87

…… CHAPTER-4

FABRICATION OF VERTICAL AXIS

WIND TURBINE WITH WIND
REDUCER AND EXPERIMENTAL
INVESTIGATIONS
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CHAPTER-4

FABRICATION OF VERTICAL AXIS WIND TURBINE WITH

WIND REDUCER AND EXPERIMENTAL INVESTIGATIONS

S. No. Name of the Sub Title Page No.

4.0 Introduction 89

4.1 Problem formulation 89

4.2 Modified moving blade VAWT designs 95

4.2.1 Design of VAWT (single moving blade) 97

model - I

4.2.2 Design of VAWT (multi moving blade) 103

model -I I

4.3 Experimental setup and its description 106

4.4 Instruments used in the investigation 108

4.4.1 Rotating disc type anemometer 108

4.4.2 Non - contact tachometer 109

4.5 Experimental procedure 110

4.5.1 Determining experimental 114

power coefficient

4.6 Summary and conclusions 114

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CHAPTER 4

FABRICATION OF VERTICAL AXIS WIND TURBINE WITH

WIND REDUCER AND EXPERIMENTAL INVESTIGATIONS

4.0 INTRODUCTION

The main objective of the present study is to increase the

efficiency of vertical axis wind turbine using wind reducer system.

The steps involved i n t h e m a n u f a c t u r e o f w i n d reducer,

moving blades arrangement system and parameters of research are

discussed in this chapter. The method of conducting an

investigation in various stages using wind reducer system is also

discussed in this chapter. Experimental setup consisting of wind

reducer and model wind turbine are demonstrated. This chapter

also includes the specifications of instruments like Anemometer,

Non- contacting tachometer. The method used in finding the

theoretical and experimental power coefficients of wind turbine in

each module of the experiment, velocity gain by air, etc. are also

presented.

4.1 PROBLEM FORMULATION

The investigation is focused on enhancing the power

coefficient. The effect of various wind reducers on power coefficient of

wind turbine is discussed in the thesis. The wind reducer set is

fabricated and fitted at topside and bottom side of the vertical axis

wind turbine rotor. The wind reducers is fabricated as per

dimensions of 3 meter of diameter each and angle of slope has been

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taken as from 100 to 400 If the angle of wind reducer increases,

the w i n d velocity a l so i n c re a se s up to 300 and further the

angle increases then the velocity decreases, more inclination will act

as obstruction. For a 300 slope, wind velocities were recorded at

various heights. Simultaneously, measurements of the velocities were

made at equal heights on plain surface. A micro-mini vane

anemometer was used for wind power measurements.

After fabrication of the wind reducer system, importance is

given to vary the angle of reducer. Details of the experimental

results and theoretical explanation are presented. The simplicity and

economic viability of the method is expected to be a boon in

converting poor windy sites to usable ones and to harness more

energy at the existing wind mill sites. Theoretically and experimentally

the power coefficient is determined under various stages of

the experiment using wind reducer system. Only, by knowing the

wind velocity at the middle of the turbine blade, the theoretical and

experimental power coefficient of the turbine is compared in

various stages of investigation at different angles of wind

reducer . Wind mill rotor shaft rotates at different speeds, hence

variation in speed studied in various stages of the experiment. The

results show that wind speed increases with reducer with 1.2 times

at the top of the reducer. The maximum increase is noticeable at

about 300 slopes. Therefore I constructed typical wind mill about 3

meter height, 300 slope and 3 meter length since the power is

increased by 1.728 times as power is cube of velocity.

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In general, the value of wind speed mentioned in meteorological

data is taken height about 12.2 meters and this is taken into

consideration while calculating the possible wind power that may be

tapped. To know the real gain in field, wind speed has to be found

with respect to the above value. The calculated values are plotted

along with a wind profile over a plain turbine. From the graph it can

be seen that the maximum gain is about 1.2and hence the power

(1.2)3 = 1.728.

To find an answer for frequent directional changes in wind,

further experiments were carried out a curved (concave shaped) 300

model and symmetrical triangular 300 model. In the curved model

wind velocities were measured at the extreme ends and the middle,

the increase was found to be almost same (about 1.2 times) at about

half of the height. The triangular model gave an increase in wind

speed of about 1.1 times at half of the height. These results show that

in coastal areas where wind direction changes in the day and night,

symmetrical 300 wind reducer can be utilized. In areas where frequent

changes in wind direction occur, curved wind reducer will be useful.

The latter experimental results may be useful to increase wind speed

at the existing windmill sites. In a bid to find a cheap material to make

sloping structures and which are mobil, for which glass reinforced

plastic has been chosen. Glass reinforced plastic wind reducer will

help to give smoothness and prevent it from rain and corrosion. In

choosing glass reinforced plastic for the sloping structure the following

advantages were taken into consideration. Glass reinforced plastic is

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abundantly available in any developing countries. Some studies by

researchers reveal that glass reinforced plastic have been found to

have half the yield strength of mild steel. It also cheap, corrosion

resistance and light in weight. It was found that reinforced plastic

slabs can be designed like steel reinforced concrete, taking permissible

tensile strength and bond strength as 24,000 KN/M2 and 350 KN/ M2

respectively. Glass reinforced plastics have low strength but its cost is

very cheap. Therefore Glass reinforced plastics are preferable.

Fig: 4.1 Upper Cone (Reducer)

Fig: 4.2 Dimensions of Cone (Reducer)

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Fig: 4.3 Blade

Fig: 4.4 Dimensions of Blade Fig: 4.5 Wind Mill Shaft

Fig .4.6 RPM reading of wind mill Fig: 4.7 Wind mill assemble
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Fig: 4.8 Measuring of wind velocity

Computational fluid dynamics is used for the validation

of air velocities from moving blade system. Computationally and

experimentally air velocities from moving blade systems are

determined and compared. Variations in fluid properties like

pressure, turbulent kinetic energy, etc, along the length of moving

blade system are also studied using CFD. Two more vertical axis

wind turbines are also designed with moving blades arrangement

system for improving efficiency. Fig: 4.9 Shows that the drag force on

different objects [167].

Fig: 4.9 Drag force on different objects

(Source: Muller, Air craft performance analysis, 2009)
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4.2 MODIFIED MOVING BLADE VAWT DESIGNS

The main drawback of Savonius is its low efficiency; this is due

to the opposing force of opposing blade with the free stream.

Fig: 4.10 Schematic view of Savonius rotor

This can be briefly explained by some simple calculations given below

Moving Blade Design of VAWT

a. Radius of the rotor (R)

b. Number of blades (B)

c. Tip speed ratio of the rotor at the design point (λ)

d. Angle of attack of the airfoil (α)

e. Material of mild steel

1. Blade 2. Shaft and 3. Support Dimensions of VAWT

Fig: 4.11 Savonius VAWT with moving blades

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1. The rotor diameter (D) is1000 mm and the diameter of centre shaft

is 80 mm.

2. The two end-plates have been made from 40 mm thick steel sheets

with 1250 mm diameter

3. The overlap distance between fixed blade and moving blade (d) =

20 mm.
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4.2.1 Design of VAWT (single moving blade) Model - I

This is another method of moving blade arrangement system

without changing the basic structure of a Savonius wind rotor to

improve the performance and increase the efficiency of the rotor. In

this study, a single moving blade arrangement is used.

Model calculations of VAWT: [169] Power generated by the drag force

1
is given by the formulae P = CD  VW  VR 2 AVR
2

(4.1)

Where: VW is wind velocity, ρ is air density A is area of the rotor and

CD on semicircular concave surface and

VR is rotor velocity.

semicircular convex surface are 2.3 and 1.2 respectively.

Hence, Power generated by the drag force on concave surface,

1
 VW  VR  AVR
2
Pconcave=2.3 * (4.2)
2

Power generated by the drag force on convex surface,

1
Pconvex=1.2 *  VW  VR 2 AVR (4.3)
2

Since the drag force on the convex side is opposing the concave

side, net power generated from the Savonius rotor is

1
P= Pconcave - Pconvex= 1.1 *  VW  VR 2 AVR (4.4)
2

This net power generated is low. Suitable modifications to the

VAWT design are needed in order to increase the efficiency of VAWT.

Hence, we introduce a moving blade arrangement without changing

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the basic structure of a Savonius wind rotor to improve the

performance and increase the efficiency of the rotor.

Construction of modified Savonius VAWT

Fig: 4.12. Modified (single moving blade) VAWT

. This modified Savonius wind turbine consists of one moving

blade on each side of rotor (convex and concave). The arrangements of

moving blades are shown in the figure 4.12. The original position of

moving blade is shown as the moving blade in closed position in the

above figure. The moving blades are designed such that they have a

provision to move through 90 degrees in clock wise direction and

return to its original position when required.

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Working of modified Savonius wind turbine:

Fig: 4.13. VAWT at zero degrees of rotation

Let us consider that the VAWT consists of two moving blades (blade A

on concave side and blade B on convex side) as shown in the above

figure.

Fig: 4.14. Rack and pinion arrangement

The moving blades can rotate through 900 by moving the pinion

gear attached to moving blade as shown in figure 4.14. The pinion

gear is driven by the rack which in turn driven by the connecting rod.

When the VAWT is rotated to 180 degrees, the moving blade B will

rotate through 90 degrees in clockwise direction and the moving blade

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A will rotate through 90 degrees in anticlockwise direction. Now the

position of VAWT will be as shown in next page.

When the VAWT is again rotated to 180 degrees, the moving

blade A will rotate through 90 degrees in clockwise direction and the

moving blade B will rotate through 90 degrees in anticlockwise

direction and this is a cyclic process.

Fig: 4.15. VAWT at 180 degrees of rotation

From the above calculations, it is derived that movable blade

design has better efficiency than the existing fixed blade design.

Hence, theoretically, Cp of VAWT with moving blades design will be

29x1.818 = 52.72. (Cp of conventional VAWT is considered as 29)

From the above calculations I found that movable blade design is

more efficient, in that movable blade design I assumed two different

shapes of blades (airfoils).

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a) Cambered Airfoil

Here it is assumed to use a cambered air foils as movable blade

Fig: 4.16 Cambered airfoil blade

Then by using this type of airfoils the total shape of Savonius rotor

will be:

Fig: 4.17 Modified VAWT with cambered airfoils

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b) Symmetrical Airfoil

Here it is assumed to use a symmetrical air foils as movable blade

Fig: 4.18 Symmetrical airfoil blade

Then by using this type of airfoils the total shape of Savonius rotor

will be:

Fig: 4.19 Modified VAWT with symmetrical airfoil sections

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4.2.2 Design of Vertical (multi moving blade) model-II

In design of VAWT the 1st issue comes with design of Airfoils

that can be place in Savonius turbine.

Details of Airfoils for my model are as given below

Chord = 184 mm

Airfoil Thickness = 9% C

Thickness location = 30% C

Camber = 0% C

Camber location = 40% C

These values are taken by considering that the swept area of

turbine is ~1sq.m. The design of turbine with above values is given as.

By considering the above value into consideration the air foil is

created in UniGraphics which is shown below

Fig: 4.20 Symmetrical Airfoil Dimensions

Fig: 4.21 Symmetrical Airfoil Modeled in UniGraphics

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WIND

Fig: 4.22 Complete Airfoil assembly dimensions

As shown in above figure, each side (convex and concave) of

rotor consists of 5 blades. Out of which only 2, 3 and 4 numbered

airfoils are movable and 1 and 5 are fixed airfoils.

These blades will rotate when the concave side of the rotor faces

the wind to minimize the opposing force of rotor on wind as shown in

above figure. In this blade 2 will rotate through 600, blade 3 will rotate

through 950 in clockwise direction and blade 3 will rotate through 400

in anti-clockwise direction. These movements are shown below in the

figure:
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Fig: 4.23 Angle of Attack of different airfoils while running

Fig: 4.24 Completed Turbine Assemblies with Airfoils

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Fig: 4.25 Assembled model of Vertical Axis Wind Turbine

4.3 EXPERIMENTAL SETUP AND ITS DESCRIPTION

Investigation requires a wind tunnel since it produces

air at constant velocity. Complete description of wind tunnel,

wind turbine, etc, are furnished in this section.

Wind tunnel is used to supply air continuously at constant

velocity. It is driven by a blower mounted at one end. Air is sucked

at the other end called inlet duct. The equipment consists of

convergent and divergent portions and, with a test section at

throat. Wind tunnel is used to analyze the lift and drag forces on

airfoil shaped blades of aero planes, wind turbine, rotary

compressor, etc. The pressure developed on blades at

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different positions can be determined using manometers. Wind

tunnel is driven by D.C blower.

Blower Specifications:

Make : Kirloskar Electrical Company Limited

Phase : Three phase induction motor

Speed : 1400 RPM

Voltage : 415 volts

Current : 4.9 A

Power : 2.2 kW

Connection : Delta

Size of the inlet duct:

Length : 0.91 m;

Width : 0.91 m Size of the test section:

Length : 0.48 m

Height : 0.29 m

Width : 0.30 m

Size of the outlet circular duct:

Diameter : 0.6 m

Total length of wind tunnel : 5.05 m

Various portions of wind tunnel and their details are stated

below. Inlet duct:

It is aerodynamically contoured section with contraction area

ratio 9:1. The square shaped duct has dimensions of 900 mm X

900 mm. For effective flow of air, the ratio of length to cell
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size of the honeycomb is taken as 6, as per the recommendations

of the vendor of wind tunnel. Further, the wire mesh smoothens

the air flow. Provision is made to remove the screen for cleaning of

wind tunnel. Also, higher velocities can be obtained if the screen is

removed, but it is not of laminar. The duct is secured to the test

section by bolts. The provision is made to separate test section and

inlet duct.

Test section:

It is the center portion of the tunnel cram between the inlet

duct and the diffuser. It has a transparent window, which facilitates

visualization easy. The traversing mechanism is fixed on its top

for the movement of pressure probe. There is a provision to

calibrate strain gauge for determining lift and drag force. A few

holes on all sides test section are made to keep airfoil model tight in

the test section and pressure probes.

4.4 INSTRUMENTS USED IN THE INVESTIGATION

Rotating disc type anemometer is used to determine air

velocity. A Non contacting (Laser beam) tachometer is used to

measure speed of turbine during power measurement.

4.4.1 Rotating Disc Type Anemometer

Rotating disc type anemometer (MEXTECH AM-4204) is placed

in the direction normal to the direction of air flow. Anemometer is

shown in Figure 4.26. The circular disc of anemometer rotates when

it is placed in the direction of air flow. The number of rotations

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made by the disc is calibrated into air velocity in m/s. Air velocity

can also be measured in knots or Kilometers per hour using such

anemometer. It works safely even in the range of 25-30 m/s. A

digital monitor is provided to indicate wind speed. Anemometer is

calibrated in the range of 6 m/s to 29.5 m/s.

Fig: 4.26 Rotating Fig: 4.27 Non Contact Tachometer

Disc Type Anemometer

4.4.2 Non - Contact Tachometer

A Non-contacting tachometer is shown in Figure 4.27. It is a

device used to measure speed of the rotating shaft of turbine in

revolutions per minute. It does not have any physical contact with

rotating shaft. Such tachometer is best suited in wind farms

since turbine is mounted at great heights.

A light beam from source is focused on to a target marked

on the rotating shaft. A photo receiver receives the reflected light

beam with the help of photo probe. Both light source and photo
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receiver are housed at front side of tachometer. The time interval

between the two consecutive sensations is calibrated into R.P.M.

A digital screen is provided to indicate speed of the rotating

shaft. The instrument is calibrated in the range of 500 R.P.M to

14000 R.P.M.

4.5 EXPERIMENTAL PROCEDURE

In various modules of experiments stated above, the

power coefficient of wind turbine is determined at various w i nd

re d u ce r orientations. Power coefficient is determined theoretically

and experimentally. The air at high speed from wind tunnel is

focused on to rotor of the turbine. In these modules, the efficiency of

the convent iona l model wind turbine is determined with and

without using the wind reducer in conical shape with deferent angles,

single moving blade and multi moving blade system at different

positions of blade, finally a slope of deferent angles with two

curtains arrangement has been considered to Savonius wind rotor to

enhance the turbine rotor speed. For module M4 schematic diagram

of the experimental set-up that has been used in this study is shown

in Figure 4.28.

The Savonius wind rotor, slope with curtain arrangement and

measurement devices have been installed away from the exit of this

wind tunnel. The Savonius rotor and slope with curtain arrangement

have been placed on a steel table. The Savonius rotor shaft has been

supported near the top and bottom by a very low friction ball bearing

to minimize the friction force. The curtain arrangements have been

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placed in front of the Savonius wind rotor. And then measurements

of rotor torque, wind velocity and the number of revolution have

been measured by a torque meter sensor, multifunctional

anemometer and a tachometer. Dimensions of curtain arrangements

are 135cm. and 156cm. and the angle of slope is 300.

Fig: 4.28 Schematic view of rotor with and without slope and curtain

The vertical shaft of the wind turbine rotates freely in bearings.

Initially, the rotor is allowed to rotate without connecting reducer.

Power coefficient is determined theoretically by knowing wind

speed at the inlet of wind turbine. Later, experimental power

coefficient is determined when the turbine is fixed with wind reducer

arrangement.

Rotating disc anemometer is placed in a direction normal to

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the flow of air to determine air velocity at the inlet and outlet of

the wind turbine. T heoretical power coefficient, which is the ratio

of theoretical power to power in the wind, is determined in

various modules.

In module M1, under the first change in the

experiment, the fabricated wind reducer is assembled to wind

turbine. The high velocity of air rotates the rotor of turbine at

high speeds. Theoretical power coefficient is determined at different

angle of wind reducer.

As part of the next evolution in conducting the

investigation i.e, under module M2, moving blades system is

joined to wind tunnel. The moving blade system produces air at

a high speed and kinetic energy due to increased coefficient of

discharge. The theoretical power coefficient is then, determined.

To study the effect of th e 3 r d method of better wind energy

c o n v e rs i on into kinetic energy by aerofoil moving blade used in

conducting the investigation i.e, under module M3, moving

blades system is joined to wind tunnel. The moving blade system

produces air at a high speed and kinetic energy due to increased

coefficient of discharge. The theoretical power coefficient is then,

determine. The change in revision is named as module M3, and

the theoretical power coefficient is determined. The curtain and

slopes system produces air at a high speed and kinetic energy

due to increased coefficient of discharge.

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Fig: 4.29 Geometrical parameters of rotor with slope and curtain

Fig: 4.30 Schematic view of experimental setup

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In all the modules of experiments, wind turbine is

placed at same distance from wind tunnel.

4.5.2 Determining Experimental Power Coefficient

The d y n a m o i s connected to produce D.C current a n d

t h e n t h e experimental power coefficient of wind turbine becomes

the ratio of power produced to the power available in the wind. It

is determined in all stages of the experiment as discussed above.

All instruments are calibrated in recording the data.

4.6 SUMMARY AND CONCLUSIONS

The problem is formulated based on determining

experimental and theoretical power coefficients of the wind turbine.

Under research methodology, various modules of experiment are

discussed. Various instruments like rotating disc type

anemometer, non-contacting tachometer etc, are demonstrated. The

research methodology in carrying out the investigation is also

discussed. After the conduct of the experiment, the results are

discussed in chapter 7 .