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DESIGN & CONSTRUCTION OF VERTICAL AXIS WIND

TURBINE
PROJECT REPORT (2013-2014)
Submitted by
NAME REG.NO
JEYAPANDIAN.K 12244610
JOHN JEBARAJ.M 12244611
KAVIN.P 12244613
KAVIYARASU.M 12244614
KOLANCHINATHAN.S 12244615
KUMARARAJA.S 12244616
GUIDE BY
Dr.N.RAJAMANICKAM
Submitted in partial fulfillment of the requirements for the award of the
DIPLOMA IN MECHANICAL ENGINEERING of the state board of technical
education, Government of Tamilnadu.






DEPARTMENT OF MECHANICAL ENGINEERING
GOVERNMENT POLYTECHNIC COLLEGE,
COIMBATORE -641014.
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GOVERNMENT POLYTECHNIC COLLEGE,
COIMBATORE -641014.
DEPARTMENT OF MECHANICAL ENGINEERING
PROJECT REPORT (2013-2014)
BONAFIDE CERTIFICATE
This is to certify that the project titled DESIGN & CONSTRUCTION OF
VERTICAL AXIS WINDTURBINE is approved record of the work done by
Mr.P.KAVIN Register No.12244613 in partial fulfillment of the requirements for the
award of the Diploma in Mechanical Engineering of the State Board of Technical
Education , Government of Tamilnadu during the academic year 2013-2014.


GUIDE HOD
(N.RAJAMANICKAM) (ESTHAR SUGANTHI PRAMOTH)



Submitted for the Board Examination Held on ..




INTERNAL EXAMINER EXTERNAL EXAMINER
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ACKNOWLEDGEMENT









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ACKNOWLEDGEMENT

We are pleased to express our gratitude and thanks to our respected Principal
Mr.A.MATHIVANAN, M.E., B,Tech, Ed., F.I.E.,M.I.S.T.E., C.Eng. for the facilities made
available in the institution.
Its our solace thanks to the head of the department of mechanical engineering
Mrs. ESTHAR SUGANTHI PRAMOTH, M.E., for providing support at every stage without
whom, the project would not be a successful one.
We extent our deep gratitude to our project guide Dr.N.RAJAMANICKAM, M.E.,
PhD,
We are grateful to express our thanks to all the staff members, friends, lab technicians
and classmates who helped us directly and indirectly to finish the project.











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CONTENTS






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CONTENTS

CHAPTER NO - CHAPTER NAME - PAGE NO

Synopsis - 01
01 - Introduction - 02
02 - Literature Review - 04
03 - Principle of working &
Design - 07
04 - Fabrication - 21
05 - Results &
Discussion - 23
06 - Cost analysis - 27
07 - Conclusion - 29
List of reference - 31
Photography - 32



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SYNOPSIS

It is understood that, the electricity demand can be increased every day. It leads current
shortage. It is a main reason for unwanted power cuts in Tamilnadu. So, it is necessary to find
easy ways for produce electricity. In present time, the electricity can be produced form Non-
renewable energy sources like thermal, nuclear and hydro. These resources exist in few years
only. So, the electricity should be produced from Renewable energy sources.
Wind is the one of the renewable energy source. It is available in any other places in the
world. So, it is important to utilize this resource. From this the wind turbines are used. It is a
machine which converts wind energy into electrical energy. Two types of wind turbines are used
for produce electricity. They are
1) Horizontal axis wind turbines (HAWT)
2) Vertical axis wind turbines (VAWT)
Vertical-axis wind turbines are a type of wind turbine where the main rotor shaft is set
vertically. Among the advantages of this arrangement are that generators and gearboxes can be
placed close to the ground, and that VAWTs do not need to be pointed into the wind. Major
drawbacks for the early designs (Savonius, Darrieus, and cycloturbine) included the pulsatory
torque that can be produced during each revolution and the huge bending moments on the blades.
In this project, were attempted to design and fabricate a Savonius Vertical Axis Wind
Turbine. It is a small scale wind turbine. So, less amount of output (electricity) can be generated
easily.





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CHAPTER-1
INTRODUCTION









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1. INTRODUCTION

Energy is the ability to do work. While energy surrounds us in all aspects of life, the
ability to harness it and use it for constructive ends as economically as possible is the challenge
before mankind. Alternative energy refers to energy refers to energy sources which are not based
on the burning of fossil fuels or the splitting of atoms. The renewed interest in this field of study
comes from the undesirable effects of pollution (as witnessed today) both from burning fossil
fuels and from nuclear waste byproducts. Fortunately there are many means of harnessing energy
which have less damaging impacts on our environment.
The alternatives are
Solar
Wind
Geothermal
Tides
Biomass
Hydroelectric
By using Wind, it is planned to produce more energy, so for getting energy wind mills are
used. By using Vertical axis wind mill electricity can be easily generated. The design and
construction of Vertical axis wind mill is simple when compared to Horizontal axis wind mill. In
vertical axis wind mill, the wind from all the direction touches the wind blades and makes the
blade to rotate. It also operates in less wind velocity.






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CHAPTER-2
LITERATURE REVIEW










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2. LITERATURE REVIEW

POWER & SOURCES
The Source of Winds
In a macro-meteorological sense, winds are movements of air masses in the atmosphere
mainly originated by temperature differences. The temperature gradients are due to uneven solar
heating. In fact, the equatorial region is more irradiated than the polar ones. Consequently, the
warmer and lighter air of the equatorial region rises to the outer layers of the atmosphere and
moves towards the poles, being replaced at the lower layers by a return flow of cooler air coming
from the polar regions. This air circulation is also affected by the Coriolis forces associated with
the rotation of the Earth. In fact, these forces deflect the upper flow towards the east and the
lower flow towards the west. Actually, the effects of differential heating dwindle for latitudes
greater than 30oN and 30oS, where westerly winds predominate due to the rotation of the Earth.
These large-scale air flows that take place in all the atmosphere constitute the geostrophic winds.
The lower layer of the atmosphere is known as surface layer and extends to a height of
100 m. In this layer, winds are delayed b y frictional forces and obstacles altering not only their
speed but also their direction. This is the origin of turbulent flows, which cause wind speed
variations over a wide range of amplitudes and frequencies. Additionally, the presence of seas
and large lakes causes air masses circulation similar in nature to the geostrophic winds. All these
air movements are called local winds.
The Power in the Wind
The power in the wind can be computed by using the concepts of kinetics. The wind mill
works on the principle of converting kinetic energy of the wind to mechanical energy. The
kinetic energy of any particle is equal to one half its mass times the square of its velocity,
Kinetic Energy=1/2 mv
2



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Amount of air passing is given by
m = A V..(1)
where
m- Mass of air transversing
A- Area swept by the rotating blades of wind mill type generator
- Density of air
V- Velocity of air (Wind)
Substituting this value of the mass in expressions of K.E.
=1/2 A V.V
2
watts
=1/2 A V
3
watts....................................(2)
Second equation tells us that the power available is proportional to air density (1.225 kg/m3) and
is proportional to the intercept area. Since the area is normally circular of Diameter D in
horizontal axis aero turbines, then
A=D
2
/4 (sq. m)
Put this quantity in equation second then
Available wind power Pa= D
2
V
3
/8 watt






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CHAPTER-3
PRINCIPLE OF WORKING
&
DESIGN




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3.1 BLOCK DIAGRAM

WIND WIND















Fig.3.11-Block diagram of wind turbine operation




WIND TURBINE

GENERATOR

ENERGY STORAGE

LOAD UTILISATION

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3.2 PRINCIPLE OF WORKING

Fig3.21:- Principle of working, indicated from top view of the rotor blade.
The flow of wind touches the rotor blade, the rotor blade and shaft starts rotating. So
from this rotation the power is transmitted to the large gear (Drive) in the gear box with the help
of shaft. The large gear is attached to the small gear (Driven) in the generator. So the rotation is
more in generator when comparing to the shaft rotation due to gear mechanism. From this the
generator rotates and produces the electricity. Here ball bearings are used to rotate the shaft
easily and smoothly. If we fix the vertical axis wind turbine above the building, the lower
supporting structure is not necessary. From this we can reduce the cost. The performance of
Vertical Axis Wind Turbine is more than the Horizontal Axis Wind Turbine.









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3.3 DESIGN

The main parts of the wind turbine and their design specifications are explained in this chapter.
3.31 Savonius Rotor Blade
It is a rotated part of this wind turbine. This Savonius wind turbine was invented by the
Finnish (Finland) engineer Sigurd Johannes Savonius in 1922. So the rotor blade is named with
his name. The rotor blade have S Shape. It is also known as S-Rotor. The rotor blade is made
from Aluminum plate with the help of rolling machine. The rotor blade is bolted with shaft.
The dimensions of the rotor blade are
Length-900 mm
Breadth-620 mm
Thickness- 3mm
It is made up of aluminum. The aluminum were chooses for light weight and also it has
the following properties
a) Yield stress-20 Mpa
b) Ultimate stress-70 Mpa
3.32 Shaft
It is used to transmit torque from rotor blade to the gear box. It is inserted in upper
supporting structure with two ball bearings and flange bearing for smooth rotation. It is a hollow
shaft, made up of Galvanized Iron (G.I). In this shaft, rotor blade is bolted in upper end, and the
spur gear (Low speed) is inserted in lower.



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The dimensions of the shaft are
Length-1700 mm
Diametre-32 mm
3.33 Supporting Structure
It is a supporting part of the wind turbine. It is made up of Cast Iron (C.I). It is welded
with 10 mm thick circular plate with four holes for bolting. It is bolted with top of the gear box.
The shat and ball bearings are placed inside the supporting structure. The dimensions are as
follows
Length-520 mm
Outer Diameter- 120 mm
Bore- 70 mm
3.34 Gear Box
It is a static part of wind turbine. It is made up of sheet metal. The spur gears (Drive and
Driven) and Flange bearing are placed inside the gear box. This box have 50 mm hole in top side
for shaft inserting. Also, its have a door with locking arrangement for generator maintenance.
The dimensions are as follows
Length & Breadth- 400 mm
Height-510 mm
3.35 Bearings
In this wind turbine, the bearings are used in the shaft for smooth rotation. Here two ball
bearings and one flange bearing are used. The ball bearings are used in mid place of the shaft.
Also, the flange bearing is used in dead end of the shaft. The dimensions are as follows
Outer diameter-70 mm
Bore-32 mm
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3.36 Generator
It is a main part of wind turbine. The electricity can be produced from the generator. It is
a DC generator, permanent magnet type. The output can be tested by using DC bulb. The yoke
can be made up of mild steel. The generator is fixed (bolted) in gear box. The specifications are
as follows
Type- DC permanent magnet
RPM-1500
Current-6 A
Voltage-12 V
3.37 Spur Gear
Here the spur gears are used in shaft and generator for torque transmission. One gear has
large size and another have small size. The large size gear is used in shaft (Drive), and small size
gear is fixed in the generators rotor (Driven). These two gears are coupled with each other(Gear
Mechanism). The gears are made up of Cast Iron (C.I). The dimensions are as follows
Large gear (Drive) Small gear (Driven)
Outer diameter-170 mm Outer diameter-69 mm
Bore-32 mm Bore-20 mm
No. of teeth- 65 No. of teeth-26






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3.38 DRAWINGS

LIST OF FIGURES

Sl.NO Figures
3.381 Gear Box
3.382 Savonius Rotor
3.383 Hollow Shaft
3.384 Spur Gear ( Low speed)
3.385 Spur Gear (High speed)
3.386 Supporting Structure
3.387 Savonius vertical axis wind turbine






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Fig-3.381: Gear Box






21







Fig-3.382: Savonius Rotor Blade





22







Fig-3.383: Hollow Shaft



23









Fig-3.384 Spur Gear (Drive)




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Fig-3.385: Spur Gear (Driven)




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Fig-3.386: Supporting Structure





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Fig-3.387: Savonius vertical axis wind turbine




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CHAPTER-4
FABRICATION






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4. FABRICATION

The fabrication process of the wind turbine is as follows
4.1) Rolling
The Rotor blade is made from aluminum plate by rolling operation. This operation was
done in rolling machine. This machine has three rollers. The plate was inserted between rollers,
and to make bends. After this bending process, the rotor blade shows S shape.
4.2) Bolting
The rotor blade-shaft, Supporting structure-Gear box, Gear box-Flange bearing, Gear
box-Generator are bolted with M12 Nut and bolt with 2 washer in a set of nut and bolt. The small
gear and generator were bolted with M8 nut.
4.3) Arc welding
In upper supporting structure, a circular plate is welded with a pipe. Also, in lower
supporting structure, square plates are welded with square hollow steel bar. The both welding are
Arc welding.
4.4) Grinding
The unwanted metal portions are removed by grinding process. This process was done
by using grinding machine. In this project, we were done grinding in shaft for insert of bearings.
4.5) Gas cutting
It is making a hole in gear in upper side of the gear box by using gas cutting.
4.6) Painting
In this process the outer and inner area of the wind turbine are painted with Wight color.

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CHAPTER-5
RESULTS
&
DISCUSSION





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5.1 RESULTS & DISCUSSION
The maximum power of Savonius wind turbine is given by (Practical Power)
P
max
=0.36 Kg/m
3
X h X r X v
3
in Watt (W)
Here
h- Height of the rotor blade in metre (0.62 m)
r- Radius of the rotor blade in metre (0.28)
V- Wind velocity in m
3
/sec
P
max
-Maximum power of Savonius wind turbine in Watt
I f the wind velocity is 10 m
3
/sec means
P
max
=0.36 X 0.62 X 0.28 X 10
3
=69.55 W
70 W
This is Mechanical power. But electrical power can be denoted by
P=VI in Watt (W)
Here
V-Voltage in Volt (V)
I-Current in Amphere (A)
From Generators specification
Voltage= 12 V
Current= 6 A
So, the electrical power is given by
P = 12 X 6
P = 78 W

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5.2 ADVANTAGES & DISADVANTAGES
The advantages and disadvantages of this wind turbine are discussed in this chapter.
ADVANTAGES
+ They can catch wind from any direction.
+ They are produced less noise.
+ They starts at low wind velocity.
+ Towers can be much lower.
+ Low installation costs.
+ They are Bird and bat friendly.
+ It is a renewable Energy Source
DISADVANTAGES
- Large effective area required.
- Cant use in very height.
- It is used in wind season only. (Common disadvantage of wind turbines)


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5.3 APPLICATIONS

Wind- turbine generator have been built a wide range of power outputs from
kilowatt (Kw) or so to a few 1000 Kw, machine of low power can generate
sufficient electricity for space heating & cooling & for operating domestic
appliances.
Low power Wind Energy Conversion (WEC) generator have been used for many
years for the corrosion protection of buried metal pipe lines.
Application of more powerful turbines up to about 50 Kw, are for operating
irrigation pumps, Navigational signal. Aero generator in the intermediate power
range, roughly 100 Kw-25 Kw can supply electricity to isolated population.







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CHAPTER-6
COST ANALYSIS







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6. COST ANALYSIS

Sl.
No
Part Material
Cost (Rs)
Labor Cost
(Rs)
Total Cost
(Rs)
01. Savonius Rotor
Blade
1450 500 1950
02. Hollow Shaft 180 - 180
03. Supporting
Structures
350 200 550
04. Gear Box - 2500 2500
05. Bearings 550 - 550
06. Generator 750 - 750
07. Spur Gear

550 50 600
08. Accessories 1000 - 1000
Overall Cost (Rs) 8080

Labor cost
The labor cost of this project for done welding, gas cutting, rolling etc.,
Accessories cost
The accessories cost of this project for purchase Bolts, Nuts, Paint, Thinner etc.,








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CHAPTER-7
CONCLUSION












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7. CONCLUSION

In this project, Design & Construction of vertical axis wind turbine has been done
successfully. The output of 12 V has been generated. In wind season the output can be increased.
Vertical axis wind mill is the easiest way to produce electricity. This project is a proof for this.




















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LIST OF REFERENCE

The following books and websites are taken for reference.
1) Renewable energy sources form N.V.Publications authored by Mr.M.Parasuram.
2) Strength of materials by R.S.Kurmi.
3) www.wikipedia.com/ wind turbine.
4) www.wikipedia.com/ vertical axis wind turbine.
5) www.wikipedia.com/ Savonius vertical axis wind turbine.














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PHOTOGRAPHY

Fig: 1-Fabricated View of wind turbine

Fig: 2- View for generator and gears are placed inside the gear box