INTRODUCTION This report explains briefly about the design procedure and the fabrication of a wind turbine blades.

The design procedure has two main steps.

I. II. CALCULATION OF THE POWER FROM THE WIND. BLADE DESIGN

I.

CALCULATION OF THE POWER FROM THE WIND.

Calculation of the power from the wind includes the calculation of the following parameters. 1. 2. 3. 4. 5. Diameter of the rotor. Power from the rotor. Mean power output. Tip speed ratio (TSR). Shaft speed.

1. DIAMETER OF THE ROTOR. Diameter, D = (P/(Cp*/2*/4*V3)) O.5 = = = = (m)

Where, , density of air, (kg/m3) Cp, Power co-efficient V, Wind speed (m/s) P, power (Watts)

1.2 ( Temperature Dependent ) Cp< 0.6, say 0.4 9 m/s ( Rated Wind Speed ) 1200 ( considering the losses )

To find the diameter lets substitute the input parameters in the equation, with the power rating of 1KW. Diameter, D = = ( 1200/(0.4*(1.2/2)*(/4)*(93))0.5 2.95 m.

The rotor may be designed for diameter up to 3 meters.

2. POWER FROM THE ROTOR. Power (in watts) is the rate of capture of energy, at any given instant. Power, P = Cp*1/2**A*V3 i.e., Power, P(watts) = = = Cp*/2*/4*D2*V3 0.4*(1.2/2)*/4*2.952*93 1236.7 Watts.

If the windmill catches 40% of the raw power in the wind. Then percentage caught is known as the 'power coefficient', Cp. The raw power in the wind depends on the following. 1. The density of air. 2. The speed of the wind. 3. The size of the rotor. Wind speed is critical, Stronger winds carry a greater mass of air through the rotor per second and the kinetic energy per kilogram of air depends on the square of its speed, so the power in the wind will increase dramatically with wind speed. 3. MEAN POWER OUTPUT. Pm= 0.14*D2*Vm3 Where, Pm Vm = = Mean Wind speed. Mean Wind velocity.

Let us consider a mean wind velocity, Vm = 9 m/s. Pm = = 0.14*(2.952)*(93) 0.14*2.952*93 = 888.17 watts on average.

4. TIP SPEED RATIO (TSR). TIP SPEED RATIO (TSR) =(tip speed of blade)/(wind speed). The tip speed ratio is a very important factor in the different formulas of blade design. Generally can be said, that a three bladed wind turbine use 5-7 as tip speed ratios. We can calculate the rotor tip speed ratio. TSR = RPM**D/60/V = 7

we calculate the rpm we can get with TSR RPM = = = 60*V*TSR/(*D) ( 60*9*7 )/( *2.95 ) 407.8

All this is based on a 9 m/s wind speed. We must also consider the power and speed conditions at low winds like 4m/s. P Rpm = = = = Cp*/2*/4*D2*43 60*V*TSR/(*D) 60*4*6/(3.14*2.95) 181.2 rpm = 104.9 Watts.

(So, the generator must produce some power at speeds under 200 rpm, if it is to work well in low winds.) 5. Shaft speed. Rpm = 60*V*TSR/( x D) = 407.8 rpm

Shaft must be designed for up to 500 RPM.

II.

BLADE DESIGN.

The 'Blade Design' section suggests the shape of the blade at each station. Say we use 5 stations along the blade length, at radius 'Rs' = 0.29, 0.58, 0.87, 1.16, and 1.47 metre. We choose, B 'CI' 'Alpha'
Length

= = =
=

3 blades. 0.8. 4.
1.47 m.

At each station we should find the setting angle 'Beta', and the chord width 'Cw' Blade setting angle, Beta Chord width, Cw Drop Thickness CALCULATIONS i. For Rs = 0.294 Beta = = Cw = = Drop = = Thickness = = ATAN(2.95/3/0.294/7)-4 21.64 5.6*1.47/(3*0.8*0.294*72) 0.210 m. 0.210*SIN(21.64) 0.077 m. 0.15*0.210 0.0315 m. = = = = ATAN(D/3/Rs/TSR)-4 5.6*L/(B*CI*Rs*TSR2) Cw*SIN(Beta) 0.15 *Cw (or 0.12 *Cw at the tip).

ii.

For Rs = 0.588 Beta = = Cw = = Drop = = Thickness = = ATAN(2.95/3/0.588/7)-4 9.43 5.6*1.47/(3*0.8*0.588*72) 0.16 m. 0.160*SIN(9.43) 0.026 m. 0.15*0.160 0.024 m.

iii.

For Rs = 0.882 Beta = = Cw = = Drop = = Thickness = = ATAN(2.95/3/0.882/7)-4 5.04 5.6*1.47/(3*0.8*0.882*72) 0.140 m. 0.140*SIN(5.04) 0.012 m. 0.15*0.140 0.021 m.

iv.

For Rs = 1.176 Beta = = Cw = ATAN(2.95/3/1.176/7)-4 2.81 5.6*1.47/(3*0.8*1.176*72)

= Drop = = Thickness = = v. For Rs = 1.47 Beta = = Cw = = Drop = = Thickness = =

0.110 m. 0.110*SIN(2.81) 0.005 m. 0.15*0.110 0.016 m.

ATAN(2.95/3/1.47/7)-4 1.45 5.6*1.47/(3*0.8*1.47*72) 0.09 m. 0.09*SIN(1.45) 0.0022 m. 0.15*0.09 0.0135 m.

Naca 23015 profile was chosen

FABRICATION OF THE BLADE EQUIPMENT REQUIRED

The blades are made from fibre glass. This fibre glass has great strength in tension and compression. The various chemicals required are listed here.

Chemicals required Resin Resin Type R 10-03 This is a general purpose rigid orthopthalic (FRP) polyester resin. It is relatively inexpensive and is used for the majority of the wind turbine blades. Resin Type Polymer 31-441 This is called a gel coat polyester resin. It is 100% isophthalic with Neo-Pentyl Glycol (NPG). It is very hard wearing and is scratch and chemical resistant. It is more expensive than the other type of resin therefore its use is limited to just the outer layers of the blade. STYRENE MONOMER This is mixed with the resin to reduce the viscosity of the resin. This makes the resulting mixture more workable and easier to paint onto the fibre glass cloth. HARDENER Hardener is added to the resin mix to start the solidification (or curing) process. The time taken before the resin sets is controlled by the amount of hardener and accelerator (cobalt) added. Once the hardener is added to the resin it must be worked quickly into the fibreglass as the resin will solidify quickly.

COBALT Cobalt is an 'accelerator' that speeds up the hardening process when added to the resin. This can be used to help control the setting time of the resin. TONER This only adds colour to the resin. It has no structural properties. It is used to colour the outer layers of resin, rather than paint the blades afterwards. This can be obtained in many different colours. Approx 5 to 10% by weight is added to the resin mixture until the correct colour is reached. Adding a greater amount than this may inhibit the solidification process. Adding toner makes the lay-up stage easier as you can clearly see where the resin is, however this makes the foam filling stage more difficult as the blade is then opaque. LOWILITE This is a UV stabilizer and must be used on the outer layers of resin. It helps to prevent material degradation by sunlight. It is supplied in powder form. DURAWAX This is a release agent. It is applied to the mould before each lay-up to ensure that the item produced does not stick to the mould. Sometimes a thin non-stick film is added to moulds to avoid the part sticking given the complex curved shape of the moulds a wax release agent was selected.

FIBRE GLASS CHOPPED STRAND FIBRE GLASS MAT (CSM) The fibres within CSM are in random orientation. This means that it has the same strength in every direction. It is the cheapest and easy to work with, as its orientation does not matter. It used to produce the moulds and a thin veil of 100gsm is used to join the sides and protect the leading edge. WOVEN CLOTH FIBRE GLASS (WC) This consists of woven strands. It is very strong in the direction of the weave but is slightly more expensive and harder to work with as the orientation of the weave when the piece is cut must be carefully chosen. The cut weave has a tendency to unravel when it is handled in a dry state. THINNERS Lacquer thinners are required to remove excess resin and to clean up any spills, paint brushes, pots and tools. It is extremely flammable. CAR BODY FILLER A two-part car body filler is used to fill small blemishes and gaps on the final blades. Usually is supplied as a tin of resin with a small tube of hardener. The resin is a thermal-set plastic. The hardener, MEK peroxide, is a catalyst. The two components are mixed in a proportion of approximately 1% to 3% hardener to resin. Use a good quality brand.

EXPANDING FOAM A two-part expanding polyurethane low density foam is used to fill the air gaps within the blade. The foam is initially two liquids which must be mixed in a ratio of 1:1. This will then expand to 25 times its initial volume. Such foam is used in boat building and construction. This foam may not be required and the structure can be left empty but it significantly improves the rigidity and strength of the blade. BLADE MANUFACTURE The blade is comprised of two blade halves, the windward half and the backward half. Each blade half is built up from 16 layers of fibre glass mat. Woven cloth (WC) is used for additional strength in the direction the forces act on the blades. Materials required: For one blade: The general process is as follows: 1. Preparation: Cut the layers of fibreglass WC. 16 layers are used in each half. 2.Preparation:Prepare batches of resin mixture and the corresponding batches of hardener. 4. Preparation: Wax the mould to ensure easy release.

5. Procedure: Fill the moulds with a layer of resin, then a layer of fibreglass WC until all 16 layers have been placed. The weave of the WC must be rotated by 45 degrees between each layer. 6. Procedure: Leave to dry. BLADE JOINING When set, the two halves of the blade need to be joined to form a single unit. To do this they need to be accurately cut so that the two pieces fit together. The join should be made with minimal impact on the blades aerodynamic shape. Also additional strength and rigidity is added to the blade through the use of a stringer from the root to the tip. A wooden core is inserted at the root. This is so the screws used to hold the blades to the wind turbine have something to bite into. It also stops the blade root collapsing when the front blade assembly is bolted onto the generator on the wind turbine. BLADE TRIMMING Firstly the excess (over lap from the mould) must be cut off. This was done with a circular cutting saw. A jigsaw or a mini-cutter could also be used. A line should be visible at the edge of the part, distinctly showing the smooth section from the mould and the excess overlap. Then grind down the inside edges at approximately 45 degrees. This is to allow the two blade halves to fit just inside each other to make a full blade. The two halves can be placed together for comparison to check they fit well. This can be a long process and usually requires a few attempts (additional grinding) until the two halves fit perfectly. BLADE ROOT A steel core is required at the blade root - where the blade is screwed to the blade hub. The blade root should fit snugly in the root of the blade and go far enough down the blade so that all the screws will bite into the steel core.

BLADE FINISHING The blade halves have been stuck together and filled with foam, the Last stage is the blade finishing. This involves filling any gaps on the blade edges, adding a thin veil of fibre glass to the leading edge, sanding down any imperfections and painting. Fill any gaps along the leading edge with good quality filler, such as car body filler. Leave this to dry. Sand the blade along the leading edge and ensure that the surface is smooth. Add a narrow strip of CSM fibreglass to the leading edge. Two layers should be applied. This is to help hold together the two blade halves and also to add an additional layer to help protect the leading edge. Sand the blade to ensure that all the surfaces are smooth, especially along the leading edge. The edge of the trailing edge should be thin, approximately 1mm or less width. This will be the final sanding process. The final blades will look like this.

CONCLUSION Thus a wind turbine blade was successfully designed and fabricated, for the given power and other requirements. The blade is designed to ultimate perfection considering the loads and stresses acting on it. The profile chosen for the blade was also analysed for its aerodynamic properties and considered as best for the implementation in the wind turbine.

ABSTRACT

Roof Top Green Energy Generator is an emerging technology in the wind energy conversion system. With the immense encouragement from our college Management and innovative guidance from our HOD and staff members, the focus is given on Alternative Energy Resources [AER] such as the Solar energy , wind energy, Biomass energy and the development of Roof Top Green Energy Generator initiated and the dream come true, that our college will have its own power generator. Focus is given to Horizontal Axis Wind Turbines [HWAT] , the most common and efficient type of wind energy conversion system. This report deals with the designing and fabrication of a 1 KW wind turbine blade.