slipring, which is
easier to assemble and has no important manufacturing
necessity. Sliprings were chosen due to their capabilities as they
52
should withstand the required rotation speeds. Moreover, their
sizes and inertias should be comparatively small. Figure.28 shows
SPB12 through bore slipring catalogue view from BGB
Engineering Ltd and also its 3D CAD drawing in solidworks.
a) b)
a) b) c)
a) b) c)
54
In the study of Elmabrok, it was suggested that using a Darrieus
blade together with a Savonius blade has better performance than
using them individually according to self-start ability and efficiency
of the turbine [21]. We can develop this idea with suggesting a
more efficient H-Type blade used with a Savonius blade, and
moreover using them in a counter rotating way to improve the
performance as shown in Figure.31.
a) b)
55
Figure.32 Centrifugal Tablock Blower Wheels by Hi-Tech
Blowers Inc. [22]
Normally these components are used to push the air through air
ducts to condition the air of buildings. Their efficiency is generally
about 65% for blowing purposes; however this is not known when
they are used for converting wind energy into electricity. They will
be used in this thesis due to their strong structure and ease of
assembly and in addition they will be needed in further studies in
the university. Due to their forward curved shape, they are
working with both drag and lift forces and to improve their
efficiency as a wind turbine, they are recommended to be used
with guide vanes.
3.4. Bearings
Figure.19 indicates the shape of the final concept of the frame, so
that bearings need to be placed as shown. The best way to do it is
56
using pillow block bearings or mounted bearings which have self
mounting abilities on the frames.
a) b)
3.5. Shafts
Shafts are the easiest components to manufacture and design, so
that they were required to be designed in connection with other
components such as impellers, sliprings, frames etc. However,
their basic cross sections need to be chosen. As all the
components have inner diameter to fit on a shaft, the outer shape
of the shaft was chosen as round. Possible round shapes for
shafts can be suggested as; solid shaft and hollow shaft.
57
Figure.34 Stepped shaft concept
59
However, none of C shape concepts were used because of the
lack of manufacturing time. So that, very basic but robust concept
which was shown in Figure.37 was suggested.
60
Chapter 4. DETAILED DESIGN and
MANUFACTURING
530N
63
inertia of the beams for individual beam parts, so that the least
material would have been used as choosing the smallest profile
cross-section.
64
4.3. Critical speeds of rotating shafts
Eccentricity of the centre of the mass and the static deflections of
a rotating shaft creates high vibrations which can cause
catastrophic failures. Critical speed is a characteristic of any
shaft at which the high vibrations are developed. The lowest
critical speed is the main decisive property of a shaft with weights
on, which is calculated as follows [25].
(E.3)
(E.4)
65
Sym.14 : density of the shaft (8000 kg/m3)
67
Table.5 20mm shaft tolerances and limiting speeds for Y-
bearings
Tolerance
h6 h7 h8 h9 h11
Grade
tolerances -13 0 0 0 0
[m] 0 -21 -33 -52 -130
Speeds
8500 5300 3800 1300 850
[r/min]
68
dmax, shaft = 20mm + 0.000mm = 20.000 mm
69
Chapter 5. EXPERIMENT AND TESTING
70
Photograph.2 GPM12 Printed DC motor and Aluminium cup
holder.
71
Photograph.4 Assembly of the turbine
US+BW+BR+DC
LS+BW+SR+BR+DC
73
5.3. Experimental Setup
Experimental rig were designed as shown in Figure.43 that we
were able to record the generated amperes and voltages over the
wind turbine. The light bulb needed to be used to complete the
circuit as a resistor (or load) which creates the voltage difference.
After designing all the circuits and wind generator, the CR-
VAMWT was placed inside the wind tunnel and placed in the
middle of the cross-section of the corridor. The machine was
about 32kg so that the friction between the wood of the base of
the tunnel was thought enough to hold the turbine in place which
is shown in Photograph.6 , therefore, no bolt connection was
necessary to fix it. Also, the power cables were taken out of the
tunnel through circular hole on the wooden basement. Slipring
was fixed to the frame using plastic locking straps which were also
used to fix impellers.
74
Figure.44 Final CAD Design
75
tunnel. This component was also recording the wind speed inside
the tunnel.
76
Experiment was done to show the benefits of using a counter
rotating wind turbine which has freely rotating generator. Tests
were done in three different cases, such as;
77
6 Both impellers rotating
5.5
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
10 10.5 11 11.5 12 12.5 13 13.5 14
Wind Speed (m/s)
0.5
0
8 8.5 9 9.5 10 10.5 11 11.5 12 12.5 13
Wind Speed (m/s)
79
In Case 3, upper impeller was fixed, so that only lower impeller
could contribute to the power production. Again according to
10m/s wind speed, power output was seen as 0.048W which is
about 35% of the power output for the same wind speed in Case2.
0.4
0.3
0.2
0.1
0
6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11
Wind Speed (m/s)
When we summed the two separate power outputs for 10m/s wind
speed it was seen that total power production was 0.18584W.
However, when both of the impellers were free to rotate in Case1,
the power output was recorded as 1.1752W which was about 6
times higher than the total power output of Case2 and Case3.
80
Chapter 6. DEVELOPMENT OF THE DESIGN
n 1 Number of Turbines
2
d
At n 0.332m
2
Turbine Swept Area
2
1 3
P Vw At 245.89W Theoretical Power
2
16
ef 55% 32.593% Efficiency
27
Px ef P 80.142 W Theoretical Generated Power
kW hr Annual Production Estimation for a
Pr 2572 293.413W
yr Recent Design
4 kW hr Annual Production Requirement
Preq Pr 4 1.029 10 Estimation
yr
3
VAWT rw Areqm 2.596m
Rotor width Areq
and height rh 6.74 m
rw
81
Previous Mathcad codes were generated to calculate and
estimate the required area of a horizontal and vertical axis wind
turbine to provide enough annual power for a single house.
Ideally while there was 24mph wind speed, a horizontal axis wind
turbine with a diameter of 0,65m can generate up to 246W.
However, due to Betz Limit and the frictions, the efficiency of the
turbine was estimated as 32.593% so that the maximum
generated power can be up to 80W.
82
perception and discretion so that explaining the ideas to any other
person becomes much easier.
a) b) c)
84
These frequencies were needed to be passed fast during the
operation of the wind turbine to prevent failure of the shaft.
85
Figure.48 First 10 deformation of mode shapes from top left to
bottom right respectively
86
Chapter 7. DISCUSSIONS, FUTURE WORK AND
CONCLUSIONS
The power output of the wind turbine was seen as too low. This
result could have been caused by wrongly applying impellers
which normally work to create centrifugal forces on the air to push
it through ducts. Perhaps providing guide vanes would improve
the outcome of this wind generator.
87
Solidworks programme provided the designer with a high vision of
the concepts, so that, every time the concepts were taken to an
advanced stage. To manage the time of the project, when the
necessary parts were obtained, the concept design was
concluded. In addition, it was understood that, each concept
should have been saved completely in separate folders, and also
each component should have been presented in different colours
in each concept.
Bending load calculations for the frame indicated that the chosen
frame was too strong. In addition, the aluminium cup was
designed as to be unnecessarily sturdy to eliminate any assembly
errors. The blower wheels were made of galvanized steel which
has a huge amount of inertia with respect to composite materials
or even the aluminium.
88
be applied to generate better looking counter rotating wind
turbines which was shown in Figure.49.
7.3. Conclusions
In this study, a counter rotating vertical axis wind turbine was
designed using Solidworks, Mathcad and Abaqus CAE programs.
The importance of using CAD software for the aim of designing a
89
machine was experienced. The importance of tolerancing in
manufacture is experienced with the help of CAD software. The
benefits of CR-VAMWTs over single rotating impeller wind
turbines were found as high as six times of the output for low
efficiencies. It should also be investigated for motors and
impellers which are operating in optimal speeds.
90
REFERENCES
91
15. M. Myrup Andreasen, S.K., T. Lund, Design for Assembly.
1983, Verlag, Berlin, Heidelberg, New York, Tokyo: IFS Ltd.
16. Aluminium Warehouse. [cited 2010 September 18];
Available from: http://www.aluminiumwarehouse.co.uk.
17. kjn Aluminium Profile & Accessories. [cited 2010
September 18]; Available from: http://www.aluminium-
profile.co.uk.
18. Early Enfield 6v Alternator C/W Stator & Rotor (RM 19).
21/09/2010]; Available from:
http://www.royalspares.com/early-enfield-6v-alternator-cw-
stator-rotor-rm-19-p-2053.html.
19. Electric Drives - Special Purpose Motors (Description and
Applications) 22/09/2010]; Available from:
http://www.mpoweruk.com/motorsspecial.htm.
20. BGB Engineering Slip Ring Assemblies. 22/09/2010];
Available from:
http://www.bgbengineering.com/content/bgbengineering/slip
ringassemblies.asp.
21. Ali.M.Elmabrok, The Aerodynamics of Vertical Axis Wind
Turbines, in The Manchester School of Engineering
(Aerospace Division). 1995, The University of Manchester:
Manchester.
22. Forward Curved Tablock Blower Wheels. Available from:
http://www.ht-blowers.com/.
23. Bucciarelli, L.L., Engineering Mechanics For Structures.
2008: Dover Publications.
24. RS Components Ltd. Online Catalogue. 25/09/2010];
Available from: http://uk.rs-online.com/.
25. M.F.Spotts, ed. Design of Machine Elements. 5th ed. 1978,
Prentice-Hall Inc.: New Jersey.
26. C.F.Beards, Engineering Vibration Analysis with Application
to Control Systems. 1995, London: Butterworth-Heinemann.
27. Matthews, C., ed. Engineers' Data Book. 3rd. ed. 2004,
Proffessional Engineering Publishing: London.
28. SKF, Y-bearings and Y-bearing units. 2004.
29. Joseph Edward Shigley, C.R.M., ed. Mechanical
Engineering Design. 1989, McGraw-Hill: Singapore.
92
APPENDIX
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