Report

To:
Richard Wilk, PhD.

From:
Mark de Jong
707 Ridge Rd
Broadalbin, NY 12025
Tel: (518) 842-4079
E-mail: dejongm@union.edu
mdejong@empireone.net
Date: 03-21-2003

Subject:
Wind Turbine Senior Design Project

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Table of Contents

Abstract...........................................................................................................................................3
2. Introduction.................................................................................................................................4
2.1 History................................................................................................................................4
Wind turbine types...................................................................................................................7
2.3 United States wind energy usage......................................................................................8
2.4 New York State wind energy usage.................................................................................10
2.5 Background......................................................................................................................11
3. Objective...................................................................................................................................12
4. Data..........................................................................................................................................12
4.1 The Site...........................................................................................................................12
4.2 Calculating wind speed at various heights.......................................................................14
4.3 Calculation of Wind Power at Location 1.........................................................................15
5. Design.......................................................................................................................................16
5.2 Prototype Wind Turbine Specifications............................................................................17
5.3 The design process of a wind turbine generator..............................................................17
6. Prototype...................................................................................................................................19
7. Conclusions..............................................................................................................................21
8. Bibliography..............................................................................................................................22
9. Appendix...................................................................................................................................22
Appendix A................................................................................................................................23
Wind Speed Measurements......................................................................................................23
Appendix B................................................................................................................................27
Wind Density Calculation...........................................................................................................27
and Rotor Sizing........................................................................................................................27
Appendix C................................................................................................................................30
Wind Turbine Prototype Drawings.............................................................................................30

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Abstract
The wind turbine design project was two fold: To test the wind conditions on Merry
Meadows Farm in Broadalbin, New York. The second phase was to design a wind turbine
prototype.
The wind conditions of the farm were determined over a one-month period over October
and November. The conditions measured were wind speed, and wind direction using an
anemometer at ground level. An extrapolation was used to determine the speed at multiple
heights at which the generator and rotor would be placed. It was determined that the wind
conditions on the farm are fair for a wind system. The wind speed for the best location was
determined to have an average speed at 10m (30ft) of 5.4 m/s and at 18m (60ft) of 5.9 m/s. The
power density was determined to be around 300 W/m2. To meet the power demand on the farm
of around 2000 W, it was determined that a rotor would have to be no less then 5 meters in
diameter, with a 29% efficiency.
The second phase of the project was to design a wind turbine prototype. This involved
using Solidworks, which is a three-dimensional design program for modeling the wind turbine
prototype that could meet the demand of power on the farm. After modeling the system the
drawings were sent for fabrication at the Union College machine shop. After completion of the
fabrication process the system was to be tested in a wind tunnel at Union College. The
fabrication process in not complete so no data was taken to conclude the necessary size of the
system. The test will include at study of multiple pitches, multiple blade lengths, varying the
material of the blades, and number of blades on the rotor. The study would also include a
calculation of the efficiency of the wind turbine prototype and to verify the Betz Limit. The Betz
limit says, “59% of the winds kinetic energy is converted into rotational shaft energy”.

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2. Introduction
2.1 History

The history of wind turbines starts with their predecessors the old fashioned windmills.
The concept of harnessing wind energy started in the 7th century AD around the region of modern
Iran and Afghanistan. These mills where constructed so that the sails rotated around in the
horizontal plane around a vertical axis. It was relatively easy to attach a grindstone directly to the
rotating vertical axle, which was constructed of wood. This type of mill was simplistic, requiring
no gears, but on the other hand, typical rotational speeds of such mills (dictated by the wind)
were unsuitable for efficient grinding of grain.
The other type of mill was the vertical or post mill. (Seen in figure II.1). The sails rotated
in a vertical plane around a horizontal axle. The other end of this axle was attached to a wooden
gear, which in turn, was attached to a gear on a separate vertical axle to which the millstone was
attached. The gear ratio was set to provide a reasonable grinding speed in a typical wind. Figure
II.1 shows such a mill with its vertical sails and a ladder up to the mill itself. If one looks closely
one can see the vertical post supporting the mill. The mill can be turned on this post by means of
the arm seen to the left near the foot of the peasant bringing grain to the mill. The arm looks here
like a small bit of a fence.

Figure 2.1 Early Post Mill (reference 1)

Evidence shows that the post mill seems to be a purely European invention developed
totally independent from the horizontal mills of the Middle East. First documentation of the mills
comes from Yorkshire, England in 1185. By 1195 the mills where so common that the Pope
ordered tithe to be paid on them. Members of the Third Crusade introduced the post mill to the
Middle East.
The post mill suffered great disadvantage if it could not be turned into the wind. To
overcome this, the entire mill housing was raised from the ground and made mobile, rotating on a
vertical axis. It was light enough to be easily turned by one man. In this way it could be kept
turned into the wind at all times. The post mill could generate roughly 2 to 8 horsepower (1 1/2 to
6 kilowatts).
A later development saw larger, permanent mills with rotatable tops. These old fashion
windmills are seen in pictures of the Netherlands with the flat landscapes and a field of tulips
surrounding a magnificent large old wooden structure. These mills contain a second sail (a large
fin) projected out the back of the mills, automatically keeping them pointed into the wind.

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Harnessing wind energy changed little from the early Middle East and European designs,
until Charles F. Brush (1849-1929) built what is today, believed to be the first wind turbine
generator. It was a giant - the World's largest - with a rotor diameter of 17 m (50 ft.) and 144 rotor
blades made of cedar wood. (See Figure II.2 and II.3)

Figure 2.2 Charles F. Brush (reference 2)

Figure 2.3 Charles F. Brush’s wind turbine (reference 2)

Charles’ wind turbine ran for 20 years and was used to charge batteries in the cellar of
his mansion. Despite the size of the wind turbine (depicted by the man mowing the lawn to the
right of the base of the turbine) the turbine was only a 12kW model. This was due to that the
slowly rotating wind turbines of the American rose type that do not have a high average
efficiency. It was later that the Dane Poul La Cour, who discovered that fast rotating wind
turbines with few rotor blades are more efficient for electricity production than slow moving wind
turbines. Charles F. Brush and Poul La Cour (1846-1908) were the pioneers of what modern wind
turbine design is today.

Figure 2.5 Two of Poul’s wind turbine designs

(reference 2)

Figure 2.4 Poul La Cour and his

Wife (reference 2)

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The demand for energy increased dramatically during and after World War II for all
countries, due to increased manufacturing and new electrical technologies. The demand caused
innovations in the wind turbine design, such as the conversion technology on wind turbines from
DC to AC power.
J. Juul designed a 200kW, 3-blade wind turbine with over speed control and
electromechanical yawing. The technology was introduced in 1956 for electricity company SEAS
at Gedser coast in the Southern part of Denmark. The machine ran for eleven years without
maintenance. The new emergent technology although effective in boosting energy output tended
to be expensive and interest in wind energy died off.

Figure 2.6 J. Juul’s 200kW Wind Turbine (reference 2)

In 1973, interest in wind turbine energy rekindled in several countries due to the first oil
crisis. In Denmark, the power companies aimed at making new large turbines, just like their
counter-parts in Germany, Sweden, the United Kingdom, and the United States. The large
630kW wind turbines suffered much of the same fate as their earlier counter-parts becoming
extremely expensive.

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Wind turbine types

There are several varieties of wind machines. Wind machines can be broken down into
two classifications, those using lift, or drag. Lift and drag are the two aerodynamic forces. Drag
is easier to conceptualize; it is the force of the blade cutting the wind at an angle to break the
wind’s force into the components of that force. The one component causes the blade to spin
around its axis, and the other pushes back. To understand lift, we look to an airplane wing. The
wind hits the wing and the wing is design so that the wind creates a low-pressure air pocket,
which pulls the wing in that direction. One a wind turbine this low-pressure pocket causes the
rotor to spin.
Types of wind machines are lift and drag devices. Wind turbines are lift devices.
Traditional wind vanes used for pumping water are drag devices. Wind vanes are used in low
speed wind because they require slow speed winds. Wind vanes don’t work as well in high wind
speed, because drag device tend to ware, and vibrate, eventually causing mechanical failure.
Unlike their counterparts wind turbine tend to do very well in higher wind speed and not so well at
low wind speeds. Wind turbines require a certain startup wind speed depending on their design
before the rotor engages in rotation. Wind turbine can put out high amounts of power at high
speed but are limited by the winds speed, and wind vanes put out lower more constant power at
lower speeds. Hence, wind turbines are used for creating power using generators and
alternators, and wind vanes are used to supply shaft power to run a pump or what have you.
Wind turbines are classified by either vertical axis or horizontal axis. Figure 2.7
demonstrates the two types. There are benefits and draw back to each. The benefit of a vertical
axis wind turbine (also known as Darius Type) is that it requires no device to keep it furled into
the wind. The benefit to a horizontal axis wind turbine is that when wind speed are to high for the
wind turbine to withstand it can furl itself using a furling device (springs or motor). This device
positions the wind turbine to absorb less kinetic energy of the wind. This can also be installed on
the Darius wind turbine but the furling is installed on the blades itself which, tend to be expensive
and complicated.

Figure 2.7 Wind turbine types (reference unknown)

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2.3 United States wind energy usage

Total energy produced in 2001 by wind turbine generation in the United States was 4,261
MW. Good wind areas, (speeds of 7 m/s or more) cover 6% of the United States. This 6% has
the potential to produce more then one and a half times the current energy consumption of the
United States.
In United State there are superb locations for wind turbines due to the locations wind
speeds. In figure III.3 these optimum sites are shaded in blue, red, and purple. The superb sites
are found on costal lines and mountain ranges. These site are designate as having a wind power
class of 5-7. This is a measure of the wind speed and wind power density. Wind classes range
from 1-7(One being the lowest and 7 being the best). Table III.1 shows the different wind power
classes and the wind power density for those classes. Wind power density will be discussed
later, but is it based on wind speed and the density of air.

Figure 2.7 Wind Power Classification (reference 4)

Table 2.1. Classes of Wind Power Density

Wind Speedb,
Wind Power Wind Power Speedb, Wind Power Speedb,
Power m/s
Density, W/m2 Density, W/m2 m/s (mph) Density, W/m2 m/s (mph)
Class (mph)
0 0 0 0 0 0
1
100 4.4 (9.8) 160 5.1 (11.4) 200 5.6 (12.5)
2
150 5.1 (11.5) 240 5.9 (13.2) 300 6.4 (14.3)
3
200 5.6 (12.5) 320 6.5 (14.6) 400 7.0 (15.7)
4
Wind Speedb,
Wind Power Wind Power Speedb, Wind Power Speedb,
Power m/s
Density, W/m2 2 2
Density, W/m m/s (mph) Density, W/m m/s (mph)
Class (mph)
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250 6.0 (13.4) 400 7.0 (15.7) 500 7.5 (16.8)
5
300 6.4 (14.3) 480 74.4 600 8.0 (17.9)

400 7.0 (15.7) 640 8.2 (18.3) 800 8.8 (19.7)

7
11.0
1000 9.4 (21.1) 1600 2000 11.9 (26.6)
(24.7)

Figure 2.8 United States Wind Generation Capacity (reference 3)

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2.4 New York State wind energy usage

Did you know that New York State has as much wind energy potential as California?
New York State currently produces 48.15 MW from wind power generation. The States’ total
wind energy potential is 7,080 MW, which is 15th among the states.
For a list of current New York State wind farm see Table III.1. For a list of proposed
wind turbine site and capacity see Table III.2.

Existing Project Owner Date MW Power Purchaser/ User Turbines/

or Area Online Units

Madison County PG&E Sept 2000 11.55 PG&E National Energy Vestas
Generating Group (7)

Wethersfield, Wyoming CHI Energy Oct 2000 6.6 Niagara Mohawk Vestas (10)
County

Fenner Wind Power Project CHI Energy Dec 2001 30.0 NY Power Pool GE Wind TZ
1.5 (20)

Table 2.1 Wind Power Sites in NY (reference 3)

Utility/Developer Location Status MW On Line By /

(Project) Capacity Turbines

Atlantic Renewable Energy Corp. Flat Rock, North Proposed 50.0 2003
(Flat Rock) Central NY

Long Island Power Authority Shelter Island Proposed 0.05 2002 / 1 AOC 15/50

NYSERDA Proposed 0.15 2002 / 3 AOC 15/50

Atlantic Renewable Energy Corp. East Central NY Speculative 10.0 Dec 2003 / TBD
(Delaware Wind power)

Table 2.2 Proposed Wind Power Sites in NY (reference 3)

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2.5 Background

In the future it is anticipated to establish a wind farm on Merry Meadows Farm. This
Farm is located in up-State New York approximately 55 miles North-West of Albany. This senior
project will help the author to understand wind turbines and the cost associated with establishing
a wind farm.
Current investigation shows that the major cost of wind energy is the initial cost of
purchasing and installing a wind turbine. Micro-turbines, which are turbine that produce 100W-
3kW have a high initial cost ranging from $800-$15,000. The cost of a W ranges from $5-$8
dollars. As the size of the wind turbine increases the cost per W decrease to $4. This is why it is
beneficial for wind farms to install large wind turbine, then more smaller wind turbine that produce
the same power.
Wind Power is a function of the wind sweep, wind speed, rotor diameter, and density of
the wind hitting the blade, governed by the equation:

P = ½ d*A*S3 Eq. (1) (reference 5)

P = power
d = density
A = area of rotor sweep
S = wind speed

P is known as the ideal power that a wind turbine can output. The theoretical power that a wind
turbine can putout is governed by the ability of the rotor to convert the wind kinetic energy into
shaft power, the alternator or generator efficiency, and the conversion efficiency. With losses
also do to friction in the conversion of mechanical power to electrical power.
The rotors conversion efficiency is called the Betz limit. The Betz limit says, that the
maximum efficiency of conversion of a wind turbines rotor is 59%. 59% of the winds kinetic
energy can be turned into mechanical shaft power.

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3. Objective
The objective of this project is to design and manufacture a feasible wind turbine on a
sub-scale and study the efficiency of energy conversion and try to improve the designs to date.
Also, to study the cost of the wind turbine generator and make it affordable to the common
homeowner to supplement their electric power demands.
It is anticipated that wind speed on Merry Meadows Farm should prove suitable for a
wind turbine generator. It is expected that output energy will increase at low wind speeds from the
wind turbine generator because of the use of lightweight composites because the blades require
very little startup energy. It is anticipated that the cost of the design wind turbine producing
energy will be more cost effective then purchasing energy from the power company.
At the end of the project it is desired to have a feasible wind turbine that is approximately
four feet tall with a rotor diameter of 1-3 ft wide. Deliverables at the end of the project will be the
manufactured wind turbine including drawings and shop drawings of the all components used.
Test data will also be delivered with a comparison of wind turbines to date. The test data will
include the startup wind speed and power output.

4. Data
4.1 The Site
Three locations for taking wind data on Merry Meadows Farm were based on the following.

Location 1: This location is in the middle of the field. This is beneficial because it means there is
a lower friction factor, more-so than the other two locations. This means a shorter tower could be
used to get above the turbulent wind layer. Location 2 and 3 have a tree line running parallel
about 100m to the west of them. This stirs up the air and causes turbulence at and above ground
level. The draw back to putting up a wind turbine generator here is that it is about 150m from the
fuse box, which is how far I would need to run the power lines.

Location 2: Location 2 was chosen because it is the benchmark on our farm. Location 2 is
1000ft above sea level. I could get a thirty foot tower and reach the unimpeded air, avoiding the
effects of the tree line. This also would give me about twenty (20) more feet clearance then
location 1 and about thirty (30) more feet then location 3. The draw back to this is that it is the
farthest away from the fuse box, approximately 300m.

Location 3: The reason I choose location 3 is to shorten the distance to the fuse box. It would
require the least amount of electrical lines and still put me on high ground. Predominate winds
on our farm are from the N-W and S-E. The draw back is that the tree line and farm affect the
winds on this location in both these direction, respectively. This would require me to put up a tall
tower. When I stand at location three, I observe halfway up the silo, which is 60ft. So I would
need a 40-60ft tower to get above this obstruction.

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Figure 4.1 The location for wind speed measurements

See Appendix A for wind data at these locations for varying tower height.

Procedure for recording wind measurements

The tool used for taking wind speed measurement was a thermistor hot probe
anemometer from 10/7/02 to 11/07/02. The procedure involved going out to each location once a
day. Facing the wind direction, the probe was placed in the wind stream at 3 meters for five
seconds. The maximum and minimum wind speed was recorded for this ten-second period.
After a minute the procedure was preformed again, and also a third time.

This previous procedure seemed to be an inaccurate way of recording wind data,

because it only would take into consideration a short period of time throughout the day. Also the
maximum and minimum values of speed may not give an accurate average value. So, to elevate
the error of averaging out the maximum and minimum wind speeds, an alternate anemometer
was selected. Extech 45158 Mini Thermo Anemometer + Humidity was selected for averaging
out wind speeds over a ten second period. Error is still associated with finding the average wind
speed throughout the day because only one measurement is recorded per day.

From the initial data it was observed that Location 1 gave the optimum wind conditions
for a wind turbine generator. Therefore, wind speed will no longer be recorded for th other
locations.

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4.2 Calculating wind speed at various heights

Location 1 was the optimum site for wind speeds, so data will only be presented
for this location.

For calculating wind speed at an alternate height you need to know the wind speed at one
height, the height, and the wind shear (α )
α
(S/S0) = (H/H0) Eq. (2) (reference 5)

S = the speed at the higher height

So= the speed at the height your measuring.
H = the height at which you wish to know the speed
Ho = the height at the ground speed
α = the wind shear

α
(S/S0) = (H/H0)

α was experimentally calculated to be .46 initially for the S-E direction. This value was
found taking the wind speed at 6 ft and then the wind speed at 20 ft then calculating α . This
value seemed a little high, so a second experiment was conducted taking the wind speeds
simultaneously.

Wind Shear Calculation for South-East

Trial Speed @ Speed @ log(S/So) alpha
4 ft m/s) 20 ft (m/s)
1 1.3 1.4 0.03 0.05
2 2.1 3.1 0.17 0.24
3 2.1 2.3 0.04 0.06
4 1.1 1.3 0.07 0.10
5 0.4 0.6 0.18 0.25
6 1.9 2.1 0.04 0.06
7 1 2.1 0.32 0.46
8 2.4 2.6 0.03 0.05
9 1.2 2 0.22 0.32
10 2 2.2 0.04 0.06
Average 0.16

log(H/Ho) 0.69897
Table 4.1 Wind shear calculation 11/18/02

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Wind Shear Calculation for North-West
Trial Speed @ Speed @ log(S/So) alpha
4 ft (m/s) 20 ft (m/s)

1 3.5 4 0.06 0.08

2 6.2 6.8 0.04 0.06
3 3.5 4.5 0.11 0.16
4 3.3 4.1 0.09 0.13
5 3.6 4.7 0.12 0.17
6 5.5 7 0.10 0.15
7 6.1 7.3 0.08 0.11
8 5 5.4 0.03 0.05
9 5.8 7.6 0.12 0.17
10 3.5 5.5 0.20 0.28
Average 0.14

log(H/Ho) 0.69897
Table 4.2 Wind shear calculation 11/17/02

These Alpha values were used for calculating wind speeds a varing heights for location 1
wind data found in Appendix A

4.3 Calculation of Wind Power at Location 1

Calculating wind power density: Power Density = ½ d S^3. The wind power density for
New York State is around 300 (watt/m2). Wind power density is a function of wind speed and the
density of air. Initially, I calculated the wind power density from the average speed that I got at 30
ft and 60 ft for location 1. I found out that my wind power density was much lower when
compared to the wind power map of New York State. I went back to the calculations and found
out that the higher wind speed have a dramatically higher wind power density. So, I took the top
five percent of my wind speeds and the lower five percent of my wind speed, to get calculate wind
power density at these points. I then average them out and calculate a wind power density that
was comparable to the wind power density of New York State wind power maps.

Wind Power Density at location 1 for 30ft

Average Max Speed = 9 (m/s)
Average Min Speed = 1.3(m/s)
Density of Air = 1.25 (kg/m3)

Max Wind Power Density = .5 * 1.25 * 9^3 = 456 (W/m2)

Min Wind Power Density = .5 * 1.25 * 1.3^3 = 1.37 (W/m2)
Average Wind Power Density = 228 (W/m2)

Wind Power Density at location 1 for 60ft

Average Max Speed = 9.5 (m/s)

Average Min Speed = 1.3(m/s)
Density of Air = 1.25 (kg/m3)

Max Wind Power Density = .5 * 1.25 * 9^3 = 536 (W/m2)

Min Wind Power Density = .5 * 1.25 * 1.3^3 = 1.37 (W/m2)
Average Wind Power Density = 269 (W/m2)

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5. Design
5.1 Farm Wind Turbine Specifications

Blades: Carbon reinforced fiberglass

Alternator: PM 3 phase brushless
Rotor diameter: 15' (5.0 meters)
Weight: 175 lbs (55 kg)
Start-Up wind speed: 7.1 mph (3.1 m/s)
Tower Hight: 60ft (18m)
Voltage: 24, 32, 48 VDC
Peak Power: 3200 Watts @ 27 mph (12 m/s)

Flow of
power

Inverter
Inverter

Battery

Power from Power

Company (backup)

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5.2 Prototype Wind Turbine Specifications

Blades: Carbon reinforced fiberglass

Alternator: unknown
Rotor diameter: 2' (.6096 meters)
Weight: approximately 40 lb(18.14 kg)
Start-Up wind speed: unknown
Tower Hight: 4-6 ft (1.21-1.82m)
Voltage: unknown
Peak Power: unknown

5.3 The design process of a wind turbine generator

1. Identification of need

To fulfill the requirement for the senior design project in Mechanical Engineering Program
at Union College. To apply principles gained from the Mechanical Engineering Program
at Union College to conceive, design, and manufacture a wind turbine generator.

2. Background research

With the increasing cost of fissile fuels, due to their depletion, along will come the
increasing cost of energy. This increase in fossil fuel energy will cause a shift in the
power market to technologies that were once more costly, like wind, hydro, and solar
powers.

3. Goal Statement

To design and manufacture a prototype of a wind turbine generator that can be

competitive with the cost of the fossil fuel energy market.

4. Task specifications
Time and money bound the problem and limit the scope. Project completion is
mandatory for March 15th, 2003 this is the end of the second period of the winter
semester 2003. The budget is approximately $700, a grant from Union College.
Possible, the project manager and student Mark de Jong will contribute funding if
necessary for completion.

5. Synthesis

A. Drag or Lift device

B. Horizontal axis: Up wind or down wind rotor blade.
C. Vertical axis: Giromill, Savonius, Darrieus.
D. Furling or brake: Furling on blades, or nacelle. Brake on main shaft or high-speed
shaft.
E. Positioning into wind: Vain or Motor driven:
F. Power producing: Generator or Alternator
G. Tower: Welded steel frame or cylindrical pole. Guided or free standing.
H. Sizing: Prototype tower height, rotor diameter, power produced.

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6. Analysis

A. Drag or Lift device: Using drag it is possible to produce low voltage power at
slower speed. Drag devices tend to work better for pumping water then
producing electricity. Lift devices response to sudden change in wind conditions
are less prevalent then drag devices. Lift devices tend to work better in higher
speed winds then drag devices. Construction of a lift device could be more
difficult to build or to purchase for a prototype.
B. Horizontal axis: Up wind or down wind rotor blade. Up wind a tail vane or other
device is need to keep it positioned into the wind. This is not necessary for down
wind systems, and also their blade can be semi-flexible because there is no
chance that they can hit the tower.
C. Vertical axis: Giromill, Savonius, Darrieus. A vertical axis machine need not be
oriented with respect to wind direction. Because the shaft is vertical the
transmission and generator can be mounted at ground level. Although, vertical
axis wind turbines have advantages, their designs are not yet as efficient at
collecting energy form the wind as the horizontal machines. The Giromill has
blades whose angle of attack is adjustable to optimize windmill performance
under varying wind conditions. Savonius is self-starting and the simplest of the
designs to construct, but is least efficient. Darrieus is not self-starting it requires a
motor to position it blades into the wind before the wind can take over.
D. Furling or brake: Furling on blades, or nacelle. Brake on main shaft or high-speed
shaft. Furling is very difficult to install on the blades but tend to work well. Furling
on the nacelle tends to be easier by using spring load. Using brakes to reduce
the rotor speed and protect the unit tend to be more expensive then furling and
require more maintenance. Brakes are more commonly used on larger wind
turbine devices. Brakes are more commonly placed on the high speed shaft, after
the gear box transmission.
E. Positioning into wind: Vain or Motor: Using a vain to position into the wind is the
cheaper solution to position the blades into the wind on up wind horizontal axis
machines. Motor work well and can also be used to protect the machine in high
wind speed, but add to the size of the wind turbines base and tower.
F. Power producing: Generator or Alternator. Generators produce DC power and
are typically used on larger scale wind turbines, more so then alternators.
Alternators produce AC power and are more commonly used on micro-turbines.
G. Tower: Welded steel frame or cylindrical pole. Guided or free standing. Welded
steel frames are readily available on the market and are easy to erect. Cylindrical
poles are easy to design and can also be found in standard sizes and lengths.
H. Sizing: Prototype tower height, rotor diameter, power. A smaller prototype will be
less costly then a larger prototype. The tower will be no more then 6 ft tall. Rotor
diameter will be no more then 3 ft, and is also limited by testing. A fan will be
used to test the prototype, so the device should not be too large. Power
produced will be limited by the sizing of the components and mainly determined
by the wind speed and generating device’s size.

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7. Selection

A. A blades will be purchased to utilize drag and lift forces.

B. A horizontal axis wind turbine will be designed for this project. Horizontal axis is
the most common wind turbine design.
C. A tail vane will be designed to position the up wind blades into the wind. The
vain will be a kidney shape. .062 in 1020 Carbon sheet metal will be used to
fabricate the vain.
D. Furling will be used to protect the machine against excessive wind speed. The
furling device will be attached to the nacelle and support. Through the use of
springs the wind turbine will reticulate or rotate back in excessive wind. A pin
joint will create the rotation pivot, which will be mounted on the motor mount.
E. A remote control planes motor will be used in the reverse direction to generate
power. The motors will be converted to a generation device by rotating the rotors
in the opposite direction to motor propulsion. The motor will be fixed with a gear
head assembly. The motors voltage range is 4.8v to 8.4v. The gear range is
64/12 providing a 5.33 gear ratio.
F. The tower will be made from a cylindrical tube.
G. The sizing of the prototype will be small to save on the budget.

7. Detailed Design

The entire design has to be capable of supporting all loads and forces, be in expensive,
and look astatically pleasing. All parts will be purchased if costs are relative to the entire
budget of approximately $700. If parts cannot be purchased at a reasonable price then
they maybe manufactured.

6. Prototype
The design drawings can be found in appendix C.

Figure 6.1 Full view

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Rotational mount used to position the rotor

in the wind. The wind will hit the vain and
cause the nacelle to rotate and position the
rotor area into the wind.

Figure 6.2 Unfurled view

Bearing Housing

Snap ring

Tower Housing

Figure 6.3 Internal view of Rotational mount

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When the wind speed is to fast, to

protect the generator the rotor will
pitch back and take the rotor area
out of the wind. When the
excessive wind subsides a spring
will pull the rotor back down to
normal operating position.

6.4 Furled View

Testing

7. Conclusions
Due to the fabrication being incomplete for the end of the winter term 2003, the prototype
was not tested. The test was to include a study of multiple pitch angles, varying the material,
changing the number of blades, and changing the length of the blades.
The test was to conclude which blade would be best suited for the wind conditions on
Merry Meadows Farm. The study was also to find the efficiency of the wind system. To verify the
Betz limit using the wind turbine prototype.
Testing will be completed and the result will be presented at a later date.

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8. Bibliography
1. Gans, Paul J. 2000, Windmills [On-line]
http://scholar.chem.nyu.edu/~tekpages/windmills.html
17 Sept. 2002.

2. Krohn, Soren 2001, A Wind Energy Pioneer: Charles F. Brush [On-line]

http://www.windpower.dk/pictures/brush.htm
7 Oct. 2002

3. American Wind Energy Association. 2001, New York State Wind Energy [On-Line]
http://www.awea.org/projects/newyork.html
14 Sept. 2002

4. National Renewable Energy Laboratories. 2002

http://www.nrel.gov/
15 Nov. 2002

5. Gipe, Paul, Wind Power for Home & Business: Renewable Energy for the 1990s and
Beyond, Chelsea Green Publishing Co., Post Mills, VT (1993)

9. Appendix

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Appendix A
Wind Speed Measurements

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Location 1
Date Time Direction Speeds 1 Speeds 2 Speeds 3 Average Average Average
max min max min max min m/s m/s m/s
(m/s) over 5 sec (m/s) over 5 sec (m/s) over 5 sec at 3 m at 10 m at 18 m
10/7/0211:30am n-w 9.5 4 11 7 10.1 6 7.9 9.4 10.2
10/8/027:30pm s-e 1.3 1.3 1.1 1.5 1.3 1.2 1.3 1.6 1.7
10/9/0211:50am n-w 5.5 2.6 6.2 3.7 5.4 3.8 4.5 5.4 5.8
10/10/027:45am n-w 4.1 3.6 3.8 3.3 4.2 3.9 3.8 4.5 4.9
10/11/026:45pm n-w 1.4 1.2 1.5 1.3 1.9 1 1.4 1.6 1.8
10/12/022:20pm s-e 7.2 6.8 9.1 8.4 8.1 6.5 7.7 9.3 10.2
10/13/023:00pm s-e 4.6 4.3 4.9 4.1 5.5 4.8 4.7 5.7 6.3
10/14/029:40am n-w 4.1 3.5 4.5 3.2 4.1 3.6 3.8 4.5 4.9
10/15/0212:35pm s-e 13.7 11.7 10.6 9.2 7.2 6.5 9.8 11.9 13.1
10/16/0212:00pm n-w 9.1 7 10.5 7.3 10.7 6.6 8.5 10.1 11.0
10/17/027:15pm n-w 4.1 2.3 5.1 3.3 5.4 4.1 4.1 4.8 5.2
10/18/024:00pm n-w 5.1 4.7 3.1 2.7 4.1 3.3 3.8 4.5 4.9
10/19/029:30am s-e 8.2 7.7 7.4 6.3 6.4 5.6 6.9 8.4 9.2
10/20/0211:00am n-w 6.4 3.9 5.4 4.5 7.2 6.1 5.6 6.6 7.2
10/21/021:30pm n-w 6.4 4.7 5.5 4.6 3.4 2.7 4.6 5.4 5.8
10/22/027:30am n-w 3.4 3 4.2 3.5 4.5 4 3.8 4.5 4.8
10/23/025:20pm n-w 5 4.7 4.7 3 5.1 4.5 4.5 5.3 5.8
10/24/021:00pm n-w 4 3.5 7 5.8 6.9 6 5.5 6.5 7.1
10/25/0210:30am n-w 0.9 0.4 1.5 1.5 0.2 0.2 0.8 0.9 1.0
10/26/025:35pm n-w 4 3.9 6.1 5.1 6.2 6.1 5.2 6.2 6.7
10/27/024:10pm n-w 5.7 5.6 4.2 3.7 5.2 5.2 4.9 5.8 6.3
10/28/028:25am n-w 1.4 0.3 0.2 0.2 0.3 0.2 0.4 0.5 0.6
10/29/022:30pm n-w 3.1 2.7 4.9 3.6 5.1 4.2 3.9 4.7 5.1
10/30/0211:05pm n-w 1.1 0.7 0.3 0.2 0.3 0.2 0.5 0.6 0.6
10/31/021:50pm s-e 6.9 4.9 5.1 4.5 4.2 3.1 4.8 5.8 6.4
11/1/0211:15am n-w 6.2 5.6 7.2 6.3 20 9.1 9.1 10.7 11.7
11/2/021:50pm n-w 4.8 4 2.3 1.4 2.3 1.8 2.8 3.3 3.6
11/3/021:50pm n-w 2.6 2.4 3.3 3.1 2.4 2.1 2.7 3.1 3.4
11/4/028:30am n-w 5.5 4.6 6.6 2.2 4.5 4 4.6 5.4 5.9
11/5/0212:00am s-e 3 1.6 3 3 3.6 0.4 2.4 3.0 3.2
11/6/024:50pm n-w 4.6 4 3.9 2.7 5.2 4.7 4.2 5.0 5.4
11/7/028:00am n-w 7.1 6 8.2 6.4 6.3 5 6.5 7.7 8.4
Average 4.5 5.4 5.9
Location 2
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Date Time Direction Speeds 1 Speeds 2 Speeds 3 Average Average Average
max min max min max min m/s m/s m/s
(m/s) over 5 sec (m/s) over 5 sec (m/s) over 5 sec at 3 m at 10 m at 18 m
10/7/0211:30am n-w 11 4 12.3 6 10 5 8.1 9.8 10.9
10/8/027:30pm s-e 0.3 0.2 0.4 0.2 0.8 0.3 0.4 0.4 0.5
10/9/0211:55am n-w 8.5 6.7 5.5 4.3 4.9 1.6 5.3 6.4 7.1
10/10/027:50am n-w 4.6 2.5 3.8 3.3 3.8 3.4 3.6 4.4 4.8
10/11/026:50pm n-w 1.8 1.7 1.3 0.9 1.4 1.1 1.4 1.7 1.8
10/12/022:25pm s-e 5.2 1.5 7.8 5.2 7.5 2.7 5.0 6.1 6.7
10/13/023:05pm s-e 5.5 4.2 4.9 4.1 5.1 4.6 4.7 5.8 6.4
10/14/029:45am n-w 5.6 4.2 5.1 3.6 4.6 3.7 4.5 5.5 6.0
10/15/0212:40pm s-e 9.2 8.9 9.5 8.9 10.2 6.5 8.9 10.8 12.0
10/16/0212:05pm n-w 9.1 7 10.2 6.4 8.6 6.3 7.9 9.7 10.7
10/17/027:20pm n-w 4.1 3.2 5.4 3 5.1 3.2 4.0 4.9 5.4
10/18/024:05pm n-w 3.5 3.1 4.3 3.7 4.7 3.9 3.9 4.7 5.2
10/19/029:35pm s-e 7.2 6.3 8.7 7.2 10.1 7.8 7.9 9.6 10.6
10/20/0211:05am n-w 6.9 5.3 4.5 3.2 7.1 5.8 5.5 6.7 7.4
10/21/021:35pm n-w 7 6.3 6.1 5.4 5.8 5 5.9 7.3 8.0
10/22/027:35am n-w 5.2 4.1 4.6 4 3.5 2.1 3.9 4.8 5.3
10/23/025:25pm n-w 2.2 2.2 4.1 3.5 4.7 3.9 3.4 4.2 4.6
10/24/021:05pm n-w 5 4.1 6.2 3.2 4.5 3 4.3 5.3 5.8
10/25/0210:35am n-w 1.2 0.8 1 0.6 0.5 0.4 0.8 0.9 1.0
10/26/025:40pm n-w 5.5 5.1 7 6.5 7.2 7 6.4 7.8 8.6
10/27/024:15pm n-w 7.9 7.5 8 6.4 6.3 5.8 7.0 8.5 9.4
10/28/028:30am n-w 0.3 0.2 0.7 0.3 1.1 0.2 0.5 0.6 0.6
10/29/022.35:pm n-w 4.3 3.9 4.6 3.8 5.2 4.1 4.3 5.3 5.8
10/30/0211:10am n-w 1.1 0.2 0.3 0.3 0.3 0.2 0.4 0.5 0.5
10/31/021:55pm s-e 4.8 1.8 1.2 0.5 2.4 1.9 2.1 2.6 2.8
11/1/0211:20am n-w 6.2 4 5.7 4 3.1 0.6 3.9 4.8 5.3
11/2/021:55pm n-w 2 1.9 1.8 1.8 2.2 1.6 1.9 2.3 2.5
11/3/021:55pm n-w 2 0.2 2.1 1.9 2.2 2 1.7 2.1 2.3
11/4/028:35am n-w 4.6 3.4 6.2 6 5.5 5.2 5.2 6.3 6.9
11/5/0212:05am s-e 2.7 1.7 3 3 4 4 3.1 3.7 4.1
11/6/024:55pm n-w 3.5 2.6 4.5 3.6 6.2 5 4.2 5.2 5.7
11/7/028:05am n-w 7.8 6.5 8 7.1 9 6.4 7.5 9.1 10.1
Average 4.3 5.2 5.8
Location 3
Date Time Direction Speeds 1 Speeds 2 Speeds 3 Average Average Average
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max min max min max min m/s m/s m/s
(m/s) over 5 sec (m/s) over 5 sec (m/s) over 5 sec at 3 m at 10 m at 18 m
10/7/02 11:30am n-w 7 3 6 2.2 8 1.7 4.7 5.9 6.7
10/8/02 7:30pm s-e 1.2 1.1 1 1 1 0.7 1.0 1.4 1.6
10/9/02 12:00pm n-w 4.5 3.6 6.5 4.5 6.2 4.7 5.0 6.4 7.2
10/10/02 7:55am n-w 3.1 2.7 4.5 3.5 3.7 2.9 3.4 4.3 4.9
10/11/02 6:55pm n-w 1.1 0.9 1.3 1.2 1.4 1.2 1.2 1.5 1.7
10/12/02 2:30pm s-e 9.7 3.5 5.2 3.5 3.2 2.2 4.6 6.1 7.1
10/13/02 3:10pm s-e 4.1 3.5 3.9 2.7 4.6 3.2 3.7 5.0 5.7
10/14/02 9:50am n-w 6.4 4.5 3 0.2 6.5 4.3 4.2 5.3 5.9
10/15/02 12:45pm s-e 7.2 6.55 8.4 7 7.9 5.4 7.1 9.6 11.1
10/16/02 12:10pm n-w 8.3 5.2 9.1 8.4 8.7 7.3 7.8 10.0 11.2
10/17/02 7:25pm n-w 3.2 2.5 4.1 3.8 4.9 3.6 3.7 4.7 5.3
10/18/02 4:10pm n-w 2.5 1.7 1.3 0.5 3.5 2.7 2.0 2.6 2.9
10/19/02 9:40am s-e 6.1 5.2 7.1 5.2 5.6 4.7 5.7 7.6 8.8
10/20/02 11:10am n-w 6.3 4.4 5.5 4.4 6.7 5.7 5.5 7.0 7.9
10/21/02 1:40pm n-w 6 5.5 4.4 3.1 3 1.9 4.0 5.1 5.7
10/22/02 7:35am n-w 4.6 4 5.1 3.8 4.6 3.1 4.2 5.3 6.0
10/23/02 5:30pm n-w 2.2 2.1 3.1 3 2.9 2.5 2.6 3.4 3.8
10/24/02 1:10pm n-w 3 3 2.8 2.1 3.4 3.1 2.9 3.7 4.1
10/25/02 10:40am n-w 2.6 0.7 2.2 2.1 2.5 1.7 2.0 2.5 2.8
10/26/02 5:45pm n-w 4.5 4.1 5.2 5 6 3.9 4.8 6.1 6.8
10/27/02 4:20pm n-w 4.1 3.2 5.5 4.6 3.2 1.5 3.7 4.7 5.3
10/28/02 8:35am n-w 0.3 0.3 0.4 0.2 0.3 0.3 0.3 0.4 0.4
10/29/02 2:40pm n-w 6.3 5.4 3.7 2.8 4 3.2 4.2 5.4 6.1
10/30/02 11:15am n-w 0.2 0.2 0.4 0.3 0.3 0.2 0.3 0.3 0.4
10/31/02 2:00pm s-e 1.8 0.8 4 1.4 1.9 0.5 1.7 2.3 2.7
11/1/02 11:25am n-w 4.6 3.6 5.2 3.7 3.7 2.1 3.8 4.9 5.5
11/2/02 2:00pm n-w 1.5 1.1 1.1 0.8 0.8 0.4 1.0 1.2 1.4
11/3/02 2:00pm n-w 2 2 1.9 1.6 1.6 1.6 1.8 2.3 2.6
11/4/02 8:40am n-w 4 3.9 5 3.5 4.6 4 4.2 5.3 6.0
11/5/02 12:10pm s-e 3 3 2.6 2 3 2 2.6 3.5 4.1
11/6/02 5:00pm n-w 2.1 2 3.1 2.9 4 3.7 3.0 3.8 4.2
11/7/02 8:10am n-w 5.1 4 6.5 6 7.2 4.5 5.6 7.1 7.9
Average 3.5 4.5 5.1

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Appendix B
Wind Density Calculation
and Rotor Sizing

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Tower Height 60 ft
Constraints
Energy Demand on Farm 6500 kWhr
Energy Cost -1170 $/yr
Tower Height 18 m Average Max Average Min
Speed at location 1 5.9 m/s 9.5 1.3
Conversion Efficency 0.2
Cost 0.18 $/kWhr 535.859375 1.373125 Power density at averages
Density 1.25 kg/m^3
hour/year 8760 hr/yr 268.61625 Power density

rotor diameter Area power density power (theorectical) Power (conversion) Energy money saved power cost/year
m m^2 W/(m^2) kW kW KWhr/yr $ $
0.5 0.2 268.6 0.05 0.01 91.2 16.4 -1153.6
1.0 0.8 268.6 0.2 0.0 364.7 65.7 -1104.3
1.5 1.7 268.6 0.5 0.1 820.6 147.7 -1022.3
2.0 3.1 268.6 0.8 0.2 1458.9 262.6 -907.4
2.5 4.8 268.6 1.3 0.3 2279.5 410.3 -759.7
3.0 7.0 268.6 1.9 0.4 3282.5 590.9 -579.1
3.5 9.5 268.6 2.6 0.5 4467.9 804.2 -365.8
4.0 12.4 268.6 3.3 0.7 5835.6 1050.4 -119.6
4.5 15.7 268.6 4.2 0.8 7385.7 1329.4 159.4
5.0 19.4 268.6 5.2 1.0 9118.2 1641.3 471.3
5.5 23.4 268.6 6.3 1.3 11033.0 1985.9 815.9
6.0 27.9 268.6 7.5 1.5 13130.2 2363.4 1193.4
6.5 32.7 268.6 8.8 1.8 15409.7 2773.7 1603.7
7.0 38.0 268.6 10.2 2.0 17871.6 3216.9 2046.9
7.5 43.6 268.6 11.7 2.3 20515.9 3692.9 2522.9
8.0 49.6 268.6 13.3 2.7 23342.5 4201.7 3031.7
8.5 56.0 268.6 15.0 3.0 26351.5 4743.3 3573.3
9.0 62.8 268.6 16.9 3.4 29542.9 5317.7 4147.7
9.5 69.9 268.6 18.8 3.8 32916.6 5925.0 4755.0
10.0 77.5 268.6 20.8 4.2 36472.7 6565.1 5395.1
Tower Height 30 ft
Constraints
Energy Demand on Farm 6500 kWhr
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Energy Cost -1170 $/yr
Tower Height 10 m max min
Speed at location 1 5.4 m/s 9 1.3
Conversion Efficency 0.2
Cost 0.18 $/kWhr 455.625 1.373125
Density 1.25 kg/m^3 228.499063
hour/year 8760 hr/yr

rotor diameter Area power density power (theorectical) Power (conversion) Energy money saved power cost/year
m m^2 W/(m^2) kW kW KWhr/yr $ $
0.5 0.2 228.5 0.0 0.0 77.6 14.0 -1156.0
1.0 0.8 228.5 0.2 0.0 310.3 55.8 -1114.2
1.5 1.7 228.5 0.4 0.1 698.1 125.7 -1044.3
2.0 3.1 228.5 0.7 0.1 1241.0 223.4 -946.6
2.5 4.8 228.5 1.1 0.2 1939.1 349.0 -821.0
3.0 7.0 228.5 1.6 0.3 2792.3 502.6 -667.4
3.5 9.5 228.5 2.2 0.4 3800.6 684.1 -485.9
4.0 12.4 228.5 2.8 0.6 4964.1 893.5 -276.5
4.5 15.7 228.5 3.6 0.7 6282.7 1130.9 -39.1
5.0 19.4 228.5 4.4 0.9 7756.4 1396.2 226.2
5.5 23.4 228.5 5.4 1.1 9385.2 1689.3 519.3
6.0 27.9 228.5 6.4 1.3 11169.2 2010.5 840.5
6.5 32.7 228.5 7.5 1.5 13108.3 2359.5 1189.5
7.0 38.0 228.5 8.7 1.7 15202.5 2736.5 1566.5
7.5 43.6 228.5 10.0 2.0 17451.9 3141.3 1971.3
8.0 49.6 228.5 11.3 2.3 19856.4 3574.1 2404.1
8.5 56.0 228.5 12.8 2.6 22416.0 4034.9 2864.9
9.0 62.8 228.5 14.3 2.9 25130.7 4523.5 3353.5
9.5 69.9 228.5 16.0 3.2 28000.6 5040.1 3870.1
10.0 77.5 228.5 17.7 3.5 31025.6 5584.6 4414.6

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Appendix C
Wind Turbine Prototype Drawings

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