Professional Documents
Culture Documents
Project
AE5 Design Small Scale Wind Turbine
for Home Electricity Generation
March 2013
By
Maheemal K.B. (0923688)
Kalinga Ellawala (0628552)
Bhavdeep Pancholi (0906043)
Mishkath Harees (0806420)
Abstract
Wind Turbines are one the oldest known method used to extract energy from the natural sources
(wind in this case). With the changing weather and wind speed, it is not possible to produce high
constant power from the wind turbine but a small scale wind turbine can be used to power small
appliances at home, e.g. fridge. This project looks into thetechnical and marketing aspects for an
innovative design of a small scale wind turbine designed for supplying home electricity. The report
includes content on design, enhancement, power management, manufacturing methods, cost
analysis & marketing issues; processes which are considered for creating new patent and putting into
development.
Acknowledgement (BP)
We would like to express our gratitude to all those who gave us the possibility to complete this
design project. We would like to thank Brunel School of Design & Engineering and all the professors
involved in this module for giving us permission to commence this project in the first instance, to do
the necessary research work and to use departmental data and knowledge.
We also like to take this opportunity to thank our project supervisor Dr. A. Gatto whose help,
suggestions and encouragement helped us stretch our ideas further then our own imaginations.
1|Page
Table of Contents
Abstract ................................................................................................................................................... 0
Acknowledgement (BP) ........................................................................................................................... 1
1
Aim .......................................................................................................................................... 0
1.2
2.2
2.3
2.4
Windon 2 kW ........................................................................................................................... 2
2.5
Bergey Excel............................................................................................................................. 3
2.6
2.7
Windsave WS500..................................................................................................................... 3
2.8
Geographical Analysis.............................................................................................................. 4
3.2
UK Historical Data.................................................................................................................... 6
4.2
4.2.1
4.2.2
4.2.3
Materials........................................................................................................................ 12
4.2.4
4.2.5
4.3
4.4
5.2
5.3
5.3.1
5.3.2
5.3.3
5.4
5.4.1
5.4.2
5.4.3
5.5
5.5.1
5.5.2
5.5.3
6.1.1
6.1.2
6.2
6.2.1
6.2.2
6.3
6.4
8.1
8.2
8.3
8.4
8.5
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
Sands ..................................................................................................................................... 31
9.10
9.11
Patterns ................................................................................................................................. 31
9.12
9.13
9.14
9.15
9.16
9.17
9.18
Forging of Metals................................................................................................................... 34
9.19
9.20
9.21
9.22
9.23
10
11
11.1
11.1.1
Design 1 ......................................................................................................................... 42
11.1.2
Design 2 ......................................................................................................................... 42
11.1.3
Design 3 ......................................................................................................................... 42
11.1.4
11.1.5
Materials........................................................................................................................ 43
11.2
11.2.1
Design 1 ......................................................................................................................... 43
11.2.2
Design 2 ......................................................................................................................... 44
11.2.3
Design 3 ......................................................................................................................... 45
11.2.4
Design 4 ......................................................................................................................... 45
11.3
11.3.1
Braking Systems............................................................................................................. 46
11.3.2
11.3.3
11.3.4
11.4
11.4.1
11.4.2
11.4.3
11.5
11.5.1
Introduction................................................................................................................... 49
11.5.2
11.5.3
11.5.4
11.5.5
11.5.6
11.5.7
11.5.8
11.5.9
11.5.10
Hysteresis .................................................................................................................. 52
11.5.11
Lead-Acid Batteries.................................................................................................... 52
11.5.12
11.5.13
11.5.14
12
12.1
12.2
12.2.1
12.2.2
13
13.1
13.2
13.3
13.4
13.5
13.5.1
Rotor .............................................................................................................................. 64
13.5.2
Stator ............................................................................................................................. 65
13.5.3
13.5.4
13.5.5
13.5.6
Method .......................................................................................................................... 69
13.5.7
13.6
13.7
13.7.1
Generator ...................................................................................................................... 71
13.7.2
14
Manufacturing (MH).................................................................................................................. 72
15
15.1
Material Costs........................................................................................................................ 73
15.2
15.3
Marketing Costs..................................................................................................................... 75
15.4
Premises Costs....................................................................................................................... 76
15.5
15.6
15.7
Revenue ................................................................................................................................. 78
15.8
16
16.1
17
18
18.1
Figures ................................................................................................................................... 87
18.2
19
Appendix-B (MT)........................................................................................................................ 91
20
6|Page
1 Introduction (BP)
With increasing awareness of global warming due to Carbon Dioxide produced from the burning
fuels, the use of natural energy source is coming into effect. Engineers are adapting the use of
natural sources (e.g. wind, solar, hydro) to generate electricity and provide power to the power
plants. The use of wind turbine is one of the oldest known methods of extracting the energy from
natural sources. Windmills were used in olden times to run the pump for pumping the water from
the well. Wind turbines are not well considered because they heavily depend on the wind blowing
along with the geographical disturbance however, a small scale wind turbine can be used to power
small home appliances reducing the cost of electricity and fuel burnt to produce equal amount of
electricity.
Wind turbine extracts energy from the wind to generate electricity. 40% of all the wind energy in
Europe blows over the UK, making it an ideal country for domestic turbines (known as 'microwind' or
'small-wind' turbines). A typical system in an exposed site could easily generate more power than
household lamps and other electrical appliances use. Just like any engineering design poses
challenges, household wind turbine also poses various challenges such as noise, aesthetics, buying
cost, maintenance cost, etc.
This report looks into the current designs of the small scale wind turbine along with the market
requirement followed by the design of an innovative wind turbine system. In the report areas such as
current designs, power generation, blade design power management and fail safe methods are
considered. The report also considers the development complications limiting the design
enhancement such as noise, aesthetics, material cost, maintenance, legal constraints and other
issues. These are the issue which affect the design, manufacturing and marketing of the product.
1.1 Aim
The main aim of the project is to design a small wind turbine that can generate electricity for home
appliances. The thought of design directs us to look into the various aspects such as manufacturing,
noise, cost which leads us to our additional aim of analysing the system to overcome the usual
technical glitches.
Evaluation of the working environment for the turbine in the UK wind speeds, weather, etc.
Calculation of the aerodynamic design and structural loads
Energy ball V200 (SeeFigure 1)) is a unique turbine design when compared to the traditional three
blade wind turbines. The design consists of six rotor blades that are assembled
assembled as a sphere shape.
The turbine weights 90kg, turbine diameter of 1.98m and minimum start up wind speed of 3 m/s.
Due to the unique design and the venture effect, the generator harness wind more efficiently. The
electricity generated from V200 Energy ball comes to direct use where it can be plugged in straight to
the electric socket (Plug-in
in product) of the property. The Inverter is connected to the property
electric breaker box. The energy harvest from V200 can be used to charge batteries and excess
unused
nused energy automatically dumped in to the grid. The Energy ball categorised as a noise less, since
the turbine does not have any wing tips it does not generate the swishing noise. The Energy balls
dimensions allow it to be installed in many countries
countries urban areas. Also it features such as less
vibration (noise less) and less shadows it ideally suited for residential or commercial rood top usage.
Figure 90 shows the power curve of the Energy ball V200 which shows the turbines operating
parameters (1).
1|Page
2.4 Windon 2 kW
The Windon 2kW (SeeFigure 4)) is a turbine which has three blades with a diameter of 3.2 meters.
Back on the turbine is a fin, which helps the turbine to steer up against the wind so that maximum
effect can be received. The tower can be 9 or 12 meters high, and the weight of the turbine is
approximately 40 kg. The minimum wind for the turbine to start generate electricity is 2.5 m/s. The
wind turbine is very quiet and demands very little service and maintenance. Figure 92 shows the
turbine power curve (4).
2|Page
coefficient of performance (power produced by turbine divided by power in the wind) of about 0.38,
which would be an extremely good performance for a micro wind turbine, which, at that size, might
have been more expected to have maximum coefficient of performance between 0.11 and 0.19 (7).
Figure 7: Windsave
Figure 8: Swift
4|Page
Wind flowing over various landscapes can get affected by its geometrical appearance. Figure 9shows
a classic example of how the wind gets affected by the landscape. It shows graphical presentation of
the CFD simulation carried for a micro scale model over the Wellington area.The wind cannot be
seen in real life but can be visualised as stream of particles flowing in a line (either straight or random
chaotic line). Figure 10&Figure 11shows animated behaviour of the wind flow over the mountain and
the cliff.
The purpose of this analysis is to show that the undisturbed flow of air is mostly uniform.However
when it flows around or across a geometry or a landscape, it creates turbulence. This turbulent
air/wind includes random movement of the air particles which leads to loss of energy the wind
contains. Therefore wind turbine needs to be placed on a landscape that places rotor and blades in
average wind flow but with little of turbulence created by the surroundings.
Artificial or natural surroundings can potentially create turbulence. Artificial surroundings include the
houses and buildings. Figure 12&Figure 13 shows CFD Analysis carried out by S J Watson at
Loughborough University. Figure 12displays filled vector plot of a house in isolated area and how
wind (flowing from left to right) creates wake resulting in no or low velocity with a change in
direction. Figure 13displays a filled vector plot of a house in urban area which shows wind flow (left
to right). In urban area there is only small amount of wind flowing below the roof tops and because
of this, minimum turbulence is created before and aft of house.
5|Page
The wind analysis of different landscape and geometrical obstacles suggest that the wind turbine
needs to be placed in open area where landscape does not create wake. If the turbine is to be placed
on top of a house roof, it needs to be place on the upwind side of the roof as downwind side has high
turbulence close to the roof. If the wind turbine is to be placed near the cliff top or on mountain, it
needs to be high above the ground as the turbulence is high near to the terrain. However at very high
level from ground, wind speed is not high therefore a balance must be found by collecting data over
certain period of time at different height scales.
6|Page
The data above clearly shows that the mean wind speed varies between 6-25 m/s at various regions
in UK. Climate conditions also play important role in wind speeds as seen from the figures above. In
summer, the wind speed measured in most urban areas is below 10 m/s and towards the Scotland
side it picks up to 25 m/s. however in winter, the urban areas experience wind speed of 10-15 m/s
and areas in Scotland and North Wales experience wind speed greater than 25 m/s. some part in
changing wind speed. Therefore if the small wind turbine is to be designed for UK households, then it
should be able to work at speeds low as 3-6 m/s and should also be able to sustain high wind speeds
of around 25 m/s.
1
=
2
Equation 2: Power
If the kinetic energy of the wind is considered to have constant velocity then the power of the wind
can be calculated by
=
,
where
=
Therefore,
1
=
2
Where is the Density, A is the Sweap Area and v is the Velocity of the wind.
7|Page
The above calculation only helps us to find out the wind power with specific wind velocity. The wind
turbine however does not extract all the power from the wind. Some of the energy is used to
overcome the profile drag (14) created by the blade geometry and the leftover energy is allowed to
pass through as extracting all the energy from the wind would mean accumulation of static pressure
particles aft of wind turbine blades. Imagine an Axial Stream Tube around a wind turbine as shown
in Figure 19; if the energy is extracted between stage 2 and 3, the pressure accumulation would
divert the incoming flow around the blade rather than passing through the blades. By extracting the
power, the turbine reduces the wind kinetic energy. Therefore the air moves more slowly
downstream of turbine compare to the upstream. This accumulates wind behind the turbine sweap
area (downstream) as its moving slowly after the energy extraction. As a result the approaching
(upstream) wind diverts around the turbine blades to avoid slow moving air. For these very reason
there is an optimum amount of power to extract from a given disc diameter (15). The ideal is to
reduce the wind speed by about two thirds downwind of the turbine, though even then the wind just
before the turbine will have lost about a third of its speed. This allows a theoretical maximum of 59%
of the winds power to be captured (this is called Betzs limit) (15).
So by taking the Betzs limit in consideration, the power available from the wind is given by the
formula below where is the Betzs limit (generally given by ratio).
1
=
2
Even after applying the Betzs limit, the wind contains energy enough to drive the blades &generator
and produce electricity. However, it depends on the blade design and its efficiency across the span to
determine how much energy is extracted. While talking efficiency, we are faced by various design
&mechanical limitations, therefore design of the blades will be considered even further in the next
section as the blades play keep role in extracting the energy from the wind.
8|Page
The equation above shows the finite wing lift equation which uses the finite wing CL value to work
out the lift. If we look at the cross section of the wind turbine blade at particular point, we would see
an airfoil shape. Air flowing over an airfoil shape generates lift due to the pressure difference. The
best lift/drag characteristics are obtained by an airfoil that has thickness approximately 10-15% of its
chord length (15). The lift can be increased by increasing the angle of attack but it also increases drag
and potential of flow separation (Figure 21). For a particular airfoil shape coefficient of lift to angle of
attack graph (Figure 22) is used to best describe the relation between lift and the angle of attack.
9|Page
The figure above shows the graph for Infinite and Finite Wing Coefficient of lift where infinite wing
curve is mostly based on experimental and computation analysis and finite wing lift can be worked
using the following formula:
=
1+
. !
"#$%
Where CL is the finite wing coefficient of lift curve gradient worked using infinite wing coefficient of
lift curve gradient (Cl), aspect ratio (AR) and the span efficiency factor (e). Using this equation the
coefficient of the lift and the lift itself can be worked out for a blade design however, the drag affects
needs to be considered. The drag force on wind turbine blade is used to rotate the blades for VAWT
but for HAWT it adds to the loss of energy from the wind and also adds to the structural load applied
to the blade and the whole system. Drag force acting on the blade is given by the following equation:
1
& = '
2
Where CD is:
' = +
()*
The above equation uses finite wing coefficient of lift value along with the aspect ration, span
efficiency factor and airfoil profile drag (skin friction drag + pressure drag) to calculate the Finite
10 | P a g e
Wing Drag. With the method of calculating the lift and drag for wind turbine blade, the design of the
blade can be altered to maximize its efficiency.
To improve the blade efficiency, the blade thick needs to be reduced relative to its width and this has
effect on the aerofoil shape and the loading of the material. Also the apparent wind, wind blowing at
an angle (Figure 23), rotates the angles of the lift and drag to reduce the effect of lift force pulling
the blade round and increase the effect of drag slowing it down. It also means that the lift force
contributes to the thrust on the rotor (15). Hence the reason the blade needs to be turned further at
the tips than at the roots, approximately around 10-20.
As mentioned earlier, the best lift/drag characteristics are obtained by an aerofoil that has thickness
approximately 10-15% of its chord length. However the due to structural requirements, the blade
needs to support the lift, drag and gravitational forces acting on it, the aerofoil needs to be thicker
than the aerodynamic optimum. The blade needs to be even thicker towards the root (where the
blade attaches to the hub) where the bending forces are greatest. Because the apparent wind is
moving slowly near to the roots (Figure 24), the need of aerodynamic efficiency is low. In which case
some designers use a flatback section (Figure 25) closer to the roots as it gives high structural
strength at the root attachment area but the attention needs to made as the section cannot get too
thick for its chord length or the air flow will separate.
11 | P a g e
4.2.3 Materials
To maintain optimum solidity and high aerodynamic efficiency, thickness of the blade is
compromised. This makes it difficult to build the strong blades as thin material can flutter and
fracture eventually. To build a strong blade, material such as Pre-Preg carbon can be used which is
stiffer and stronger then glass fibre but drives the cost of material high. For a small scale wind
turbine blade material; aluminium alloy, iron, wood or strong plastic are more suitable due to its low
cost of manufacturing compared to carbon fibre (blade aerofoil shape does affect the manufacturing
cost).
where u is the wind speed velocity, c is the blade chord length and is the dynamic viscosity of the
fluid (air in this case). If the Reynolds number is high the stall coefficient of lift value for a particular
airfoil shape is also higher (Figure 27), therefore more leverage in the angle of attack. High Reynolds
number also reduces the drag for given angle of attack (Figure 26).
12 | P a g e
F = force, r= radius from the centre point to where the force is acting
Therefore the efficiency of the wind turbine can be determined by dividing the Power extracted (PR)
by the Power Available (P):
%
3 =
Equation 12: Coefficient of Performance(17)
The efficiency of the turbine gives us good idea on how where the turbine needs to be altered to
improve the coefficient of performance but with the improvement comes the cost of manufacturing
and maintenance. The wind turbine also ends up losing some efficiency to overcome the frictional
affects and some energy is lost as heat and noise.
The noise from the mechanical rotating parts can be reduced by lubricating the parts however
maintenance of these parts is expensive and difficult if the wind turbine is mounted on roof top or
high mast. Blade rotating through air also produces noise which can only be reduced by containing
the turbine blades in a cylindrical diffuser built with high acoustic material e.g. foam. The mechanical
parts and blades are not the only source of noise but the electrical generator also emits noise when
wire is turning in the magnetic flux area or when high voltage current is passing through the coils.
This situation not only emits noise but also transfers heat to the surroundings reducing the overall
efficiency of the turbine. To summarise, properly insulating the wires,
wires, placing the acoustics around
the turbine and lubricating the mechanical system regularly keeps the turbine efficiency high but the
maintenance cost increases.
5 Generator (KE)
Torque is transferred from the rotor through a connecting
connecting shaft to the generator
genera
which generates
electricity. The shaft is either directly connected or is connected through
t
the gearbox which then is
linked to the generator. Gearbox is placed to increase the rotational speed if the rotor is not turning
fast enough for the generator to produce high frequency electricity. Some wind turbine would also
incorporate changing gear system managed by the controlled feedback system,
system, i.e. it would change
the gear depending on the rotor speed to keep the generator speed constant.Generators
constant.
can be
placed at the top of the tower or at the base (connect by the gears) for HAWT and at the base for
VAWT. An electrical generator is used to convert mechanical energy into electrical energy. The
torque transferred by the rotor is used to rotate acoil of wire
re or a magnet to generate electricity.
14 | P a g e
5.2 InductionGenerator
Electricity can also be generated by rotating magnet and fix stator with coils to induce current in.
Induction generator uses principle from induction motor where the wind turbine rotor blades are
connected to the magnet that rotates between a stator with coils wounded around the stator. When
the magnet rotates it creates flux in the stator which cuts the coils and generates voltage (Figure 30).
The magnet then turns to change the magnetic field and the flux direction which sets the scenario for
changing flux between fixed coils resulting in alternative current produced.
15 | P a g e
16 | P a g e
Figure 34: Cross Sectional View in radial direction and in axial direction
Figure 35: Cross Sectional view in radial direction and in axial direction
Transversal flux machines are manufactured by mounting the plane of flux path perpendicular to the
direction of rotor motion. The transversal flux machines can used in applications where required high
17 | P a g e
torque density requirements. The transversal flux machines can independently adjust the current
loading and the magnetic loading. The main disadvantage of transverse PMSG is that high leakage
flux results in poor power factor; this can be avoided by reducing the number of poles where in turn
reduces torque density. Another drawback in rotating transverse PMSG is the mechanical
construction is weak due to large number of parts(21).
Figure 37: Inner rotor PMSG (left) and an outer rotor PMSG (right) (ref3)
Slotless design is where the coil is placed in the air gap. This air gap increases the distance between
stator and the rotor increasing the reluctance causing increase in PM (Permanent Magnet) leading to
18 | P a g e
a reduction in flux density. More magnetic material or copper winding are needed to compensate
this. A slotless design has less steel and therefore less hysteresis and Eddy current losses. The power
density of a slotless design is three times lower than in a slotted design(21).
Variable blade pitch, which gives the turbine blades the optimum angle of attack. Allowing
the angle of attack to be remotely adjusted gives greater control, so the turbine collects the
maximum amount of wind energy for the time of day and season.
19 | P a g e
The tall towers allow access to stronger wind in sites with wind shear. In some wind shear
sites, every ten meters up, the wind speed can increase by 20% and the power output by
34%.
High efficiency, since the blades always moves perpendicularly to the wind, receiving power
through the whole rotation. In contrast, all vertical axis wind turbines, and most proposed
airborne wind turbine designs, involve various types of reciprocating actions, requiring
aerofoil surfaces to backtrack against the wind for part of the cycle. Backtracking against the
wind leads to inherently lower efficiency.
Taller masts and blades are more difficult to transport and install. Transportation and
installation can now cost 20% of equipment costs.
Stronger tower construction is required to support the heavy blades, gearbox, and generator.
Reflections from tall HAWTs may affect side lobes of radar installations creating signal
clutter, although filtering can suppress it.
Mast height can make them obtrusively visible across large areas, disrupting the appearance
of the landscape and sometimes creating local opposition.
Downwind variants suffer from fatigue and structural failure caused by turbulence when a
blade passes through the towers wind shadow (for this reason, the majority of HAWTs use
an upwind design, with the rotor facing the wind in front of the tower).
They require an additional yaw control mechanism to turn the blades toward the wind. (22)
20 | P a g e
turbine (HAWT), a VAWT rotates around the shaft vertically. VAWTs provide good performance in
urban and suburban environments due to their inherent design characteristics.
Ability to effectively capture turbulent winds which are typical in urban settings, especially in
built-up areas.
No need for a yaw mechanism to face the blade rotor into veering wind directions; VAWTs
therefore have higher efficiency and no orientation parts to maintain.
Operation at lower rotational speeds, thereby reducing or eliminating turbine vibration and
noise.
Durability and reliability working in multi-directional wind.
Easier and less expensive repair and maintenance with generator on rooftops.
Lower noise and vibration. (23)
A VAWT can receive winds from any direction, this is important in locations where winds Are
turbulent, gusty and constantly changing directions. There is no down-time as the rotor
does not have to yaw to face the wind, in addition there are no gyroscopic effects preventing
yaw. The more obstacles (e.g. trees and buildings) in your environment the more turbulent
the wind is likely to be.
Aerodynamic noise is primarily generated by the fast moving tips of the blades through the
air. A VAWTs tips are much closer to the axis of rotation and therefore moving more slowly
through the air.
A VAWT for the same swept area has a smaller plan area than a HAWT, making it more space
efficient, an important consideration when siting close or onto buildings
Loads are more evenly distributed with a VAWT than a HAWT which results in lower vibration
making VAWTs a better option for roof mounts.
VAWTs HAWTs
Effective in laminar winds (1)
Yes
Yes
Yes
No
Yes
Sometimes
21 | P a g e
Ground mounting
Yes
No
Rooftop mounting
Yes
Sometimes
1) Laminar: fluid air flow which occurs in "sheets" parallel to each other.
2) Turbid: flow that changes directions quickly and often and has turbulences. (25)
Once the electricity generation process has been completed, it is then sent down through wires to a
transformer unit which increases the voltage up to a few 1000 kV depending on the scale of the wind
turbine. The transformer is needed for either on-shore or off-shore wind turbines where the
electricity generated needs to travel a large distance.
Depending on the type of generator used within the turbine, it will produce either AC or DC power.
An inverter is used in order to convert from DC to AC for domestic use. The electricity can now be
connected directly to the national grid network, stored in batteries for future use or connected to a
household mains grid. When connecting to a household mains grid, another transformer would be
used to reduce the voltage to 120/240 V AC.
22 | P a g e
A small scale wind turbine to be used for domestic purposes will contain slight variations to be more
suited for the purpose. Figure 42shows
42
a typical system which might be used for a household wind
turbine.
Due to various design and build limitations in small scale wind turbines, a few additional systems
needs to be put in place to provide safe power that can be used in a home system. Typically, they do
not have variable pitch rotor blades and due to this, the rotor speed would constantly change
according the change in wind
nd speed. This does not present a favourable situation for the power
management system because the output voltage and frequency provided by the generator is
proportional to the speed of the rotor while the current produced is proportional to the torque on
the rotor shaft.
Once the electricity is generated, it is sent through a rectifier in order to convert the AC current
produced through the generator. This is done because AC constantly changes direction while DC
maintains a single direction, thus making it easier to regulate. Once this current is converted, it is
sent to a Voltage Regulator unit which is used to maintain the voltage at a constant level
independent of the variability presented to the system. This regulator system can also ensure that
the voltage
oltage supplied is at the correct frequency and phase.
The system is then taken over by a DC control unit which works in a similar method to an Engine
Control Unit (ECU) in a vehicle. Now that we have a constant voltage supply which is regulated, we
can distribute
stribute the electricity using various methods. The electricity could be stored within batteries
for future use. If it is required to be used within a household grid, an inverter would be used to
convert DC to AC which can then be distributed. Another option
option available for home owners is to sell
excess electricity back to the national grid which could help recuperate some of the costs of the
system. Such systems however would need to be agreed to by the supplier and considerations would
need to be made if it would be better to store excess electricity within batteries or to sell back to the
grid, where once sold, if the wind turbine does not produce enough electricity, cost of purchasing the
same amount would be higher.
by having a ball resting on a ring where the ball is connected to a switch through a chain. If vibrations
reach an excessive limit (which can bet set at a required amount), the ball will fall out of the ring
which would enable to switch to turn off the turbine. Advanced electronic sensors which are
connected to the electronic control system of the turbine could also be employed to monitor
vibration levels.
24 | P a g e
Sonic, Termographic etc.). Therefore the timely testing and observation to such damage could
prevent incidents such as a blade failure, gearbox failure etc.
would need to be manufactured and also its end service life. These factors would also
directly affect the cost of manufacture and labour skills required to carry out the various
tasks.
1. Casting
Expendable Mould
Permanent Mould
2. Forming and
Shaping
3. Machining
Turning,
Turning, Boring, Drilling, Milling, Planing, Shaping
Broaching, Gringing, Ultrasonic Machining
4. Joining
5. Finishing
Honing,
Honing, Lapping, Polishing, Burnishing, Deburring
Surface Treating, Coating and Plating
27 | P a g e
that relate to the topics discussed above. For example, certain materials which are brittle and/or
hard cannot be shaped easily but casting is a more relevant method.
Within the next few sections, common manufacturing techniques will be discussed and
recommendations can be made for manufacturing techniques relative to the turbine. The types of
materials will be broadly categorized into metals and plastics. Firstly, a brief discussion on their
various properties which make it suitable for each process will be discussed, followed with methods
in which they could be manufactured.
Process
Advantages
Limitations
Sand
Shell mould
Expendable
pattern
Plaster mould
Ceramic mould
Limited size.
28 | P a g e
Permanent
mould
Die
Centrifugal
The casting industry is impacted by two major trends. The first is continuing mechanisation and
automation of the casting process, leading to changes in the use of equipment and labour. The
second trend is the increasing demand for high quality casting with low dimensional tolerances and
no defects. SeeTable 3 for general characteristics of the casting processes.
Process
Sand
Shell
Expendable Plaster
mould
mould
pattern
Typical
Materials Cast
All
All
All
Nonferrous All
(high All
(Al, Mg, Zn, melting
Cu)
point)
Nonferrous All
(Al, Mg, Zn,
Cu)
Minimum
Weight (kg)
0.05
0.05
0.05
0.05
0.005
0.5
<0.05
Maximum
Weight (kg)
No limit
100+
No limit
50+
100+
300
50
5000+
1-3
5-20
1-2
1-3
2-3
1-2
2-10
Porosity*
2-3
1-2
2-10
Shape
Complexity*
1-2
2-3
1-2
3-4
3-4
3-4
Dimensional
Accuracy*
Minimum
Section
0.5
Centrifugal
29 | P a g e
Thickness (mm)
Maximum
No limit
Section
Thickness (mm)
No limit
75
50
12
100
Table 3: General Characteristics of Casting Processes. *Relative rating: 1 best - 5 worst. (30)
The surface finish of the products depends on the material used in making the mould, as
well as on the manufacturing route selected. Surface roughness figures can be observed in
Figure 43.
Figure 43: Surface Roughness in Casting and other Metalworking Processes (:272)
30 | P a g e
9.9 Sands
Silica sand (SiO2) is used by most sand casting operations. Sand is cost effective and is suitable as a
mould material due to its resistance to high temperatures. There are two general types of sand:
naturally bonded (bank sand) and synthetic(lake sand). The last one is preferred as it can be
controlled more accurately (30).
9.11 Patterns
Patterns are employed to mould the sand into the shape of the desired casting. They can be made of
different materials and their selection is made based on the shape and size of the casting, the
dimensional accuracy, the number of finished products and the moulding process. SeeTable 4 for
characteristics of pattern materials.
The strength and durability of the pattern material should be selected according to the number of
castings desired. The pattern may be made out of more materials to reduce wear in critical regions
and they are designed to suit the application and economic requirements. There are a few types of
patterns, such as the one-piece, split and match-plate patterns (30).
Rating*
Characteristics
Wood
Aluminium
Steel
Plastic
Cast Iron
Machinability
Wear Resistance
31 | P a g e
Strength
Weight**
Repairability
Resistance to
Corrosion***
Resistance to
Swelling***
Table 4: Characteristics of Pattern Materials. *relative rating: 1 excellent, 2 good, 3 fair, 4 poor. **as a factor in operator
fatigue. ***by water (30).
Figure 46: Designs of squeeze heads for mould making: (a) conventional flat head; (b) profile head, (c) equalising squeeze
pistons; (d) flexible diagram (30)
e.g.stress relieving, annealing etc. In addition, the wear resistance of the metal can be enhanced at
the surface by laser hardening.
33 | P a g e
High-melting-point alloys of aluminium, magnesium and copper are normally cast using this method.
Molten-metal temperatures start at about 600 degrees Celsius for aluminium and some magnesium
alloys and increase considerably for copper and iron based alloys (30).
Figure 49: Properties and Typical Applications of Common Die Casting Alloys (30).
34 | P a g e
A component that can be forged successfully may also be manufactured economically by other
methods, such as casting. However, each process has its own advantages and limitations with regard
to strength, toughness, dimensional accuracy, surface finish and defects (30).
The open die forging uses simple, inexpensive dies, but it is limited to simple shapes and a low
production rate. The closed die forging has good dimensional accuracy and reproducibility, but
machining is often necessary for the finished product (30).
Forging was considered as an alternative manufacturing route to casting, but due to its limitations or
high cost, metal casting is the preferred manufacturing technique employed for the wind turbine
components.
Characteristics
Extrusion
Long, uniform, solid or hollow complex crosssections; high production rates; low tooling
costs; high tolerances.
35 | P a g e
Injection moulding
Blow moulding
Rotational moulding
Thermoforming
Compression moulding
Transfer moulding
Casting
36 | P a g e
Figure 50: Injection moulding with (a) plunger, (b) reciprocating rotating screw (30)
37 | P a g e
Rotational moulding can produce parts with complex with complex hollow shapes and with a
wall thickness starting from 0.4 mm. Cycle times are longer than in other moulding
processes, but equipment costs are low. Quality control considerations usually involve
accurate weight of the powder placed in the mould, thorough rotation of the mould and
temperature-time relationship during the oven cycle(30).
38 | P a g e
4.1.2.The turbine is to be designed to operate within a range of wind speeds between 5 and
20 m/s and appropriate safety systems to ensure shutdown in the event of excessive
wind speeds as per section 4.5
4.1.3.The design of the turbine should comply with the Betz limit which limits the power
extracted from the wind at 59.25%
4.2. Legal Constraints/Building Regulations
4.2.1.The requirements set out below are to be met at all times in order for the turbine to be
installed without requiring further planning permission
4.2.2.It is recommended however that the local council of the area in which the turbine is to
be installed, be contacted in case separate regulations exist
4.2.3.Such development rights are applicable for building mounted wind turbines applicable
to detached houses or other detached buildings within the boundaries of a house or
block of flats.
4.2.4.In addition to the criteria set out in 4.2.2 a block of flats should not contain commercial
premises
4.2.5.The installation of the wind turbine must comply with criteria set out in the Micro
generation Certification Scheme Planning Standards (or equivalent)
4.2.6.The installation cannot be carried out on protected land i.e. national parks, heritage
sites, protected and/or land with restricted access for legal reasons
4.2.7.Only the first turbine installation is exempt from planning permission. Any further
installations would be subject to permission from the local council as applicable by
their requirements.
4.2.8.The turbine in an installed condition is not allowed to protrude more than 3 meters
above the highest part of the roof (excluding the chimney) or exceed an overall height
(including building and turbine) of 15 meters, whichever is lesser
4.2.9.The distance between the ground level and lowest part of the wind turbine blade must
not be less than 5 meters
4.2.10. No part of the turbine is allowed to be within 5 meters of any boundary
4.2.11. The swept area of the turbine blades must be no more than 3.8 square meters
4.2.12. In Conservation Areas, an installation is not permitted if the building mounted wind
turbine would be on a wall or roof slope which fronts a highway
4.2.13. The materials used within the blades must be non-reflective
4.2.14. The turbine is to be removed as soon as it is reasonably practicable when no longer
needed for micro generation
4.2.15. The turbine is to be sited (or mounted), so far as practicable, to minimise its effect on
the external appearance of the building
4.3. Power Requirements
4.3.1.As set out in Section 3, in order to fulfil its primary duty of providing power to a
domestic refrigerator, a minimum production of 0.5 kW/h is expected although it is
aimed to be able to produce between 1-1.5 kW/h in order to satisfy secondary duty as
set out in 3.2
4.4. Power Management
4.4.1.A system needs to be in place in order to manage the power that is generated by the
turbine, including regulators and converters
4.4.2.The power management system is also required to provide, at least, a simple interface
for the end user where information about the current system can be gained
4.4.3.A power consumption and production log is beneficial to have for maintenance and
analysis purposes
4.5. Safety Systems
4.5.1.In the event of a wind over speed event, a mechanical brake system is to be applied to
stop the turbine from rotating and thereby posing a safety risk
39 | P a g e
5.
6.
7.
8.
9.
10.
4.5.2.Safety systems are to be built into the power management system where the current is
to be regulated before delivered to the household
4.6. Building Mounting
4.6.1.It is required that the turbine is designed to be mounted on a typical UK household
4.6.2.The mounting system is to be designed to be able to withstand forces produced by the
turbine and nature
4.6.3.The design of the mounting system should permit ease of access to the turbine and its
components during maintenance and capability to remove the turbine if necessary
Material Selection
5.1. The selection of materials for the construction of any part of the turbine should be done
with the aim of achieving the requirements set out in sections 3 and 4 i.e. the material
selected must be fit for function and purpose
5.2. In order to meet the cost requirement set out in 4.1.1 the cost of each selection needs to be
carefully reviewed and if a selection of materials (which meets the criteria) is available, then
the cheapest material should be used unless any other valid reasons exist.
5.3. As highlighted in 4.1.2 prices for materials should be based on bulk purchase prices, as this
would reduce the overall manufacturing cost of the turbine.
5.4. The materials selected should also be considered for their recycling and disposable
properties at the end of the turbine life
Production
6.1. If the design of the wind turbine requires customised parts, then it should be investigated if
such parts are cheaper to be manufactured in-house or from a specialist manufacturer
6.2. Packaging of the turbine should be designed to minimise shipping costs and space and
wherever possible, consist of sustainable and recyclable materials
Selection of Conceptual Design
7.1. All members of the group are to be involved in an equal manner regarding the selection of
conceptual designs
7.2. All members are to be given specific areas of responsibility in the design of the turbine and
it is expected for them to carry out a thorough research into such areas and inform the
other members of their findings
7.3. The selection of the final conceptual designs are to be made as a group where input from
the areas researched in 7.2 is required
Maintenance
8.1. The design of the turbine should, as practicable as possible, not include user serviceable
parts due to safety reasons
8.2. Routine service maintenance is to be carried out by a certified technician at six (6) month
intervals and a thorough safety and electrical check carried out every twelve (12) month
period
8.3. If any part(s) that are contained within the turbine is judged to have a limited life either
through hours of operation or limited life cycles, they are to be made clear in the product
service schedule and made clear to the end user
Financial
9.1. The production costs of the turbine must not exceed 250 (GBP)
9.2. The turbine is to be presented to the market at a profit of 15% above all costs incurred per
unit
9.3. The final cost at which the turbine is sold at should take into account all manufacturing,
labour, shipping and other such costs
9.4. The cost of the turbine is to be determined once a final value of the components is made
and it is then to be scaled to a production cost per unit for 20,000 units
Target Markets
10.1.
The intended target market for this product is domestic home users where the
power requirement is for a medium sized refrigerator (or similar appliance)
40 | P a g e
11.
12.
13.
14.
15.
10.2.
In addition, as stated in 3.2, extra flexibility is given to the user regarding power
consumption through additional power sockets made available through battery banks
10.3.
The product is to be marketed as a relatively inexpensive wind turbine where the
cost of purchase and installation would reflect as such
Operational Safety
11.1.
It should be noted at all times during the design stage that the safety should be of
paramount importance at all times. Any aspect of the design should not post any safety risks
either to the consumer or cause damage to any surroundings.
11.2.
The turbine should be designed that wherever possible, Foreign Object Damage
(FOD) should be prevented or minimized
11.3.
Adequate protection needs to be given to any systems within the turbine containing
moving parts
11.4.
Any systems that contain electrical elements are also required to be given proper
insulation and sealing properties
11.5.
The turbine is to be accompanied with a thorough manual which provides clear
instructions to the user about its operation and safety features
11.6.
The safety systems described in section 4.5 is to be tested as part of section 12 and
the results made available to the end user
Quality Assurance
12.1.
In order to be compliant with various safety standards, the turbine is to be put
through a thorough testing process before it is launched into the market
12.2.
Testing is to be carried out for the following conditions:
12.2.1. Expected range of operating wind speeds
12.2.2. Safety systems at wind over speed event
12.2.3. Expected temperatures throughout the year
12.2.4. High rain or snow events
12.3.
Maintenance to be carried out at intervals specified in section 8
Engineering Drawings
13.1.
Complete engineering drawings are to be done for the design of the turbine and its
components
13.2.
Any such drawings are to be kept securely at all times
Intellectual Property (IP)
14.1.
The design of the turbine should take into account any existing patents, copyright or
design protection(s) and should not at any time infringe such protection(s)
14.2.
If any part of the turbine design requires design or copyright protection, applications
for such should be carried out
Revisions
15.1.
Revisions to the Product Design Specification should be clearly marked at the top of
the document and the table provided below where the changes made are to be
documented
11 Design Conceptualisation
11.1 Blade (BP)
A blade can be designed to have various shapes but as described in section 4.2.2, the lift and the drag
force need to be accounted for. The lift and the drag force depend on their coefficient value which
eventual depends on the aspect ratio (for finite blade structure) therefore changing the aspect ratio
would change the lift and drag force which will help us determine the advantages and disadvantages
of different blade structures.
41 | P a g e
11.1.1 Design 1
Trapezoidal Planform Area design would allow us to account for the apparent wind (see section 4.2).
With length (h) being the span area, smaller chord length can be placed towards the tip of the blade
to reduce the chances of stall near to the root section. It also angles the blades from the root section
to increase lift due to the apparent wind as mentioned earlier. However, the aerodynamic centre for
this shape shifts towards the root chord which reduces the linear velocity (acting at the aerodynamic
centre due to the lift force) as its proportional to the force and the radius.It also lowers the aspect
ratio (compared to the rectangular planform with same root chordlength) which eventually increases
the induced drag and the requirement for the angle of attack. The other problem this design imposes
is the changing chord length, which changes the thickness of the aerofoil shape (see section 11.1.4).
This does not allow us to work out the volume of the blade structure accurately during the design
stage in order to estimate the mass accurately.
b
h
456789
Planform Area =
Volume : = A t, where A is the planform area and t is the thickness
9 45678
X axis Centroid = = 45678
11.1.2 Design 2
Rectangular Planform Area can also be used to design the wind turbine blade. This design has high
aspect ratio relative to the Trapezoidal Planform design (with same root chord length). Increase in
aspect ratio reduces the downwash but this design does not account for the apparent wind. However
the simplicity of this design (constant aerofoil shape) allows us to measure the volume more
accurately than any other planform shape, which means we can calculate the mass of the blade
accurately at design stage. Although caution must be paid while working out the volume as its not a
rectangular box but an aerofoil shape with rectangular planform area. This design has high aspect
ratio and therefore high coefficient of lift and low induced drag however; it has relatively high profile
drag.
a
b
Planform Area = ? @
Volume : = A t, where A is the planform area and t is the thickness
5
X axis Centroid =
11.1.3 Design 3
Triangular Planform areahas minimum span area but low aspect ratio as the trapezoidal planform
design and therefore poses the same problem of downwash. However it has relatively low profile
drag and low volume compared to the other two designs therefore the mass of the blade would be
low too.
42 | P a g e
a
b
57
Planform Area =
Volume : = A 1 t,, where A is the planform area and t is the thickness
7
X axis Centroid =
11.1.5 Materials
The wind
nd turbine blade can be made out of range of materials available but the choice of material for
individual design heavily depends on the design aspects e.g. Lift the aerofoil shape generates, Length
of the blade, Tip velocity, etc. For large wind turbine blades,
blades, material chosen needs to be strong but
light therefore carbon fibre reinforcement on a strong plastic is widely used. For a small scale wind
turbine blades, aluminium is more commonly used as they are more resistive to corrosion then iron.
High strength
ngth plastic can also be used for blades but the manufacturing cost could be high as the
blade surfaces would require smoothening. However plastic are really light weight for small scale
wind turbine and, if reinforced with enough thickness to sustain structural
structural damage, they can produce
high angular velocity due to low mass.
43 | P a g e
Description: Figure 52 illustrates the first preliminary for the generator the wind turbine. The
permanent magnet generator is mounted to a central shaft which runs through the bearing and
housing.
Materials: Rotor is made out of Magnetite or Neodymium and stator is made using copper.
Advantages: No gear box required due to direct drive mechanism.
Disadvantages: Average cost of a 0.5 kW generator start from 100 which will increase the cost of
the product.
11.2.2 Design 2
Description:Figure 53 shows the second generator design for the wind turbine. This concept was
extracted from the permanent magnet generator theory. In this design, magnets are mounted on the
blade tip where the fluxes
luxes are distributed and the blades represent the rotor. A non-magnetic,
non
Nonconducting circular section holds a number of circular bobbin wound armature copper coils
positioned circumferentially around the circular ring which acts as the stator of the generator.
ge
The
power is generated when the blade tip magnet pass through the copper coil banks mounted onto the
outer ring.
Materials: For the rotor, Neodymium magnet was chosen due to its high performances. The copper
wires were chosen for the stator due to less resistance.
Advantages: Since blade tip has the highest speed, the electricity generate from the generator is
much higher when comparing to the axial fixed generator. Also the mechanical resistance is much
lower (Blades are connected to a bearing not
not to a yaw shaft) so the losses are low which will enable
the turbine to operate at a lower wind speed. This design reduces the noise, vibration and the size of
the wind turbine.
Disadvantages: The blade tip mounted magnets will add extra weight to the blade
bl
tip which
increases the cut in wind velocity.
44 | P a g e
11.2.3 Design 3
Description: Figure 54 illustrates the third generator design for the wind turbine. It also uses the
blade tip power generation system. However in this design the magnets are mounted on the outer
ring (Rotor) and the coils are wounded at the tip of the blade.
Materials: For the rotor, Neodymium magnet was chosen due to its high performances and copper
wires were chosen for the stator due to less resistance.
Advantages: The magnets are fixed in a N-S arrangement to create higher and uniform magnetic flux
between the two magnets, this effect create higher electricity from the turbine.
Disadvantages: Since the blade tip are equipped with coils the aerodynamic efficiency of the system
decreases. Total number of 8 magnets is used in this system which increase the total cost of the
system.
11.2.4 Design 4
Description: Figure 55shows the schematics of the fourth conceptual design of the generator.
Turbine consists of two rotating rotor sections. Where the Inner blades tip consists of wounded
copper coils.
Materials: For the rotor, Neodymium magnet was chosen due to its high performances and copper
wires were chosen for the stator due to less resistance.
Advantages: The two counter rotating blade systems increases the frequency of flux-coil interaction
generates more electricity.
Disadvantages: Mechanically complicated to build due to the two counter rotating blade system.
Additional materials required to build outer rotating system, which increase the cost of the product.
45 | P a g e
Hub
Figure 56: Design 1
46 | P a g e
Hub
Disc
Shaft
47 | P a g e
Mast
base
48 | P a g e
11.5.1 Introduction
A charge controller or charge regulator limits the current being delivered by the power source to the
battery. To be useful, "12 volt" wind generators need to be capable of delivering 16 to 20 volts in
moderate winds (at say 250-400rpm). Most 12v batteries need around 14 to 14.5 volts to get fully
charged.
Wind turbines need to be protected from 'over speed' which could occur if a load was suddenly
removed or switched 'off'. Over speed protection is normally achieved by maintaining a constant
electrical load on the turbine as well as providing voltage regulation the charge controller also
ensures that this electrical loading is present at all times. The electrical load is either provided by
charging the battery, or if the battery is fully charged then the excess power is normally diverted to a
dump load/braking resistor (which could be used for air, water or under floor heating)in this
situation, the excess power would be sold to the national grid under Feed-In-Tariff.
49 | P a g e
charge controllers as they would cause the turbine to over speed and damage would result from
excessive centrifugal force or excessive vibration.
11.5.3 ShuntRegulators
Have the following characteristics
The wind generator is not regulated or controlled and continuously delivers the available
power to the regulator and battery.
The regulator constantly monitors the battery voltage and switches between two states
determined by the battery voltage.
If the battery voltage falls below a "low" set limit the controller disconnects the dump
load and allows the battery to charge.
If the voltage rises above a "high" set limit the controller turns on a dump load and isolates
the battery from further charging.
In normal operation the wind controller will cycle between these two binary operating states
(Charging and Charged), thus achieving the battery voltage regulation between the controllers low
and high voltage set points* (*Note: see hysteresis below) (32).
PWM charge controller regulates the power being sent to the battery.The PWM regulator is
a proportional controller which is capable of varying the charge duty cycle between 0 and
100%. The controller constantly checks the state of the battery to determine how fast to
send pulses, and how long (wide) the pulses will be. In a fully charged battery with no load, it
may just "tick" every few seconds and send a short pulse to the battery. In a discharged
battery, the pulses would be very long and almost continuous, or the controller may go into
"full on" mode. The controller checks the state of charge on the battery between pulses and
adjusts itself each time.
50 | P a g e
A PWM dump load controller regulates the 'excess' power which needs to be dumped. This is
an alternative way in which a PWM regulator can be configured. Instead of regulating the
power being sent to the battery (see above) it regulates the excess power that needs to be
dumped into a braking resistor. With a discharged battery, pulses would never be sent to the
braking resistor. When the battery is fully charged and excess power is still being generated
then the PWM dump load controller sends pulses or may go into "full on" mode if the
generated power is high.
With the development of PWM charge controllers came a new and improved way of charging
batteries using bulk, absorption, float and equalization charges. These are a great improvement over
shunt charge controllers as they are able to keep the battery voltage much more stable.
been embedded within the wind turbine manufactured by Macro-Wind to ensure compatibility with
a solar style charge controller which has no provision for a dump load.
You should not assume that a new solar style charge controller which has no provision for a dump
load will be compatible with your existing wind generator. You need to check for compatibility with
your generator and the solar style charge controller suppliers. Apart from the damage referred to
above caused by the application of frequent shorts to the generator output there will be the
additional problem that the turbine would be beset with frequent stops. If the winds are light then
frequent stops means that you will lose the ability to generate power in low winds.
11.5.10
Hysteresis
Hysteresis is an integral characteristic with shunt regulators (but not with PWM regulators).The
regulator is either 'off' or 'on', with nothing in between. The regulator is a system; its input is the
battery voltage, and its output is the 'Charging' or 'Charged/Dumping' binary state. If we wish to
maintain a battery voltage of 12.5v, then the regulator may be designed to turn the dump load 'on'
when the battery voltage rises above the 12.6v set limit, and turn it 'off' when the battery voltage
falls below the 12.4v set limit. The controllers "low and high voltage set points" and a "lock out" time
constant within the controller define the characteristic hysteresis properties of the controller.
Domestic central heating thermostats also exhibit hysteresis. Further information on hysteresis can
be found on Wikipedia.
11.5.11
Lead-Acid Batteries
Lead-acid batteries fall into two categories. 1. Shallow cycle - these are the type used to start your
car. They are designed to deliver a large amount of current over a short period of time. This type is
unsuitable for a home power battery bank. They cannot withstand being deeply discharged, to do so
shorten their life. 2. Deep cycle - Designed to be discharged by as much as 80% of their capacity, this
is the type of choice for home power systems. The life of deep cycle batteries will be extended if the
discharge cycle is limited to 50% of the battery capacity and if they are fully recharged after each
cycle (this avoids positive plate sulphating). The quickest way to ruin lead-acid batteries is to
discharge them deeply and leave them standing "dead" for an extended period of time. When they
discharge, there is a chemical change in the positive plates of the battery. Batteries that are deeply
discharged, and then charged partially on a regular basis can fail in less than one year.
Second hand batteries from computer UPS and GSM base-station installations frequently come onto
the market. These batteries are normally removed from service when the battery backup time (i.e.
52 | P a g e
the battery capacity) has fallen below acceptable operational limits. Batteries always have a
manufacturers date code on them (for warranty purposes), make sure you know what it is before
you purchase. Second hand traction batteries (milk float, fork lift and submarine) are ideal but
difficult to value. However the price will never fall below the scrap value for lead. Storage batteries
need adequate ventilation(33).
State of Charge (approx.)
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
12 Volt Battery
12.7
12.5
12.42
12.32
12.2
12.06
11.9
11.75
11.58
11.31
10.5
11.5.12
Typically 0.5 to 2.0 ohms (for example: a 12volt 200watt dump load would consume 16.6amps and
have a resistance of0.72ohms).
The dump load should be dimensioned to dissipate the generators maximum output power. You can
use a "car ceramic heater" or a regular 12/24/48v immersion heater. If you need a higher capacity
dump load you can use a cheap DC-AC inverter to generate 240volts and a domestic oil filled
radiator.
Car headlight bulbs may be used for experimentation, but are not suitable as a permanent fixture
since they will burn out during high winds and without the dump load the controller will either "boil"
the battery or fail to load the generator which will then over speed (depending upon the controller
design and failure mode). Incandescent bulbs also have low impedance when cold and induce very
high switching currents. Dump loads can be controlled by MOSFET's or by relays.
11.5.13
Typically 1 to 5 ohms
To determine your optimum braking resistor value you may need to experiment with different power
resistors during various wind conditions. A very low impedance braking resistor would cause the
turbine to slow instantaneously to a low speed, which could place unnecessary stresses on the
turbine. The benefit of the turbine brake controller" configuration, which slows the rotor down, is
less wear and tear on the rotating components while the battery remains in its fully charged state. A
Rheostat is useful in determining the ideal brake resistor value when configured in the "turbine brake
controller" configuration. The braking resistor should be dimensioned to dissipate the generators
maximum output power.
11.5.14
A grid-tie inverter or a (GTI) is an electrical device that allows turbine or solar panels to complement
their grid power with renewable power. It works by regulating the amount of voltage and current
53 | P a g e
that is received from the turbine or solar panel and converting this into alternating current. The main
difference between a standard electrical inverter and a grid-tie inverter is that the latter also ensures
that the power supplied will be in phase with the grid power.This allows individuals with surplus
power (wind, solar, etc.) to sell the power back to the utility. This is sometimes called "spinning the
meter backwards" as that is what literally happens.
On the AC side, these inverters must supply electricity in sinusoidal form, synchronized to the grid
frequency, and limit feed in voltage to no higher than the grid voltage including disconnecting from
the grid if the grid voltage is turned off. A major advantage of Grid Tie Inverters is that the
requirement for batteries is eliminated.
Grid-tie inverters have a maximum permitted input voltage. As wind speeds increase, this limit may
be exceeded. In these circumstances the grid-tie inverter will automatically disconnect the turbine
from delivering power to the mains. At this point the rotor is no longer loaded and it will rapidly
increase to a dangerous speed. High voltages are still being applied to the input of the "off-line" Gridtie inverter, which will destroy it. Then the rotor may also be destroyed by high speed vibration and
centripetal forces. An additional problem is mains failure as this will also remove the loading on the
rotor, with the same consequences. A frequency switch can be used to apply a diversion load and
brake to slow the turbine down to a safe speed, during either of these two conditions.
Grid-tie inverters also have a minimum input voltage which needs to be maintained if you wish to
remain connected to the grid. Falling outside of this min-max window will result in the GTI
disconnecting from the grid. To reach the minimum voltage you need to improve your ability to
capture the wind by changing the tower height, rotor size, number of blades, blade design, etc. (34)
Design Features:
NACA 0010 Airfoil Shape
Ultra High Molecular Weight Polethylene
Bolted by two M8 to the hub
6 angle of attack considering infinite wing Cl graph
High aspect ratio as the span to chord length ratio is high
Low induced drag as aspect ratio is high however; high profile drag
The initial design of the blades included trapezoid mount with thin section going into the hub bolted
together using M8 bolts. The design is not practical as it requires bolts to attach the blade with the
hub. This would induce high stress concentration on the plastic blade around the bolt area which
could result in a crack or a fracture. Plastic is also likely to deform if a constant force is applied which
54 | P a g e
means the bolt holes are likely to elongate making blades vibrate more and deform further resulting
in a catastrophic failure. The hub is made of aluminium and does not have any significant effect
compare to the blades. The cone is also plastic and bolted with the aluminium hub however; cone
has no major force acting on it and therefore the bolt hole elongations is not significant for the cone.
55 | P a g e
The design is based on wind tip generator concept. However, the magnets are mounted on
Design 2_The
the blade tips which add extra weight. The cut in wind speed of the system is much higher in order to
generate power. Also cost of the magnets is higher and mounting it on a rotating component will
reduce the life cycle. Conceptual design 2 wasnt selected for the final design.
The conceptual design 4 has a two counter rotating blade system, where the system
sy
will
Design 4_The
exceed the size limitation set by governing bodys (This was discussed in the beginning of the report).
Also the cost of the manufacturing will increase due to mechanical complexity.
Figure
igure 66: Preliminary CAD Design for the generator
Figure 66 shows the CAD drawing of the preliminary design. The magnets were mounted N-S or S-N
pole arrangement, where it creates constant axial magnetic flux distribution between two magnets.
This arrangement
angement increases the electricity generation form the rotating coils (stator-mounted
(stator
on the
blade tip). After the CAD analysis it was identified due to the outer ring which support magnets
reduces the blade tip aerodynamic efficiency. To solve this issue outer ring thickness was reduce and
the magnets were mounted on the inner surface of the ring in series arrangement. This modification
increases the blade aerodynamic efficiency and high wind energy is captured to generate electricity.
Figure 80 shows the magnetic flux arrangement of the magnets
magnets in preliminary design.
Figure 67:
67 Magnetic Flux Arrangement in Conceptual Design 3
56 | P a g e
57 | P a g e
58 | P a g e
59 | P a g e
As you can see from the above figure, you can notice some deformation in the blades. But safety
factors are well above breaking point proving that the wind turbine would survive a worst case
scenario. If the deformations are plastic (unlikely) the blades would need replacing.
60 | P a g e
Another analysis was carried out for more likely high wind situation of 25m/s wind. This level of wind
speed is not an everyday occurrence but it is a likely situation the wind turbine would encounter.
Deformations in blades are slightly above 1mm, well within the elastic limit for Ultra-high-molecularweight polyethylene proving the wind turbine is capable of withstanding this level of strong wind
without any problem.
Further FEA analysing was carried out to find out at what speeds, plastic deformations would occur in
the wings. The results revealed the winds higher than 25 meters per second wind would cause
plastics deformation in blades. To prevent that anemometer will detect the wind speeds above 23
m/s and apply the brakes stopping any damage to the wings/system
When FMEA was carried out on the system, the break mechanism was flag as a system of high risk.
This is due to fails in brake system would be recognised only in the annual maintenance. This is not as
the there are many ways the break system can fail and if the turbine is faced with a high wind
situation after the beaks had failed, that would cause plastic deformation in blades requiring costly
replacements.This was unacceptable and the solution had to be easy on the customer, preferably a
solution that automated requiring no involvement from the residents or maintenance.
The implemented solution is an innovative automated monthly check system. The circuit run through
the utility meter (the model specified in the price list capable of running small programs) is system
that would supply power to the breaks once a month and compare the power generated against the
wind speed registered by the anemometer. When the fail safe check in operation, for any wind speed
above zero, the power generated also should be zero as the check system is powering the breaks. If
the turbine is generating power, that means the beak system has failed and indication would be
displayed of this in the utility meter.As this system is run monthly, chance of damaging situation
occurring is very low.
61 | P a g e
62 | P a g e
7I
J
K.I
= K.K = 3
RST
U
.11K.
.VW1KXY
= 37065
At calculated Re value, the coefficient of lift value curve gradient is approximately 0.1/
Therefore the Finite Blade CLgradient is given by: Z =
K.
Y[.\1].^
64
8
]._Y1`1\
= 0.0598
c
d = 0.16
CD can be worked out using airfoil Cd Value (0.12): ' = 0.12 + bK.V1"1
63 | P a g e
The bearings need to lubricate in order increase longevity. For the bearing in the hub with blades,
this needs to be lubricated daily. This would be done via a small pump and an oil reservoir. Time
control unit would be a circuit based on a 555
555 time control IC that would operate ones a day for small
period of time to lubricate the bearing. Power will be drawn from the battery to run this circuit.The
large bearing inside the mast for yaw movement is not rapidly moving and no used long periods of
o
time. This bearing is lubricated manually ones a year.
13.5.1 Rotor
64 | P a g e
Figure 79 shows the final generator design; the outer ring is defined as the rotor.
16 magnets (see Table 7)
7 are mounted on the stationary ring (355mm inner diameter ring)
made out from plastic material to reduce the flux absorption from the magnets. 16 magnets
were chosen in order to generate
generate more electricity from the generator, also considering the
cost of the total generator.
Neodymium magnets were chosen for the rotor, the magnets are made out from Iron and
Boron which is class as the strongest magnets. It creates strong magnetic fluxes, which will
influence the total electricity generation higher. Most of the renewable appliance used
neodymium magnets.
Two magnets were place in series in order to create higher flux density around the magnets.
Error! Reference source not found.,
found., shows the flux arrangement between two magnets.
N42 gradeneodymium magnets were chosen due to its optimal balance of magnets strength
and durability for the price.
Shape
Magnetic Face:
Thickness:
Grade:
Plating:
Performance (Gauss):
Vertical Pull (Kg):
Slide Resistance (Kg):
Max Temp (degrees C):
Fixing:
Rectangle
46 x 30mm
10mm
N42
Ni-Cu-Ni ( Nickel )
2700
30
6
80
Araldite/Loctite
Table 7: Magnet specification (35)
13.5.2 Stator
It was decided to use removable stator parts to be fitted to the tip of the blade, which will
gives user to replace the stator section and replace with the new part in case of damage to
the stator. In total 6 stators each was fitted to each blade tip and it was connected via screws
to the blades.
Stator main plate was made out from the plastic material, which has zero permeability and
zero conductivity. These properties enhance the electricity generation form the coils and
reduce loses.
Since the copper wires were used in stator, due to its excellent electricity conductivity, its
metal properties and low cost.
Copper wires were winded (10 rotations) in slots on the main stator blade, which increases
the higher winding factor and subsequently increases the electricity generation.
The copper wire winding pattern was done in a way to satisfy Faraday low, Figure 82 shows
the diagram of the stator winding arrangement for flux direction from the magnet.
Insulated copper was used to protect the copper from electricity discharge and other
damages. Also this layer of plastic was applied on the side top and bottom face of the stator
to increase the aerodynamic performances on the tip of the blade.
Figure 83, shows the stator connection to the blade, where stator is connected by screws to
the blade. Also Error! Reference source not found. shows the wire connection to the main
blade.
66 | P a g e
Figure 85, Shows the Magnets placement on the outer ring of the rotor.
S
N
Figure 86 shows the stator and rotor intersection when blades rotating.
Figure 86: Cross Section of Stator & Rotator Flux Arrangement in Generator
67 | P a g e
Figure 87
2700
30 10N 46 10N
gtanN g
k
(
242 10N 84442 10N 8 + 430 10N 8 + 446 10N 8 8 j
30 10N 46 10N
tanN g
kk
242 10N + 10 10N 8m442 10N + 10 10N 8 + 430 10N 8 + 446 10N 8 n j .
Stator is wound with copper coils, the length on one wound is 1.3cm on one side and there are 10
rotations of coli going through on one slot. Also there are 7 coils wounds in one stator.
The total length cutting the magnetic flux is can be found from below equation,
= 10 7 1.3 10N 2 = 1.82m
The area of flux enclosed per second (A) can be found using the below equation,
= 1.82 V (blade tip linear velocity)
It was calculated that the angular velocity 4/ = 3.14 2? /p8 of the turbine blades at the minimum
operating wind speed of 6 m/s. The relationship between angular velocity and linear velocity (V) can
be found from the below equation,
: = / *42? qr+p = 3.14 2? jp 350 10N = 1.099 p
emf charge per second 4t8 can be found from equation (one stator),
t = = e = 1.82 1.099 9574.12 10Nu = 1.91:
t = )v
= :rw
?Q)
In order to find the current flowing through the circuit resistance of copper wires need to be
calculated. The resistance was calculated by using below equation,
R= Resistance
L= Length of the wire
K=Resistivity of copper wire (Copper = 1.73 X 10-8)
A= Cross sectional area of wire (0.6 mm copper wire was used)
P
1.73 10NW
= 1.82 g
k = 0.0278z
( 40.6 10N 8
The current flow in the circuit can be found from the below equation,
R=L
68 | P a g e
I=
1.91
t48
=
= 68.70
0.0278
*
The power generated from one stator can be found from the below equation,
= :|
= 1.91 1 68.7 = 131.217H
The system is equipped with 6 stators, to find the total power generate from the system the P1 need
to be multiplied by 6.
= 131.217 1 6 = 787.30 H
Power Curve
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
0
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
13.5.6 Method
Voltage or coil e.m.f generated due to the magnetic flux can be calculated by below equation,
t = = :e
t = )v
= :rw
?Q)
V=blade tip linear velocity
L=length of the wire (0.182m)
B=magnetic flux (9574.12 X 10-4T)
t = = : 1 9574.12 1 10Nu 1 1.82 = V 1 1.7424
Also the liner velocity and the angular velocity related by below equation,
: = / 1 2 = / 1 350 1 10N
r =Radius of the area covered by blades
P = vI
P= Power
v=Voltage
I= Current
Where,
I=
*
69 | P a g e
R=Resistance
By replacing I in equation,
4: 1 1.74248 4/ 1 350 1 10N 1 1.74248
=
=
= 13.39/
P=v1 =
*
0.0278
0.0278
*
P = 13.39/
70 | P a g e
1) Wind turbine tower would be the new innovative wind turbine design presented in this report.
2) Wind turbine control unit looks after charging the batteries. This prevents the batteries from
overcharging (providing power when the battery is full reduces the battery life) and undercharging
(draining the battery below 20% will irreversibly reduce the battery capacity). It charges the batteries
at the earliest opportunity, minimising battery cycling (charging and discharging rapidly).
The charge controller and voltage regulator provides the capability for maintaining the state of
charge for 12V or 24V storage batteries. The charge controller circuit performs as a fully automatic
voltage regulator. It has been designed for unattended site operation and is supplied in a
weatherproof plastic enclosure, suitable for mounting on a vertical pole or on a wall.
The charge controller constantly monitors the battery voltage and if required the batteries are
allowed to charge. As the float voltage is approached a load is applied to dissipate power. The charge
controller continues to monitor the battery voltage and if it subsequently drops below a threshold
then the load is disconnected and the charging action will resume.
3) Bator yank stores the energy generated from the wind turbine for the purpose of distribute it to
the loads when necessary. Standard batteries provided are two non-sealed deep cycle batteries of a
capacity of 75 Ampere Hour at 12 volts. Deep cycle batteries are very durable (needs replacing about
every six years) and can handle cycling of leads (charging and withdrawing rapidly). Non sealed
batteries are used as it allows the user to replenish the fluid inside themselves rather than replacing
the battery. Non sealed batteries last longer than sealed batteries but requires replenishing fluids
about every six months.
The two batteries supplied are able to power a typical refrigerator for two consecutive days.
Customer can have increased capacity batteries installed if they wish to do so.
4) The inverter converts the battery stored direct currant to alternating current of 230 volts which is
what the typical grid supply would be. Being a grid tie inverter this not only provide AC currant for
the refrigerator, it is also capable of exporting the excess electricity in to the national grid under the
Feed-In-Tariff. The customer would be paid 16 pence per kilowatt hour exported to the grid.
This specific model of inverter has two power outlets, so the customer can chose between exporting
the extra power and running a another appliance such as a washing machine when too much power
is generated from the wind turbine.
5) Utility meter provides the customer with important information about the system performance.
Utility monitor displays the amount of power generated, power exported and battery level.
Customer can use this information to manage the power accordingly if necessary.
71 | P a g e
Stator coils are subjected to vibration due to blade tip acceleration. Also the stator is exposed to the
temperature changes and high wind speeds. So the durability of stator might reduce. The inspection
of stator should be carried out annually.
The table below highlights all the components that are suited for manufacturing using the
methods detailed above, and the justification for choosing them.
14 Manufacturing (MH)
Component
Hub (Main body)
Hub Centre Rod
Hub Cone
Generator Housing
Brake Disc
Blades
Mount: Mast
Tail: Shaft
Manufacturing Method
Justification
Good dimensional accuracy
Casting/ moulding
needed, intricate part details
Relatively simply part but
Extrusion or Drawing
strength required
Part is of a simple design,
Compression Moulding
therefore can be moulded at
a relatively high rate
Complex shape which
requires a very high
Die Casting
tolerance of finish in order to
house magnets in place
Moderate shape, large
Sand Casting
volumes required due to 3
parts per turbine
Simple shape, moderate
Sand Casting
dimensional accuracy is
sufficient
Complex shape, hollow
structure, high production
Injection Moulded
rates at 6 parts per turbine,
high strength plastics to be
used
Forging or extrusion/drawing Relatively simple shapes and
Forging or extrusion/drawing constant hollow sections in
72 | P a g e
Mount: Base
Forging
Tail: Vane
Casting
centre
Due to varying dimensions
(non linear), forging is the
best method of manufacture
Heavy weight due to
counterbalancing function
and therefore high accuracy
not required but casting
presents the easiest
production option
SubSystem
Turbine Blades
Hub
Generator
Unit Cost
()
Comments/Source
2.22
6 Turbine blades
Hub (Body)
5.66
Centre
17.28
Cone
0.40
Housing
3.39
Frame
Support
1.78
Magnets
227.40
Coils
10.50
8m of coils
73 | P a g e
2.99
22.68
http://www.kartpartsuk.com/product.php?id=1299
Pads
7.95
http://tinyurl.com/cxc7dha
Battery x2
160.00
60.00
http://tinyurl.com/ahkmxke
45.00
http://tinyurl.com/b2wb276
45.00
http://tinyurl.com/acllfea
Wires
Brushes
Disc
Braking
System
Power
Management
Mounting
System
Tail
Other
Calliper
Grid Tie
Inverter
Shunt
Regulator
Power
Output
Monitor
Wires
16.00
Mast
1.12
Base
4.14
Shaft
0.57
Vane
13.46
Hub
Bearing
Mast
Bearing
28.96
42.36
Miscellaneous
30
Total Unit
Cost
748.86
Final Unit
Price
524.20
As seen in the above table, the total unit cost for the material of the turbine is nearly 750. As
mentioned previously, this figure is calculated at retail cost value and also material prices per kg
obtained from CES Edupack.
For a production rate of 20,000 units, a wholesale price can be agreed with the manufacturers of the
components within the turbine. A 30% markup on price is generally accepted and if this is factored
into the cost model, it reduces to approximately 525.
Before we can determine the retail price for the turbine, we have to consider all other cost factors
involved within the business and also consider the current market conditions at which we need to
sell the turbine at. These costs can be broadly categorized into the following:
74 | P a g e
75 | P a g e
promotions are not always clear. A nominal budget of 1,000 can be spent on developing a
campaign to promote the product
Magazine: Many renewable energy magazines exist in the UK market and they are also
popular sub topics of consumer advice magazines. A budget of 5,000 could be spent on
developing a printed ad campaign in this medium.
Paper: Paper advertising has enormous potential as it has a very firm user base with a very
wide demographic. The same ad campaign used for magazines could be run in national or
local newspapers. Since newspaper ads are more costly, a 10,000 per year budget could be
set for this.
Therefore, initially a total budget of 20,000 per annum is to be set up for advertising and
marketing the product.
Position
Average Annual
Salary
Assembly
line 15,000
worker
Skilled Labour
24,000
Amount
of staff
needed
4
Annual
Source
Cost for
position(s)
60,000
http://tinyurl.com/conleva
120,000
http://tinyurl.com/az7lcel
Administrative
Assistant
Security
15,000
15,000
http://tinyurl.com/ablfg3r
15,000
15,000
http://tinyurl.com/bbzmsrz
Supervisor
25,000
50,000
http://tinyurl.com/akm5dmb
5,000
76 | P a g e
40,000
305,000
The table above shows an estimated cost for labour and staffing per annum. The job positions were
determined to fit the type of business requirements.
Assembly line worker Assembly line workers are required once the products are
manufactured, to assemble the components together as well as finish packaging
Skilled Labour Skilled labour is required to operate the casting and moulding machines as
well as producing parts which require any kind of work done to it
Administrative Assistant As with any office, an administrative assistant is required to carry
out all administrative duties and assist with paperwork and other employee enquiries
Security Since the business will be holding high value items, a security guard is needed at
the premises to protect it as well as its employees
Supervisor While the production is being carried out, 2 supervisors are needed, each at the
manufacturing and assembly sections, to ensure the quality of the product is upheld and the
production runs on schedule and budget.
Type
I.T.
Security
Systems
Subtype
Computer
Systems
Staff Training
Maintenance
/Support
CCTV
Cameras
One-off costs
(installation,
etc)
Annual
Cost
25,000
5,000
Total Initial
Cost (Oneoff +
Annual)
30,000
2000
1,000
5,000
3,000
5,000
2000
Initial
400
Installation
CCTV
Monitoring
Premises
Security
Stationary Initial Cost
500
Total annual costs for year 1
2,000
400
1,200
1,200
2,000
2,000
500
44,100
http://www.icctvsystems
.co.uk/Item/izeus16_hdi
psystem1
Cost
600,000
20,000
62,500
305,000
77 | P a g e
Operational
Total Cost
44,100
1,031,000
15.7 Revenue
Since the business would be classified as a start-up, the only expected income is from product sales.
The cost estimates were carried out for an annual production basis and an estimate of the annual
production for the turbine in the first year is set to be 20,000.
Given the market conditions and current demand for wind turbines, it is not realistic to sell 20,000
turbines within the first year. In order to be conservative, 10,000 units are to be estimated as an
initial sales target for the first year.
It is of paramount importance to price the turbine according to current demand and market
conditions. As a new entrant to the market and as specified in the PDS, this turbine is to be sold at a
lower cost than current similar models. During the initial literature review, it was highlighted that
similar turbines will cost upwards of 2,000, which is a substantial initial investment. Therefore it is
reasonable to be priced at 1,500, which is lower than the current average market price for similar
turbine models.
78 | P a g e
Proces
s
Owner:
Maheemal/Mishkath/Bh
avedeep/Kalinga
Centre
Abrasion
Improper
maintena
nce
Improper
Maintena
nce
How
often
does
cause or
FM
occur?
How
well can
you
detect
the
Cause
or the
Failure
Mode?
Routine
Annual
Check
FMEA Date
(Orig):
08/03/2013
Actions
Recommend
ed
Resp.
Who is
Responsibl
e for the
recommend
ed action?
No Further
Action
Maintenanc
e Crew
No Further
7 Action
Maintenanc
e Crew
Actions
Taken
of
RPN
DET
OCC
Total
failure,
Excessive
Vibration
Noise, Low
Power
Output
What are
the
Outcomes
Resulting
From
This?
Maheemal
SEV
Facture
How
Severe
is the
effect to
the
custome
r?
Current
Controls
RPN
Centre
Outcome
s
DET
What is the
cause for
the
Variables?
Cause
OCC
In what
ways can
the
Process
Step or
Input fail?
Potential
Failure
Mode
SEV
Key
Proce
ss
Step
or
Input
What
is the
Proces
s Step
or
Input?
Prepared by:
Rev.
Proces
s or
Produc
t
Name:
Page:
1 1 9
1 1 7
Note the
actions
taken.
Include
dates of
completi
on.
79 | P a g e
Cone
Cone
Fracture
Screws
loosing
due to
vibration
Break
Disk
Fracture
Break
Disk
Breaking
at
attachme
nt point
Break
Disk
Wear and
tear
Break
Disk
Power
failure to
Callipers
Break
Disk
Blades
Vibration
casing
misalignm
ent in
callipers
and pad
Fracture
Blades
Becoming
Lose
Blades
Becoming
Lose
Improper
Maintena
nce
Vibration
Ineffective
Breaks in a
Over speed
Event
Ineffective
Breaks in a
Over speed
Event
Ineffective
Breaks in a
Over speed
Event
Ineffective
Breaks in a
Over speed
Event
Ineffective
Breaks in a
Over speed
Event
Low Power
Output
Excessive
Vibration
Excessive
Vibration,
Misalignm
ent of
Callipers
Long
Term Use
Power
Supply
System
Failure
Excessive
Vibration
9
Excessive
Vibration
Routine
Annual
Check
Opposite
Directionally
Tapped
Screws (3
Screws in
each
direction)
Routine
Annual
Check
Routine
Annual
Check
Routine
Annual
Check
Routine
Annual
Check
Routine
Annual
Check
Routine
Annual
Check
No Further
8 Action
Maintenanc
e Crew
Annually
Check
Screws For
4
Tightness
0
Maintenanc
e Crew
No Further
Action
Maintenanc
e Crew
No Further
Action
Maintenanc
e Crew
No Further
Action
Maintenanc
e Crew
Automated
Fail Check
8
(Explained in
1
the Report,
Run Monthly)
No Further
Action
2
7
Customer
No Further
5 Action
Maintenanc
e Crew
1 1 8
1 5
1 1 9
1 1 9
1 1 9
1 9
8
1
1 3
2
7
1 1 5
4
0
Maintenanc
e Crew
80 | P a g e
Blades
Blades
Blades
Misbalanc
ing
Deformati
on over
time
Excessive
Noise,
Fracture
Blades and
Other
Component
s
High Heat,
Long
Lasting
High Wind
Situation
Foreign
Object
Damage,
Excessive
Vibration
Low
Power
Output
Bird strike
7
Frame
Suppor
t
Frame
Suppor
t
deformati
on over
time
fracture at
joint,
High Heat,
Long
Lasting
High Wind
Situation
Excessive
Vibration
Frame
Suppor
t
vibration
cracks
Fracture
Compone
nts,
Excessive
Noise
Damage
to Blades
Excessive
Vibration
7
Routine
Annual
Check,
Visual
Checks by
Customer in
case of
Excessive
Noise
Routine
Annual
Check
No Further
Action
1
No Further
Action
1
Routine
Annual
Check
1
Routine
Annual
Check
8
4
No Further
Action
1 1 4
1 1 7
1 1 8
1 1 7
3 4
Customer
No Further
Action (as 2
Support
Rods can
effectively
7
Hold the
Frame
Safely)
1 1 9
Customer
Visual Check
By Customer
Maintenanc
e Crew
No Further
Action
1
Maintenanc
e Crew,
Customer
Visual Check
By Customer
Misalignm
ent
Between
Blades
and
Magnets
Resulting
in Low
Power
Output
Misalignm
ent
Between
Blades
and
No Further
Action
Maintenanc
e Crew
Maintenanc
e Crew
81 | P a g e
8
4
Frame
deformati
on due to
vibration
Excessive
Vibration
Base
Base
Base
Tail
failure of
screws,
Metal
Fatigue
fracture,
Excessive
Vibration
joint
between
mast and
base
failing
weld
fracture
Excessive
Vibration
bird
strike
Total
Failure
Routine
Annual
Check
3
Total
Failure
9
High Gust
5
Tail
Magnets
Resulting
in Low
Power
Output
Misalignm
ent
Between
Blades
and
Magnets
Resulting
in Low
Power
Output
Total
Failure
Loss of
Yaw
Control,
Low
Power
Output
Insignifica
nt
Deformati
on
No Further
Action
Replacement
of Screws
Every 10
Years
Routine
Annual
Check
Routine
Annual
Check
Routine
Annual
Check
Routine
Annual
Check
4
2
No Further
2 Action
7
Maintenanc
e Crew
No Further
9 Action
Maintenanc
e Crew
No Further
Action
Maintenanc
e Crew
No Further
Action
1
Maintenanc
e Crew
3 2
4
2
1 3
2
7
1 1 9
1 1 9
1 1 5
1 1 1
Maintenanc
e Crew
No Further
Action
Maintenanc
e Crew
82 | P a g e
Tail
Suppor
t
weld
fracture,
Hub
fracture at
joints,
Excessive
Vibration
failure at
joint
between
bearing
and hub
fail at the
joint,
Excessive
Vibration
bearing
freeze up
Extreme
Cold
Temperatur
e
Hub
Base
Mount
Bearin
g
Base
Mount
Bearin
g
High Gust
1
Base
Mount
Bearin
g
Magne
t
pitting of
the roller
bearings
Magne
t
vibration
wear off, ,
Loss of
Yaw
Control,
Low
Power
Output
Total
Failure
Extreme
Cold
Temperatur
e
thunder
strikes
Total
Failure
9
Excessive
Vibration
6
Vibration
2
Total
Failure
Loss of
Yaw
Control,
Low
Power
Output
Noise,
Wear and
Tear
Reduced
Power
Output
Reduced
Power
Output
Routine
Annual
Check
Routine
Annual
Check
Routine
Annual
Check
Routine
Annual
Check
No Further
Action
1
No Further
9 Action
Maintenanc
e Crew
No Further
Action
Maintenanc
e Crew
No Action
1
Routine
Annual
Check
Routine
Annual
Check
No Further
Action
Maintenanc
e Crew
1 1 1
1 1 9
1 1 9
1 1 9
1 1 4
1 1 7
No Further
Action
1
Routine
Annual
Check
Maintenanc
e Crew
No Further
Action
Maintenanc
e Crew
No Further
7
Action
2
Maintenanc
e Crew
4 3
7
2
No Further
2
Action
4
Maintenanc
e Crew
4 3
2
4
83 | P a g e
16 Conclusion (KE/MT)
All the calculation show that this project would be a success and it will be more than capable
cap
of
providing operating power to a refrigerator without needing support from the grid. The next stage of
the project would be to protect this design from being copied. We plan to do so by applying to a
patent UK and International. Our research shows this
this has never been done before, so we can go to
the prototype, felid trials and manufacturing stages with confidence with the patent pending (As
international patents can take up to six years to process)
Figure 89
Rated Power
Applications
Solutions
Architecture
Blade Material
Blade type
Generator Type
Cut In Speed
Cut Out Speed
Cost
Weight
Overall Height
Span Diameter
Number of Blades
Inverter
Safety System
Tower Type
Tower Height
Tower foundation
Operating Temperature Range
Warranty
84 | P a g e
17 Works Cited
1. www.home-energy.com. [Online] [Cited: 06 02 2013.] http://home-energy.com/int/ebv200.htm.
2. Honeywell wind turbine is a breeze to run and a light one at that. Gizgam. [Online] [Cited: 06 02
2013.] http://www.gizmag.com/earthtronics-honeywell-windgate-wind-turbine/11990/.
3. www.microstrain.ie. [Online] [Cited: 06 02 2013.] http://www.microstrain.ie/hannevind.html.
4.
www.bettergeneration.co.uk.
[Online]
[Cited:
06
02
2013.]
http://www.bettergeneration.co.uk/wind-turbine-reviews/windsave-ws1000-wind-turbine.html.
5. www.bergey.com. [Online] [Cited: 06 02 2013.] http://bergey.com/products/wind-turbines/10kwbergey-excel.
6.
www.windenergy.com.
[Online]
[Cited:
06
02
2013.]
http://windenergy.com/products/skystream/skystream-3.7.
7. better generation. [Online] [Cited: 04 02 2013.] http://www.bettergeneration.co.uk/wind-turbinereviews/honeywell-wt6500-wind-turbine.html.
8. www.renewabledevices.com. [Online] [Cited: 06 02 2013.] http://renewabledevices.com/rd-swiftturbines/overview/.
9. Reid, Steve. Wind and Wind Energy. NIWA - Water & Atmosphere. [Online] 2005. [Cited: 20 01
2013.] http://www.niwa.co.nz/publications/wa/vol13-no4-december-2005/wind-and-wind-energy.
10. Is wind power right for you? Energy Matters. [Online] [Cited: 20 01 2013.]
http://www.energymatters.com.au/renewable-energy/wind-energy/wind-power-guide.php.
ISO8859-1.
11. Watson, S J.Predicting the yield of micro-wind turbines in the roof-top urban environment. [Power
Point Presentation] s.l. : Loughborough University.
12.
Climate.
Met
Office.
[Online]
Met
Office.
[Cited:
20
01
2013.]
http://www.metoffice.gov.uk/public/weather/climate/#?tab=climateMaps.
13. Wind Turbine Power Calculations. npower. s.l. : The Royal Academy of Engineering.
14. Yechout, Thomas R., et al., et al.Introduction to Aircraft Flight Mechanics. s.l. : AIAA, 2003. ISBN
1-56347-577-4.
15. Wind Turbine Blade Aerodynamics. [book auth.] WE Handbook. 2-Aerodynamics and Loads.
16. Ingram, Grant.Wind Turbine Blade Analysis using the Blade Element Momentum Method. s.l. :
Durham University, 2011.
17. Wind Turbines. University, Boston. s.l. : Coherent Application Threads.
18. Edurite.DC Generator. Youtube.
19. Generating Electrical Current. [Online] School for Champions, 10 12 2012. [Cited: 20 01 2013.]
http://www.school-for-champions.com/science/electrical_generation.htm.
20. Whitehouse, Jon Ogborn & Mary.Advancing Physics. s.l. : Institute of Physics. ISBN 0-7503-06777.
21. Madani, Nima.Design of a Permanent Magnet Synchronous Generator for a Vertical Axis Wind
Turbine. Sweden : s.n., 2011. XR-EE-EME 2011:013.
22. Wind Energy. [Online] Deodaar Automation, 02 2013. http://www.deodaar.com/#!windenergy/c1fdu.
23. Key Benefits of Vertical Axis Wind Turbines (VAWTs). [Online] Cleanfield Energy, 02 2013.
http://www.cleanfieldenergy.com/key_VAWT_benefits.php.
24. Wind Energy Noise Impacts. Acoustic Technology Institute. [Online] Cleanfield energy, 02 2013.
http://www.acousticecology.org/srwind.html.
25. Why a Vertical Axis Wind Turbine (VAWT) ? [Online] macado, 02 2013.
http://www.verticalgreenenergy.co.za/all_about_wind_vawt.htm.
26. Exploring Green Technology. [Online] http://exploringgreentechnology.com/images/windenergy-diagram.gif.
27. Wind Power. Battery and Energy Technologies. [Online] [Cited: 20 01 2013.]
http://www.mpoweruk.com/wind_power.htm.
85 | P a g e
28. Anti-icing and de-icing techniques for wind turbines: Critical review. Olivier Parent, Adrian Ilinca.
8 January 2010, s.l. : Elsevier, Vols. Cold Regions Science and Technology 65 (2011) 8896.
29. Erik Isaksson, Magnus Dahlberg.Damage prevention for wind turbines. s.l. : Elforsk report 11:18,
July 2011.
30. Kalpakjian, Serope and Schmid, Steven R.Manufacturing Engineering and Technology. s.l. :
Prentice Hall, 2001. ISBN 0-201-36131-0.
31. Liu, Jessica. KHCK. KHCK. [Online] Kee Hing Cheung Kee Co., Ltd., 2011. [Cited: 2013 01 16.]
http://www.khck.hk/New-Energy.htm.
32. Shunt Regulator. REUK.co.uk. [Online] [Cited: 26 01 2013.] http://www.reuk.co.uk/ShuntRegulator.htm.
33. Wind Turbine Regulators and Charge Controllers. Ebay.co.uk. [Online] Ebay. [Cited: 2013 01 28.]
http://reviews.ebay.co.uk/Wind-Turbine-Regulators-and-Charge-Controllers-Part1?ugid=10000000006308446.
34. Grid Tie Inverters. REUK.co.uk. [Online] 06 2011. http://www.reuk.co.uk/.
35. F63010. High Performance Neodymium Magnets & Outstanding Customer Service. [Online] 02
2013.
http://www.first4magnets.com/f63010---46-x-30-x-10mm-thick-n42-neodymium-magnet--30kg-pull-x1-d31o-786-p.asp.
36. Town and Country Planning, England. Statutory Instruments. 2011 No. 2056.
86 | P a g e
18 Appendix-A (ALL)
18.1 Figures
87 | P a g e
88 | P a g e
89 | P a g e
90 | P a g e
19 Appendix-B (MT)
Technical Drawings
91 | P a g e
20 Appendix-C (ALL)
92 | P a g e