Final Project Black Book-2
Final Project Black Book-2
Final Project Black Book-2
PROJECT REPORT
ON
WIND MILL OPERATED HYDRAULIC PUMP WITH POWER
GENERATION
IN PARTIAL FULFILLMENT OF
DIPLOMA
IN
MECHANICAL ENGINEERING
SUBMITTED
BY
In partial fulfillment of
Diploma in Mechanical Engineering
Submitted by
PARTH PAREKH
DHANASHRI GULVE
ASHOKKUMAR CHAUHAN
ZAFAR SHAIKH
Project Guide
Prof. ZAID ANSARI
DEPARTMENT OF MECHANICAL
ENGINEERING
H. J. THIM TRUST’S
THEEM COLLEGE OF ENGINEERING
Boisar chilhar Road, Boisar (E), Tal. Palghar
Dist. Thane, Pin- 401501
2018-2019
Academic Year 2018-19
2018-19
Mechanical Engineering
Declaration
Date: ___________________
Acknowledgement
It’s our pleasure to take this opportunity to thank with deep sense of gratitude
to our guide, staff members of Mechanical Department & everyone who have directly
or indirectly contributed to our project as a success. With immense pleasure we
express our deep sense of gratitude & vote of thanks to our project guide Lectr. Zaid
Ansari for his constant interest, motivation & valuable guidance during work &
completion of this project report.
We are very thankful to Lectr. Furqan Hassan, Lectr. Shoeb Khan and the
whole staff of the Mechanical Department for giving us the opportunity to work on
this project and for his extensive co-operation and guidance. We offer sincere thanks
to, Prof. Sayyad Layak Principal (Diploma) and Prof. Nitin Galwade (Head of
Department) for their inspiration and providing full administrative support and
departmental infrastructure facilities for this report.
We are also very thankful to all those who supported us without which project
would not have been completed successfully.
ABSTRACT
1.4 Background 4
1.5 Types of windmills 5
1.5.1 Horizontal axis windmill 5
1.5.2 Vertical axis 5
1.5.3 Darrieus wind turbine 6
1.5.4 Giromill 6
1.5.5 Twisted savonius 6
2 LITERATURE REVIEW 7
2.1 Introduction 7
2.2 Literature survey 7
DESIGN OF WATER PUMPING WIND MILL 9
WITH POWER GENERATION
3.1 Design challenges 9
3.2 Background research 9
3 3.3 Effect of number of blades 9
3.3.1 Effect of blade number or aerodynamic performance 9
3.4 Methodology 11
3.4.1 Design procedure outline 11
3.4.2 Proposed design procedure 11
3.5 Initial blade design methodology 14
3.6 Initial design and shaping of blades 14
4 RISKS ASSESSMENT 16
4.1 Risks in project designing 16
5 FABRICATION 18
5.1 Resource requirement design 18
5.2 Construction , fabrication 18
5.3 Fabrication 19
5.3.1 Blades 19
5.3.2 Hub 19
5.4 Fabrication Processes 20
5.4.1 Rolling process 20
5.4.2 Cutting process 20
5.5 Assembly 20
6 HYDRAULIC RECIPROCATING PUMP 21
ASSEMBLY
6.1 Rotor blade 21
6.2 Blade hub 21
6.3 Crank shaft 21
6.4 Connecting rod 21
6.5 Gears 22
6.6 Shaft 22
6.7 Ball bearing 22
6.8 Pillow bearing 23
6.9 Displacement pump 23
6.10 Tower 24
6.11 Assembly 24
6.12 Working of hydraulic pumping system 25
7 POWER GENERATION ASSEMBLY 26
7.1 Rotor blade 26
7.2 Blade hub 26
7.3 Crank shaft 26
7.4 Connecting rod 26
7.5 Gears 27
7.6 Shaft 27
7.7 Ball bearing 27
7.8 Pillow bearing 28
7.9 Alternator 28
7.10 Battery 29
7.11 Assembly 29
7.12 Working of power generation system 30
8 CALCULATIONS 31
8.1 Gear properties 31
8.1.1 Gear calculations 32
8.2 Force and moment required to pump 33
8.3 Swept area 33
8.4 Discharge Capacity of Pump 34
9 COST ESTIMATION / ANALYSIS 35
10 PHOTOS CATALOGUE 36
11 CONCLUSION 38
12 FUTURE SCOPE 39
13 REFERENCES 40
LIST OF FIGURES
Sr.No. Figure No. Title Page no
1 1.1 Wind mill with combined systems 1
2 1.2 Wind mill 3
3 3.1 Tip speed vs. Power coefficient 10
4 3.2 Coefficient of performance vs. tip speed ratio 10
5 3.3 Blades (a) 15
6 3.4 Blades (b) 15
7 5.1 Rotor blades 19
8 5.2 Hub 19
9 5.3 Assembly of wind mill 20
10 6.1 Gear set 22
11 6.2 Ball bearing 22
12 6.3 Pillow bearing 23
13 6.4 Hydraulic pump 23
14 6.5 Tower 24
15 6.6 Hydraulic reciprocating pump assembly 24
16 6.7 Working of hydraulic pumping system 25
17 7.1 Gear set 27
18 7.2 Ball bearing 27
19 7.3 Pillow bearing 28
20 7.4 Alternator 28
21 7.5 Power generation assembly 29
22 7.6 Working of power generation system 30
23 8.1 Gears meshing 31
24 8.2 Force and moment required 32
i
LIST OF TABLES
Sr.No. Table No. Title Page no
1 4.1 Risks assessment 16
2 8.1 Gear specifications 31
3 8.2 Gear teeth 31
4 9 Cost estimation 34
ii
NOMENCLATURE
N - Number of Teeth
D - Pitch Diameter
P - Diametric Pitch
PA - Pressure Angle
P - power
ρ - air density
A - swept area of blades
r - radius of the blades,
V - velocity of the wind
h - head from water surface
to tank in meter
hL - head losses in meter
θ – angle
F - force required to lift the
water in newton
b - length of the
corresponding lever in
meter
iii
Wind mill operated hydraulic pump with power generation
INTRODUCTION
1.1 PREAMBLE:
The Imminent exhaustion of fossil energy sources, spreading global
warming, expanding greenhouse effect, higher need of energy, less availability of
power supplies motivates us to use renewable source of energy like wind-energy
2018-19
which is most prominent for our suitable application.
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near the ground, using a direct drive from the rotor assembly to the ground-based
gearbox, improving accessibility for maintenance. However, these designs produce
much less energy averaged over time, which is a major drawback. The key
disadvantages include the relatively low rotational speed with the consequential
higher torque and hence higher cost of the drive train.
1.5.4 Giromill
A subtype of Darrieus turbine with straight, as opposed to curved, blades. The
cycloturbine variety has variable pitch to reduce the torque pulsation and is self-
starting. The advantages of variable pitch are: high starting torque; a wide, relatively
flat torque curve; a higher coefficient of performance; more efficient operation in
turbulent winds; and a lower blade speed ratio which lowers blade bending stresses.
Straight, V, or curved blades may be used.
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LITERATURE REVIEW
2.1 Introduction:
Wind Turbines are one of the recent machines for wind energy conversion.
Wind turbines are mainly classified into horizontal axis wind turbines (HAWT) and
vertical axis wind turbines (VAWT). The horizontal axis wind turbines are mostly
used for electricity generation and also for water pumping. However, to use the recent
wind turbines for water pumping, the average wind velocity of the region should be
greater than 4 m/s. Windmills are one of the oldest methods of harnessing the wind
energy to pump water. But currently, the technology has experienced are viral due to
the increasing price of fossil fuel all over the world. The content of this chapter is an
overview of the available literature and information on wind turbine design that will
ultimately be used as a foundation throughout the design project.
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and much others. One that very interesting to make conclusion and discussion is
relation between number of blade and coefficient of performances of wind turbine
machines. The best blades number from 3 until 12. When designing number of blade,
the number of blade that we choose influences the aerodynamic performance like
coefficient of performances. Modern wind turbines are neither built with many rotor
blades nor with very wide blades even though turbines with high solidity have the
advantage of enabling the rotor to start rotating easily because more rotor area
interacts with the wind initially. Since, our current goal is to convert the wind energy
into electricity, rotors will not benefit with high solidity because it is neither cost
effective nor efficient. The number of the blades of a turbine has great impact on its
performance. Picture below shown coefficient of performances between 3, 6, and 12
blades with same solidity and same speed 5 m/s.
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3.4 Methodology
3.4.1 Design procedure outline:
There are a variety of different approaches that can be taken in wind turbine
design and accordingly there are also a number of issues that need to be taken into
account. The design procedure outlined in “(McGowan 2003)” (p248), sets guidelines
for the design of a wind energy converter and has been taken into consideration for
application in this project.
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by friction which must be minimized. Turbines operate for long periods at ground
level where insect and dust particulate build up is problematic. This build up known
as fouling can have detrimental effects on the lift generated. Provision is therefore
made for the reduced sensitivity to fouling of wind turbine specific aero foil designs.
The structural requirements of turbine blades signify that aero foils with a high
thickness to chord ratio be used in the root region. Such aero foils are rarely used in
the aerospace industry. Thick aero foil sections generally have a lower lift to drag
ratio. Special consideration is therefore made for increasing the lift of thick aero foil
sections for use in wind turbine blade designs.
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RISKS ASSESSMENT
4.1 Risks in project designing
The design and construction of a wind turbine incorporates various risks
and hazards that need to be brought to the attention to anyone who is involved in the
processing of parts, assembly and operation of the machine. The majority of risks and
hazards are common in industry and there is professional training available to prepare
individuals for safe operation within a hazardous environment.
The majority of hazards associated with the project are:
Hazard / Risk Description / significance/ likelihood/ exposure Consequences/
counter measures
Fumes During the fabrication the fumes can cause nausea and extreme
headaches and if exposed to them for extended periods can cause
brain damage. If proper breathing masks and eye protection are
used during the handling of the chemicals the risk is minimized.
Protective clothing and gloves should also be applied to avoid
contact with skin.
Machining The machining and fabrication of parts is a hazardous procedure
Fabrication mainly due to the exposure to moving parts and cutting equipment.
Interference with the equipment can result in serious injury;
abrasions, cuts, bruising. To avoid contact and minimize the risk of
these occurring, no loose fitting clothing should be worn during
operation of the equipment. Steel toed boots, ear muffs and
appropriate eye protection should be worn during the operation of
equipment. If possible the work should be carried out under the
supervision of professionals.
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FABRICATION
5.1 Resource Requirements Design
As the project deals mainly with the design and implementation of a wind
turbine and actual construction is only a secondary project objective that will only be
conducted if time permits, the majority of resources will be in the form of software
and literature.
The design of the wind turbine will be based on existing technology which
will be investigated in the literature review. This will provide the background
knowledge and aid in optimising the technical design parameters of the project;
materials, geometry, structure, electrical generator selection etc... The University
Library will be the primary source of information aiding the design procedure along
with private publications from industry.
The geometric and physical design and modelling will require a CAD
package such as PRO Engineer or SOLID Works. The software is available for use at
the university along with ANSYS for finite element analysis of the design and testing
of individual components.
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5.3 FABRICATION
Parts Detail
5.3.1 Blades
Nine Blades of GI sheet, thickness=0.8mm (gauge 22)
Length=30 inches (762mm), length of arc=8 inches
Fig5.2 Hub
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6.5 Gears
The type of gearing system and configuration depends upon the selected
induction motors synchronous speed. The lower the synchronous speed the better, as
this will require a lower gearing ratio and will consequently result in a lower input
torque requirement. In gearing reduction systems there is a high speed input with a
low speed high torque output. As we are reversing the cycle and gearing-up to achieve
higher rotational speeds, torque will be the primary factor that will attribute to the
effective functionality of the gearing system.
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6.10 Tower
The tower raises the turbines assembly well above the turbulent air current
close to the ground and captures higher wind speeds. Tower design is particularly
critical, as it must be as economically possible, robust, enable access to the turbine for
maintenance and yet not add unnecessary to the cost of the system.
It is made of M.S which has a high resistance to breakage. Mild steel, as
opposed to higher carbon steels, is quite malleable, even when cold. This means it has
high tensile and impact strength. Higher carbon steels usually shatter or crack
under stress, while mild steel bends or deforms. Tower with height 6ft. (180 inches)
and width 25 inches.
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7.5 Gears
The type of gearing system and configuration depends upon the selected
induction motors synchronous speed. The lower the synchronous speed the better, as
this will require a lower gearing ratio and will consequently result in a lower input
torque requirement. In gearing reduction systems there is a high speed input with a
low speed high torque output. As we are reversing the cycle and gearing-up to achieve
higher rotational speeds, torque will be the primary factor that will attribute to the
effective functionality of the gearing system.
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7.10 Battery
Electrical batteries or accumulators are regularly used in wind energy
applications and can be charged by wind energy system.
Lead acid batteries are a good choice since they are well suited for trickle
charging. In terms of electrical output they have a high efficiency of 80 – 90 %, and in
terms of energy, their efficiency is 70-80%. Thick plates are used in special batteries
for large installations.
Small installations can cause bank of ordinary automotive batteries. The main cause
of deterioration is overcharging or being left for in the discharged state.
Nickel cadmium batteries are not usually used in wind power applications
as they have low efficiency at low intensities and lower than lead acid batteries at all
intensities. The advantages are that they are not damaged by overcharging nor by
occasional over discharging, they do not self-discharge, and not easily damaged by
freezing temperatures compared with the lead acid batteries.
7.11 Assembly
An assembly line is a manufacturing process (most of the time called a
progressive assembly) in which parts (usually interchangeable parts) are added as the
semi-finished assembly moves from workstation to workstation where the parts are
added in sequence until the final assembly is produced.With the main shaft coming
from wind blades on which big diameter gear is coupled. Big diameter gear meshes
with the two small gears. One small gear on which hydraulic system will work and on
the other power generation system will work. The small gear has clutch type
mechanism, as it will get engage and disengage with the rotations of main gear.
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CALCULATIONS
This is another way of saying that gear 1 rotates 3 times while gear 2 rotates 1
time. It’s the same as saying the gear ratio is 3.5:1. If we know the number of times
gear A rotates we can divide that number by 3.5 to find the number of times gear 2
rotates.
You can now ask the class: What’s a way to find a gear ratio without
actually turning the gears?
Add the teeth ratio expression to the equation you wrote earlier:
Gear ratio= =
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Gear ratio =
Formula = P = ρ A V3
Where,
P is power,
ρ is air density,
A is swept area of blades given by A = π r2 where r is the radius of the blades,
V is the velocity of the wind
Given data:
Wind speed v = 4.5 m/s, radius (r) = 0.91 m, air density ρ = 1.23 kg/m3.
The area is given by,
A = πr2
A = π ×0.912
A = 2.60 m2
The wind power formula is given by,
P= ρAV
P = 145.70 watts
F= [N]
Where,
ρ is the density of water in kg/m3 ;
g is the gravitational acceleration in m/s2 ; Fig 8.2 Force and moment required
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The maximum moment required occurs when the lever is in a 90° angle in
relation to the pump, and is computed with:
Mpump = Fb [NM]
Where,
F is the force required to lift the water in newton and
b is the length of the corresponding lever in meter
Given value:
ρ = 1000 kg/m3
g = 9.81 m/s
h=3m
hL = 0.0177 m
F=
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Q =V/t
Q=Ad/t
Where,
A = cross sectional area of a section of a pipe,
d/t = v
Q = Av.
A (Area) = 0.001 m2
v = 0.4 m/s
Q = A* v
Q = 0.001* 0.4
Q = 0.0004 m3 /s.
Q = 0.4 liters/ sec.
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PHOTOS CATALOGUE
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CONCLUSION
The goal of project is accomplished from the requires analysis and
fabrication of prototype that is utilization of wind power to pumping water and
generate electricity. From result we have seen the efficiency of aerodynamic shape
blade.
Our work is to show that the horizontal axis wind energy conversion system
are practical and potentially very contributive. Thus we have used our new design of
wind turbine to pump out water. This will provide liters of water for drinking purpose.
At the low wind velocity in the range below 3.5 m/s, the discharge is not so much
effective, however with increased speed of wind energy considerably enhanced to the
rate of v3 , therefore discharge becomes high.
Gears and bearings are subject to very high heat losses due to friction and
this will be greatly minimized by application of oil and grease and therefore greatly
improving the efficiency. All materials used are locally available and at a low cost
making the model economically viable.
Small scale wind energy conversion systems are an effective,
environmentally friendly power source for household and other applications.
Although they are subject to climatic behavior and do not always deliver a constant
supply of energy, they can be adapted to energy storage units that allow the selective
distribution of the energy once it has been converted.
The resultant design of the project is a small scale 145.70 watts electrical
energy producing at 3.5 m/s wind speed. Its design is based on a horizontal axis wind
turbine for the application of charging a battery bank in remote communities, rural
areas.
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FUTURE SCOPE
Although the efficiency of power generation using wind mill is not that high
as required, the various advantages of it like zero pollution, free of cost power
generation and the ever reducing cost of the system makes it a preferable option of
power generation.
Once the optimum operating conditions are determined, the gear box and
generator can be redesigned to a configuration that produces maximum efficiency.
This design can then be manufactured and tested to determine the realistic operating
performance in an uncontrolled environment.
As the turbine was designed primarily from a mechanical perspective, there is
allot of electrical based engineering to do to ensure a safe, effective electrical power
regulation and distribution circuit is constructed. Basic electrical theory and circuits
were investigated during the course of the project however no specifications were
made with respect to the sizing of electrical items and units.
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REFERENCES
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