FAILURE ANALYSIS AND DESIGN MODIFICATION OF TEETER DAMPER BOX OF A TWO BLADED WIND TURBINE USING ANSYS

A PROJECT REPORT

Submitted by BALAJI. M(41501114019) ELANGO. S(41501114025)

in partial fulfillment for the award of the degree of BACHELOR OF ENGINEERING in MECHANICAL ENGINEERING

S.R.M. ENGINEERING COLLEGE, KATTANKULATHUR-603 203, KANCHEEPURAM DISTRICT.

ANNA UNIVERSITY : CHENNAI - 600 025

MAY 2005

BONAFIDE CERTIFICATE that this project report FAILURE ANSYSis

Certified

ANALYSIS

AND DESIGN

MODIFICATION OF TEETER DAMPER BOX OF A TWO BLADED WIND TURBINE USING the bonafide work of BALAJI.

M(41501114019)ELANGO. S(41501114025)who carried out the project work under my supervision.

Mr.T.V.GOPAL HEAD OF THE DEPARTMENT SUPERVISOR Assistant Professor MECHANICAL ENGINEERING S.R.M.Engineering College Kattankulathur - 603 203 Kancheepuram District MECHANICAL ENGINEERING S.R.M.Engineering College Kattankulathur - 603 203 Kancheepuram District

ABSTRACT The Renewable Energy Research laboratory (RERL) at the University of Massachusetts runs an Experimental wind turbine on Mount Tom. It is the original prototype unit for the ESI-80 wind turbine manufactured by ESI Inc. In the 1980s. This turbine is a two bladed machine with a teetered rotor. Hence to damp the teeter motion the Teeter damper box is used .In the year of 95-96 the teeter damper box had a failure that caused it to lock up and no longer retract as the blades teetered. The loads predicted from this model needed to cause failure were in the range of 93,430 N (21,000 pounds) to 1, 02,330 N (23,000 pounds) which was detected using strain gauges. These loads were below the previously expected maximum loads on the teeter box by the factor of two.

The main aim of the project is to provide a suggestion to reduce the stress concentration on the teeter box and also to improve the life and quality of the same by suggesting a suitable design modification. In this project, first of all the finite element model of the Teeter damper box was constructed using Analysis package- ANSYS,V8.Since the teeter box is

symmetrical about both axis, only 1/4th of the original model is taken for analyzing purpose. After analyzing existing model, the stress concentration was found to be more in side members of the teeter damper box. Then the design modification has been carried by trying out with stiffeners of different cross sections. Finally it was found that the stress concentration reduced by 87.215 N/mm2 (4 Psi) using T section which was more when compared with other sections OBJECTIVE: The main objective of the project is as follows To identify loads those are acting in the existing model of the teeter damper box of two bladed wind turbine. To analyze the existing model and to find the deformation and stress concentration in the same. To modify the existing model by providing stiffeners to withstand the loads and stresses to the required horizon. To analyze the modified model and to compare the results. To provide a conclusion for the improved design and life of the teeter damper box.

LIST OF FIGURES FIGURES Basic components of wind turbine Line diagram of two bladed wind turbine Existing model of teeter damper box 1/4th meshed view of existing model Deformed shape in X direction Deformed shape in Y direction Deformed shape in Z direction Overall deformation Total deformation Stress obtained Modified model of teeter damper box Full meshed view of modified model 1/4th meshed view of modified model Deformed shape in X direction Deformed shape in Y direction Deformed shape in Z direction Overall deformation Total deformation Stress obtained PAGE NO. 6 20 24 28 29 30 31 32 33 34 38 39 40 41 42 43 44 46 47

ACKNOWLEDGEMENT This project was the result of the throughput process combined, of not just ourselves, but also a group of other people. This thesis would be incomplete without expressing our heartfelt gratitude to them. We would like to thank Prof.D.Prithviraj, HOD Mechanical engineering Department, S.R.M. Engineering College for permitting us to undertake this project. Mr.T.V.Gopal, Assistant Professor, Mechanical engineering Department, who guided us for performing this project, needs more than a word of mention as he was the driving force behind our work. Our special thanks to him for being a constant source of inspiration and his encouragement and extensive suggestions throughout the

tenure of our work. He has made many important and imaginative improvements towards successful completion of our work. We would like to thank Mr.C.Venkataramanan, Manager Human resource and development Department and Mr.K.R.Daniel Assistant Manager, Operations and maintenance of SUZLON Coimbatore who extended their timely and valuable help in between their busy work schedule for completing this project. We would like to thank our project coordinator Mr.Z.Edward Kennedy, senior lecturer Mechanical engineering Department, for extending his kind

cooperation to us. We profoundly thank all the staff members of Mechanical engineering Department for their continuous encouragement and help towards the successful completion of this project.

TABLE OF CONTENTS

CHAPTER

TITLE

PAGE NO.

ABSTRACT OBJECTIVE LIST OF FIGURES 1. BASICS OF WIND POWER 1.1 Basic definitions. 1.2 History of wind energy. 1.3 Advantages and disadvantages of wind energy. 1.4 Picture of wind turbine. 1.5 Important components and construction of wind turbine. 1.6 Working principle of wind turbine. 1.7 Classification of wind turbines. 2. TWO BLADED WIND TURBINE 2.1 Why two bladed wind turbine?

i iii iv

1 2

4 6

7 10 11

14

2.2

Specifications of UMT 80 15 17 17 18 19

wind turbine 2.3 Mechanisms. 2.2.1 2.2.2 2.4 3. Teetering mechanism. Yaw mechanism.

Purpose of teeter damper box.

TEETER DAMPER BOX 3.1 3.2 3.3 3.3 Line diagram of wind turbine. Specifications Loads. Failures encountered. 20 21 22 23

4.

ANALYSIS OF EXISTING DESIGN 4.1 4.2 Model creation. Meshing consideration. 4.2.1 4.2.2 4.2.3 4.2.5 Assumptions. Mode of analyzing. Element selection. 1/4 meshed view.
th

24

25 26 27 28

5.

RESULTS OF THE EXISTING MODEL 5.1 Figures 5.1.1 Deformed shape in X direction. 29 5.1.2 Deformed shape in Y direction. 30 5.1.3 Deformed shape in Z direction. 31 5.1.4 Overall deformation. 5.1.5 Total deformation. 5.1.6 Stress obtained. 5.2 5.3 Summary of the result. Observations. 32 33 34 35 36

6.

DESIGN MODIFICATION 6.1 Modifications done on the existing model. 37

7.

ANALYSIS OF MODIFIED DESIGN 7.1 7.2 Modified model. Meshing. 7.2.1 Full meshed view. 39 38

7.2.2 8.

1/4th meshed view.

40

RESULTS OF THE MODIFIED DESIGN 8.1 Figures. 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.2 8.3 Deformed shape in X direction. Deformed shape in Y direction. Deformed shape in Z direction. Overall deformation. Total deformation. Stress obtained. 41 42 43 44 46 47 48 49 50 52 53

Summary of the result. Observations.

9. 10. 11.

COMPARISION OF THE RESULTS CONCLUSION SCOPE FOR FURTHER WORK REFERENCES

CHAPTER-1 BASIC DEFINITIONS: TURBINE: It is a machine for producing power in which a wheel or rotor, typically fitted with vanes and is made to revolve by a fast moving flow of a fluid. WIND TURBINE: It is a turbine driven by wind. TEETER: The unsteady and rocking motion. HISTORY OF WIND ENERGY: Since early-recorded history, people have been harnessing the energy of wind. Wind energy propelled boats along the Nile River as early as 5000B.C.By 200B.C simple windmills in China were pumping water, while vertical-axis windmills with woven reed sails were grinding in Persia and the Middle East. New ways of using the wind eventually spread around the world. By the 11
th

century, people in Middle East were using windmills extensively for food production; returning merchants and crusaders carried this idea back to Europe. The Dutch refined the windmill and adapted it for draining lakes and marshes in the Rhine River Delta. When settlers took this technology to the New world in the late 19th century, they began using windmills to pump water for farms and ranches, and later, to generate electricity for homes and industry.

Industrialization, first in Europe and later in America, led to a gradual decline in the use of windmills. The steam engine replaced European water-pumping windmills. In the 1930s, the Rural Electrification Administrations programs brought inexpensive electric power to rural areas in the United States. However, industrialization also sparked the development of larger windmills to generate electricity. Commonly called wind turbines, these machines appeared in Denmark as early as 1890. In the 1940s the largest wind turbine of the time began operating on a Vermont hilltop known as Grandpas knob. This turbine, rated at 1.25 megawatts in winds of about 30 mph, fed electric power to the local utility network for several months during World War II. The popularity of using the energy in the wind has always fluctuated with the price of fossil fuels. When the price of oil skyrocketed in the 1970s, so did worldwide interest in wind turbine generators. The wind turbine technology R&D that followed the oil embargoes of the 1970s refined ideas and introduces in new ways of converting wind energy into useful power. Many of these approaches have been demonstrated in wind farms or wind power plants groups of turbines that electricity into the utility grid in the United States and Europe. Today, the lessons learned from more than a decade of operating wind power plants, along with continuing R&D, have made wind generated electricity very close in the cost to the power from conventional utility generation in some locations. Wind energy is the worlds fastest-growing energy source and will power industry, business and homes with clean, renewable electricity for many years to come. ADVANTAGES AND DISADVANTAGE OF WIND ENERGY Wind energy offers many advantages, which explains why its the fastestgrowing energy source in the world. Research efforts are aimed at addressing the challenges to greater use of wind energy. ADVANTAGES:

Wind energy is fueled by the wind, so its a clean fuel source. Wind energy doesnt pollute the air like power plants that rely on combustion of fossil fuels, such as coal or natural gas. Wind turbines dont produce atmospheric emissions that cause acid rain or greenhouse gasses. Wind energy is a domestic source of energy, produced in the United States. The nations wind supply is abundant. Wind energy relies on the renewable power of the wind, which cant be used up. Wind is actually a form of solar energy; winds are caused by the heating of atmospheric by the sun, the rotation of the earth, and the earths surface irregularities. Wind energy is one of the lowest-priced renewable energy technologies available today, costing between 4 and 6 cents per kilowatt-hour, depending upon the wind resource and the particular project. Wind turbines can be built on the farms or ranches, thus benefiting the economy in rural areas, most of the best wind sites are found. Farmers and ranchers can continue to work the land because the wind turbines use only a fraction of the land. Wind power plant owners make rent payments to the farmer or rancher for the use of the land. DISADVANTAGES: Wind power must compete with conventional generation sources on a cost basis. Depending on how energetic a wind site is, the wind farm may or may not be cost competitive. Even though the cost of wind power has decreased dramatically in the past 10 years, the technology requires a higher initial investment than fossil-fueled generators. The major challenges to using wind as a source of power is that the wind is intermittent and it does not always blow when electricity is needed. Wind energy cannot be stored (unless batteries are used); and not all wins can be harnessed to meet the timing of electricity demands.

Good wind sites are often located in remote locations, far from cites where the electricity is needed. Wind resource development may compete with other uses for the land and those alternate uses may be more highly valued than electricity generation. Although wind power plants have relatively little impact on the environment compared to other conventional power plants, there is some concern over the noise produced by the rotor blades, aesthetic (visual) impacts, and sometimes birds have been killed by flying into the rotors. Most of these have been resolved or greatly reduced through technological development or by properly siting wind plants. PICTURE OF WIND TURBINE:

IMPORTANT COMPONENTS AND CONSTRUCTION OF WIND TURBINE: Conventional type of wind turbines consist of following parts. ANEMOMOTER: Measures the wind speed and transmits wind speed data to the controller. BLADES: A disc brake, which can be applied mechanically, electrically, or hydraulically to stop the rotor in emergencies. CONTROLLER: The controller starts up the machine at the wind speeds of about 8 to 16 miles per hour (mph) and shuts off the machine at about 65 mph. Turbines cannot operate at the speeds about 65 mph because their generators could overheat. GEAR BOX: Gears connect the low-speed shaft to the high-speed shaft and increase the rotational speeds from about 30 to 60 rotations per minute (rpm) to about 1200 to 1500 rpm, the rotational speed required by most generators to produce electricity. The gear box is a costly (and heavy) part of the wind turbine and engineers are exploring direct-drive generators that operate at lower rotational speeds and dont need gear boxes. GENERATOR: Usually an off-the-shelf induction generators that produces 60-cycle AC electricity. HIGH-SPEED SHAFT: Drives the generator.

LOW-SPEED SHAFT: The rotor turns the low-speed shaft at about 30 to 60 rotations per minute. NACELLE: The rotor attaches to the nacelle, which sits a top tower and includes the gear box, low-and high-speed shafts, generator, controller, and brake. A cover protects the components inside the nacelle. Some nacelles are large enough for a technician to stand inside while working. PITCH: Blades are turned, or pitched, out of the wind to keep the rotor from turning in winds that are too high or too low to produce electricity. ROTOR: The blades and the hub together are called the rotor. TOWER: Towers are made from tubular steel or steel lattice. Because wind speed increases with height, taller towers enable turbines to capture more energy and generate more electricity. WIND DIRECTION: Upwind turbine operates facing into the wind. A Downwind turbine operates away from the wind direction. WIND VANE: Measures wind direction and communicate with the yaw drive to orient the turbine properly with respect to the wind. YAW DRIVE:

Upwind turbines face into the wind: the yaw drive is used to keep the rotor facing into the wind as the wind direction changes. Downwind turbines dont require a yaw drive, the wind blows the rotor downwind. YAW MOTOR: Powers the yaw drive. WORKING PRINCIPLE OF WIND TURBINE: Wind is a form of solar energy. Winds are caused by the uneven heating of the atmosphere by the sun, the irregularities of the earths surface, and the rotation of the earth. Wind flow patterns are modified by the earths terrain, bodies of water, vegetation. Humans use this wind flow, or motion energy, for many purposes: sailing, flying a kite, and even generating electricity. The terms wind energy or wind power describes the process by which the wind is used to generate mechanical power or electricity. Wind turbines convert the kinetic energy in the wind into mechanical power. This mechanical power can be used for specific tasks (such as grinding grain or pumping water) or a generator can convert this mechanical power into electricity. So, a wind turbine works the opposite of a fan. Instead of using electricity to make wind, like a fan, wind turbines use wind to make electricity. The wind turns the blades, which spin a shaft, which connects to a generator and makes electricity. The electricity is sent through transmission and distribution lines to homes, businesses, schools, and also so on. CLASSIFICATION OF WIND TURBINES: The following are the general classifications of conventional wind turbines. ACCORDING TO THE NUMBER OF BLADES USED: One bladed wind turbine

In this type of wind turbines only one blade is fixed to the hub of the rotor. The rotation is very much unbalanced even though a balancing mass is attached and is used for very low power generation requirements. Two bladed wind turbine In this type of wind turbines two blades are attached to the hub of the rotor opposite to each other. The rotation is much unbalanced. Three bladed wind turbines This is the most commonly used type and blades are well fabricated with an angle of 120 to each other. Very good balancing is achieved is this type of wind turbines. ACCORDING TO THE SHAFT AXIS: Horizontal axis turbine This is most commonly used type and the axis of the turbine will be oriented in horizontal axis. Vertical axis turbine This type of wind turbines are most rarely used with difficulty in fabrication. The working of this type of wind turbines will be similar to the working of governors in automobiles. ACCORDING TO THE DIRECTION OF WIND: Up wind turbine Upwind machines have the rotor facing the wind. The basic advantage of upwind designs is that one avoids the wind shade behind the tower. By far the vast majority of wind turbines have this design.

On the other hand, there is also some wind shade in front of the tower, i.e. wind starts bending away from the tower before it reaches the tower itself, even if the tower is round and smooth. Therefore, each time the rotor passes the tower, the power from the wind turbine drops slightly. The basic drawback of upwind designs is that the rotor needs to be made rather inflexible, and placed at some distance from the tower (as some manufacturers have found out to their cost). In addition an upwind machine needs a yaw mechanism to keep the rotor facing the wind. Down wind turbines Downwind machines have the rotor placed on the lee side of the tower. They have the theoretical advantage that they may be build without yaw mechanism, if the rotor and nacelle follow the wind passively. For large wind turbines this is somewhat doubtful advantage, however, since you do need cables to lead the current away from the generator. A more flexible advantage is that the rotor may be made more flexible. This is an advantage both in regard to weight, and the structural dynamics of the machine, i.e. the blades will bend at high wind speeds, thus taking part of the load off the tower. The basic advantage of the downwind machine is thus, that it may be built somewhat lighter than an upwind machine. The basic drawback is the fluctuation in the wind power due to the rotor passing through the wind shade of the tower. This may give more fatigue loads on the turbine than with an upwind design. ACCORDING TO THE SIZE OF WIND TURBINE: Small sized wind turbine This type of wind turbines will have the tower height less than 80 feet. Large sized wind turbine This type of wind turbines will have the tower height of 80 feet and above.

CHAPTER-2 WHY TWO BLADED WIND TURBINE? There are many advantages and disadvantages by using two bladed wind turbine. They are as follows. ADVANTAGES: Two bladed wind turbine designs have many advantages when compared to the general purpose three bladed turbine design. They are, Weight reduction of the third blade Cost reduction of one blade Reduced time in fabrication Easy erecting DISADVANTAGES: However they tend to have some difficulties in penetrating the market, partly because of the following reasons. Requires high rotational speed to yield the same energy output Stability and Balancing problem due to even number of blades

SPECIFICATION OF UMT-80 (TWO BLADED) WIND TURBINE: ROTOR: 80ft. Diameter Two Bladed Fixed Pitch Downwind Wood/Epoxy Laminate 60 RPM Free Yaw HUB: 3 degrees free teeter Abex gas spring/hydraulic dampers for 3 more degrees Adjustable Delta-3 hinge TRANSMISSION: Flender Planetary Gearbox 30:1 Ratio

GENERATOR: 250 kW Marathon Electric Induction Generator 480-volt 3 Phase Vectrol Soft Start BRAKE: Industrial Clutch Mechanical Disk Brake Spring Applied Pneumatic Released TOWER: 80 feet tall Open Truss Free Standing Tilt Down/Tilt Up

MECHANISMS: Generally there are two main mechanisms are used in most of the two bladed wind turbine. They are as follows. Teetering mechanism Yaw mechanism TEETERING MECHANISM: Two-bladed machines require a complex design with a hinged (Teetering hub) rotor. Teetering rotor means, the rotor has to be able to tilt in order to avoid too heavy shocks to the turbine, when a rotor blade passes the tower. This flapping of blades is mainly due to the varying wind speed. The rotor is therefore fitted onto a shaft which is perpendicular to the main shaft, and which rotates along with the main shaft. These arrangements may require additional shock absorber to prevent the rotor blade from hitting the tower In addition, teetering of the blades is provided by use of a hinge pin where the blades attached to the rotor shaft. It reduces the loads and fatigue in the rotor system, which also reduces cost and improves reliability. This teetering rotor results in an enormous reduction of the blade-root bending loads. Reducing these loads allows us to safely reduce the amount of material employed in the blades, drive train, and throughout the turbine. This patented innovation, based on a concept previously employed in the helicopter industry, was the result of a through system level design of the two-blade downwind turbine. YAW MECHANISM: Wind turbine utilizes the motion or flow of the wind for its working. But the direction of the wind is not continuous and unidirectional. The flow direction varies with time to time.

So to facilitate the turbine to work even under small variations in the direction of wind, the Yaw mechanism is used. This mechanism used to follow the wind direction as the direction changes. For this Yaw mechanism a Yaw motor is used. It allows the rotor to be operated at high Yaw angles that is turned edgewise to the wind, and with variable yaw rates. An electric clutch allows free yaw operation. PURPOSE OF TEETER DAMPER BOX: The teetering mechanism normally, teeters the hub continuously to some angle. Due to this teetering effect, vibration is created and it affects the whole drive train very badly. This may cause severe damage to the wind turbine. Along with this teetering mechanism, the Yaw mechanism will also transmits shock and loads to the drive train. So, this effect may also leads to the failure of wind turbine. Due to this noise is created inside the turbine. In order to reduce these vibrations and shock loads, a damping element is used between the hub and the drive train, which is called as Teeter Damper Box. The main aim of using this Teeter Damper Box is to give smooth running and to damp the vibration. CHAPTER-3 LINE DIAGRAM OF WIND TURBINE: 1. HUB 2. BLADE 3. TEETER DAMPER BOX 4. GEAR BOX 5. COUPLING 6. GENERATOR 7. SUPPLY LINES 8. CASING 9. TOWER

SPECIFICATIONS OF THE TEETER DAMPER BOX: Specifications of teeter box of two bladed wind turbine are given below. Dimensions: The end that dampers the bolt are 1 inch thick. The rest is inch thick. Length is 24 inch. Height is 11.06 inch. Width is 14 inch. Material:

Mild steel. LOADS ACTING ON THE TEETER DAMPER BOX: Normally there are two types of loads that are acting on the Teeter Damper Box. They are as follows Static Load Dynamic Load STATIC LOAD: Static load is the load, due to the self weight of Rotor (weight of blades and weight of hub) on the cantilever beam at the free end. DYNAMIC LOAD: Dynamic loads are the load, due to the Vibration effect caused by the Teetering and Yaw mechanism. FAILURES ENCOUNTERED: In the teeter box of two bladed wind turbine due to heavy shocks that are transmitted by teetering and yaw mechanism, the side member of the teeter damper box has been failed. The forces were great enough that the teeter damper box failed. This caused the box to lock up and no longer retract as the blade teeters. The exact forces exerted by the teeter blades on the teeter dampers and thus on the teeter damper box are unknown. From dynamic model created by the ESI 80 these forces are estimated to be in the range of 2, 00,204 N to 4, 44,898 N (45,000 to 100,100 pounds) force.\

CHAPTER-4 MODEL CREATION: The full model of teeter damper box is created using Ansys software for the given specification. The created model is given below.

ASSUMPTIONS MADE IN ANALYSIS: The system could be modeled by of the teeter damper box due to the symmetry of the box. On the edges cut by symmetry, the model was constrained in the degree of freedom perpendicular to the cut surface The forces on the box could be modeled by a static equivalent force applied perpendicularly to the end of the box. The bottom of the model of the teeter damper box was constrained in all degrees of freedom. The load acting on the teeter damper box is being shared equally by the seven bolts which hold the damping material. The wind turbine shaft, the bearing which mounts the shaft, the damping material around the bearing all are assumed to be rigid. So that no deformations or failures occurs to them. The material of the teeter damper box is throughout homogenous and isotropic. MODE OF ANALYZING: ACTUAL LOAD ACTING AREA: In two bladed wind turbines the shaft is held by the bearing. The bearing is held by the damping material. The damping material is rigidly bolted to the teeter damper box. So all the loads acting over the teeter damper box acts directly to the bolt holes of the damping material. INTENSITY OF LOAD: The teeter damper box should be designed to with stand a minimum load of 45000 pounds and a maximum load of 100000 pounds. So the minimum intensity load of 45000 pounds was taken into account for analyzing purpose at first stage.

DIRECTION OF THE LOAD: The load or force acting on the teeter damper box compresses it at the face and hence the tensile force is acting at the X axis towards the rotor. AREA OF APPLICATION OF LOADS IN ANALYSIS: Since it was found out that the load is directly acting on the bolt holes to which the damping material is bolted, in our analysis the load or force is applied to the nodes which are attached to the areas of the bolt holes. ELEMENT SELECTION: Even though many type of elements are available for analyzing purpose, the element chosen for analyzing in this problem was 3-D, 10 noded tetrahedral structural Solid.

REASON FOR CHOOSING THE ELEMENT: Normally in ANSYS package any type of geometrical structure can be analyzed by choosing particular element type. The property of the particular element chosen will match for the geometrical profile of the structure which is being analyzed. Since the load acting in our problem is on the bolt holes which have the geometrical profile of circle, the above said element is chosen.

This element will give very good accuracy while analyzing the sections with circular profile. The other brig elements will not give much accuracy while analyzing circular profiles.

CHAPTER-5 RESULTS OF THE EXISTING MODEL: After modeling the existing teeter box the analysis is carried out in order to find the deformation in X, Y & Z direction, total deformation, overall deformation, and stress obtained. The results of the existing model are shown in the following figures.

SUMMARY OF THE RESULTS: Thus the maximum deformation, overall deformation, and stress obtained in the existing model of the teeter damper box is given below. Maximum deformation in X-direction : 0.0007188 mm (0.0000283 inch.) Maximum deformation in Y-direction : 0.02962 mm (0.001166 inch.) Maximum deformation in Z-direction : 0.059868 mm (0.002357 inch.) Over all deformation : Maximum stress : OBSERVATIONS: Even though the load is applied towards the X axis, the deformation observed in X direction is very low, when compared to Y and Z directions. The deformation observed in Y direction is also lower than the Z direction as stated earlier. So ultimately the deformation in Z direction is more. Since the bolt holes are directly taking the loads as tensile force, the stress concentration is ultimately predominant at the top center of the side faces as shown in the figure. This stress concentration elongates the teeter damper box and hence it looses its rigidity and starts yielding. So the rigidity of the side faces of the teeter damper box is not sufficient to withstand the tensile force exerted by rotor of the turbine. This is the observation made after the analysis of the existing model of the teeter damper box. 0.8204 mm (0.032301 inch.) 88.243 N/mm (12794 psi.)
2

CHAPTER-6 MODIFICATIONS DONE ON THE EXISTING MODEL: As a result of analysis done on the existing model, the side members of the teeter damper box is found to be failed and the stress concentration also more in the side member as shown in the figure. In order to reduce the stress concentration in the side member of teeter damper box stiffeners are to be added. The stiffener may of same material or different. But for this problem it is considered as same material Normally for stiffeners we can use rectangular section, T section or I section. But if the rectangular section is used there wont be much improvement in the results. And if the I section is used the weight of the teeter damper box may increase. So, in this case the T section stiffeners are added to the side members of the teeter damper box. This is the modification done on the existing model of the teeter damper box. Now the modified model has to be created and the new deformation and stress concentration are to be found by analysis. CHAPTER-7 MODIFIED MODEL: The new modified model was created by using analysis software. The modified model created was shown in the figure.

RESULTS OF THE MODIFIED MODEL: After modeling the modified teeter box the analysis is carried out in order to find the deformation in X, Y & Z direction, total deformation, overall deformation, and stress obtained. The results of the modified model are shown in the following figures.

SUMMARY OF THE RESULTS: Thus the maximum deformation, overall deformation, and stress obtained in the existing model of the teeter damper box is given below. Maximum deformation in X-direction: 0.0007188 mm (0.0000283 inch.) Maximum deformation in Y-direction: 0.02956 mm (0.001164 inch.) Maximum deformation in Z-direction : 0.0598 mm (0.002354 inch.) Over all deformation Maximum stress OBSERVATIONS: The following are the observations made from the existing model. There was no change in the deformation in X direction. There was decrease in deformation in Y direction. There was decrease in deformation in Z direction. There was decrease in maximum displacement. There was decrease in overall deformation. There was decrease in stresses developed. CHAPTER-9 COMPARISION OF RESULTS: The deformation in X, Y, & Z direction, overall deformation, and stress obtained by both the existing model and the modified model are compared below. : 0.08117 mm (0.003196 inch.) : 87.215 N/mm2 (12790 psi.)

EXIXTING

MODIFIED

Maximum deformation in X-direction

0.0007188 mm

0.0007188 mm

Maximum deformation in Y-direction

0.02962 mm

0.02956 mm

Maximum deformation in Z-direction

0.059868 mm

0.0598 mm

Over all deformation

0.8204 mm

0.08117 mm

Maximum stress

88.243 N/mm2

87.215 N/mm2

Thus we can clearly identify from the above comparison that, after providing stiffeners to the side members the deformation in Z axis, overall deformation and stress obtained are reduced when comparing with the existing model.

GRAPH BETWEEN LENGTH OF SIDEMEMBERS AND DEFORMATION: EXISTING MODEL:

MODIFIED MODEL:

CHAPTER-10 CONCLUSION: Thus by providing a stiffener of T cross section the stress was reduced to 87.215 N/mm2 and maximum deformation was reduced to 0.18117 N/mm2. This was

comparatively low with other cross sections. Thus the stiffener with T cross section improved the life of the teeter damper box by reducing the maximum stress concentration and maximum deformation. Moreover T cross section enabled weight reduction along with fabrication ease. So the stiffener with T cross section might be suggested for the requirement. CHAPTER-11 SCOPE FOR FURTHER WORK: In our project work we had made some assumptions to simplify our problem. In future considering some real situations the assumptions made may not be followed due to some practical difficulties. By considering such situations the following scopes may be followed. At times the forces acting on the teeter damper box may not be uniform. At such situations a statically equivalent force cannot be applied for analysis. The material of the teeter damper box may not be homogeneous and isotropic. At such situations assuming of material properties may differ in analysis. At practical situations the shaft of the wind turbine, the bearing that holds the shaft, the damping material that holds the bearing all are not rigid and undergo deformations by taking the loads. But since our project area focuses only on teeter damper box we assumed that all other elements other than teeter damper box are rigid. REFERENCES: http://telosnet.com/wind/20th.html#UlrichHutter http://telosnet.com/wind/govprog.html http://www.motherearthnews.com/arc/1471/ http://www.iran-daily.com/1383/2084/html/energy.html http://www.nrel.gov/docs/fy02osti/2665.pdf

http://www.edn.com/article/CA468444.html http://www.autogyro.com/technic/f-1.htm http://wind.nrel.gov/designcodes/papers/windflow_stage1_prospectus.pdf http://www.synchrolite.com/1127.html http://www.synchrolite.com/1239.html