10EGS4 - ARKA MUKHERJEE

ENGINEERING AT2 2024

WIND TURBINE DESIGN AND

CONSTRUCTION
 TABLE OF CONTENTS

Topic Page

Introduction 3

Research 4

Design Analysis 7

Data Collection 9

Drawings 11

Bibliography 15
 INTRODUCTION

For the term 3(AT2) for engineering the class was assigned to construct a wind turbine, focussing on the maximum
efficiency to create energy through a small 3V generator. Our group included Preet, Khenav, me(Arka) and Ashams who
joined later in the project. Throughout the project we all had different roles and did our part to complete in the given
amount of time.

Roles

Arka Mukherjee - I oversaw the project and came up with the plans and foundation of the wind turbine that our group is
creating. After this I created the base and the tower, whilst working with Preet and Khenav to create the tip, rotor and
blades. I also did most of the work with machinery (e.g drills, lathe, bandsaw).

Preet Soni - Preet was an important member of the group who worked on the construction of the windmill as well as
parts of the folio. The notable things that he has done in this project included the tip, rotor and some sanding aspects.
Where he truly shined was the creation of parts of the folio which included the drawings and sketchup.

Khenav Katariya - Khenav helped to work on the wind turbine, investing most of his time doing this. Jobs that he
completed included cutting, sanding and molding the metal parts on the anvil. He also constructed the rotors with Preet
and I, gathering and placement of materials as well as working on the original design with me.

Ashams Anish Kumar - Ashams joined later in the project but he managed to help others with physical tasks regarding
the construction of the wind turbine.

For this assessment our group was required to use varied new and recycled parts and materials to design and create a
wind turbine. Whilst restricted to a maximum height of 300 mm our primary goal was to generate enough energy to
light a 5mm LED using a 3V generator. A leaf blower will be provided on the day of testing to stimulate (close to) natural
conditions, allowing the turbine’s efficiency to be thoroughly tested.

This project aimed not only to demonstrate the group’s understanding for the engineering design process but also
encourage innovation in the material selection, balancing the factors of efficiency, durability and consideration of
environmental aspects. (Environmental impact in the context of global efforts to reduce fossil fuel dependency.)

The roles were divided appropriately to ensure that the individual skills and contribution of each team member formed a
team where each member complemented the others. In theory this would mean that all aspects of the wind turbine,
from base to tip would be accomplished with great success and efficiency. This project was able to highlight both the
potential and shortcoming of wind energy.
 RESEARCH

Wind turbines are devices that convert the kinetic energy of wind into mechanical energy, which can then be used to
generate electricity. They are a key component of modern renewable energy systems and play a crucial role in reducing
reliance on fossil fuels. Wind turbines have large blades that are designed to catch the wind, as it blows the blades spin.
The blades are connected to a rotor, which is linked to a shaft, as the rotor turns, it spins the shaft. The spinning shaft
turns a gearbox which increases the rotational speed to a level suitable for generating electricity. Wind turbines are
equipped with control systems that adjust the blade angle and orientation of the turbine to optimize energy capture and
protect the turbine from high wind damage. There are about two different types of wind turbines, there include
horizontal-axis wind turbines and vertical-axis wind turbines. Horizontal-axis wind turbines are the most common type,
with blades that rotate around a horizontal axis. They usually have a large rotor diameter and are often seen in wind
farms. Vertical-axis wind turbines have blades that rotate around a vertical axis; they are less common but can be
advantageous in certain settings due to their ability to capture wind from any direction.

Jaisalmer Wind Park

The Jaisalmer Wind Park is located in the desert of Rajasthan,

India, it is one of the largest wind energy projects in the
country. It is a significant part of India's efforts to increase its
renewable energy capacity and reduce its use of fossil fuels.
The park has a total installed capacity of around 1065
megawatts, making it one of the largest wind farms in India.
The project has been developed in multiple phases over
several years.

Muppanal Wind Farm

The Muppanal wind farm is located in the

Kanyakumari district of Tamil Nadu, India. It is also
one of the largest wind farms in India and plays a
significant role in the country's renewable energy
sector. The Muppanal wind farm has approximately
1500 megawatts. This makes it one of the largest
wind farms in India, with a substantial contribution
to the country's renewable energy capacity. As
technology continues to advance, future ungraded
and further expansion is likely to increase the farm's
efficiency and output. The project serves as a model
for large-scale wind energy development and highlights the potential of wind power to meet energy demands
sustainably.
Vestas V236-15.0

The V236-15.0 (vestas) is a state-of-the-art wind turbine

developed by Vestas, a leading global wind turbine
manufacturer. This turbine represents Vesta's commitment to
advancing wind energy technology and increasing the
efficiency and scalability of wind power. The turbine has a
nominal power capacity of 15 megawatts, making it one of
the most powerful offshore wind turbines available. This high
capacity enables it to generate a substantial amount of
electricity, making it suitable for large-scale offshore wind
farms.

Goldwind GWH252 - 16MW

The Goldwind GWH252-16MW is a high-capacity

wind turbine developed by Goldwind, a leading
global wind turbine manufacturer based in China.
The turbine represents a significant advancement
in wind turbine technology, especially for large-
scale offshore wind farms. The Goldwind
GWH252-16MW has a nominal power capacity of
16 megawatts. This makes one of the most
powerful turbines available, designed to
maximize energy production from each turbine. \

Advantages and Disadvantages of Wind Turbines

Advantage Disadvantage

Wind energy is renewable and inexhaustible as long as Wind energy is variable and depends on wind availability,
the wind blows which can be unpredictable and inconsistent.

Wind turbines produce electricity without emitting The installation of wind turbines involves high upfront
carbon dioxide or other greenhouse gasses. costs, including equipment, infrastructure and land.

Once installed wind turbines have relatively low operating Wind turbines can pose a risk to frying animals such as
and maintenance costs compared to fossil fuel plants birds and/or bats, which may collide with the turbine
blades.

The wind energy sector creates jobs in manufacturing, Turbines can generate noise, which some find unpleasant.
installation, and maintenance. Additionally, their visual impact can be considered
unsightly by some communities.
Wind farms can be built on various scales, from small Wind farms require significant amounts of space to avoid
residential turbines to large offshore farms. turbulence between turbines and to optimize
performance.
 DESIGN ANALYSIS

1. Blade Design

The design of the blades has a great relation to the efficiency of the wind turbine. Considered various blade
configurations included:

Straight Blades: Much easier to make from recycled materials, such as a plastic bottle or an aluminum can. This design is
simpler to build and test; however, one of the main problems with straight blades is that they tend to have a lower
efficiency since their shape cannot catch the wind energy as effectively.

Curved Blades: Emulating wind turbines, curved blades-made with PVC pipes or plastic, among other materials-will be
able to capture more energy produced by the wind due to their more aerodynamic form. It increases the speed of
rotation for the blades and the energy output in general.

MultiBlade Designs: Increasing the number of blades would increase catching the wind but may also increase the
amount of resistance. Several blade configurations were tested, and it was concluded that using three blades produced
the best balance between speed and resistance. This design also models real-world applications of large wind turbines.

Choice: A four-blade curved design was opted for because of its higher efficiency and ease of construction with wood.

2. Base and Structures

The materials to be used for the turbine base had to be capable of supporting the weight and rotation of the blades, but
also had to be of a sustainable nature. Some options considered were:

Wooden Base: This could be easily sourced from scrap or recycled wood and would offer a good level base; it could
deteriorate if not treated, though, under harsher outdoors conditions.

Recycled Metal Base: Aluminum or steel parts from old appliances could provide a solid, long-lasting base resistant to
environmental wear. The only negative with metal is that it's harder to shape and assemble.

Choice: The reason a recycled-wooden base was chosen instead is that it was easily available, created minimal
environmental impact, and could be constructed easily. Any metal components would have to be made from scrap in
order to cut down on waste and were also not available.

3. Placement and Integration of Generator

Direct placement of a generator has much to do with the efficiency of energy conversion. Various placements that could
be considered are:
Direct Attachment to Blade Shaft: In this case, the generator would directly turn with the blades, capturing all the
energy efficiently and transferring it. However, the precision in alignment is very important.

Belt or Gear System: This would be another method of transferring rotational energy via gears or a belt system.
Although it provides increased torque, the drawbacks of added complication and friction loss are also introduced.

Choice: The generator's direct attachment to the blade shaft was chosen to facilitate ease and efficiency regarding the
transfer of energy. It minimizes moving parts and friction loss, ensuring maximum energy generation.

4. Design Testing and Modifications

Several prototypes were built and tested, using different blade angles and materials. Each was put through their paces
to measure the following criteria:

Rotational Speed: How fast the turbine rotated under different conditions of wind speed.

Energy Output: As measured by the multimeter attached to the 3V generator.

Structural Stability: Base stability under different wind pressures.

5. Results

Blade Angles: The 30 degree had the best balance of capturing wind and stability.

Energy Output: The model used provided a constant voltage output, measured by a multimeter, which lit the LED
accordingly.

Stability: Wood-based base had been pretty sturdy during testing with the leaf blower, at a reasonable or higher level of
wind speed.

6. Conclusion

The four-bladed curved design base, made of recycled wood, and direct attachment of the generator, confirm that this
design will provide the most efficient and sustainable performance of our turbine. This turbine is designed to achieve
maximum energy production by utilizing recycled materials and having blades at the ideal angles.
 DATA COLLECTION

This section outlines the testing process and results for the 4 blade wind turbine, constructed entirely of wood. Various
parameters were tested to assess the performance and energy generation of the turbine using a 3V electric generator.

Test Variables
1. Blade Number: 4 blades (final design).
2. Blade Angle: 15°, 30°, and 45°.
3. Wind Speed: Low, Medium, and High (controlled via an electric leaf blower).
4. Output: Voltage generated (measured via multimeter), and LED brightness.

Test Setup
Generator: 3V electric generator connected to a 5mm LED and a multimeter.
Wind Source: Electric leaf blower (adjustable wind speed).
Duration: Each test was conducted for 30 seconds at three wind speed levels.
Measurements: Voltage readings from the multimeter, and observations of the LED’s brightness to indicate power
generation.

Test Results
Table 1: Performance Data for Blade Angle 15°
Wind Speed Voltage (V) LED Status Observation

Low 1.2V Dim Minimal rotation; low

energy output

Medium 2.1V Bright Moderate rotation; decent

power generation

High 2.7V Bright Fast rotation; near

maximum power output

Table 2: Performance Data for Blade Angle 30°

Wind Speed Voltage (V) LED Status Observation

Low 1.5V Dim Moderate rotation; low

energy output

Medium 2.5V Bright Good rotation; strong

energy generation

High 3.0V Bright Fastest rotation; highest

energy output
Table 3: Performance Data for Blade Angle 45°
 Wind Speed Voltage (V) LED Status Observation

Low 1.0V Dim Minimal rotation; low

energy output

Medium 1.8V Dim Moderate rotation; less

efficient power output

High 2.4V Bright Fast rotation but less

efficient than 30°

Results Summary

Optimal Blade Angle: The 30° blade angle consistently generated the highest voltage output, particularly at medium and
high wind speeds, making it the most efficient configuration.
Wind Speed Impact: Higher wind speeds resulted in greater voltage output, with the highest performance recorded at
the high wind speed setting.
Blade Angle Efficiency: The 45° angle resulted in lower power output due to increased air resistance, while the 15° angle
did not capture enough wind energy at lower speeds.

Conclusion
The final 4 blade wooden turbine, with blades set at a 30° angle, proved to be the optimal configuration for energy
generation. This setup provided the highest voltage output (up to 3.0V), successfully lighting the LED at medium and
high wind speeds. This demonstrates the efficiency of the chosen design in harnessing wind energy for practical
electrical generation.
 DRAWINGS

Paper

IMAGE MEANING
This drawing and
sketching is a freehand
sketch of multiple parts of
the windmill, on the far
right there is a top view of
the windmill and a
diagram of the rotor
system, whilst on the left
there is the turbine,
wooden pole and wooden
wing as well as a side
view of the windmill.

Out of the many options,

the second blade was
chosen as it provided the
most effective for our
wind turbine design.

Of the many options for

the nose/tip of the wind
turbine, the first one was
chosen as it proved the
best fit and most
aerodynamic for the
project.
 The circular design was
chosen from both
windmill tower designs as
it was more smooth,
favorable and neater than
the second option.

Sketch up

IMAGE MEANING

This image gives the front view of the designed wind

turbine. It shows the overall height and scale
concerning the human figure in order to understand
the dimensions of the turbine and the size intended
in the design
This image shows the planform view of the wind
turbine; thus, it is easy to see the layout of the
blades. It also serves to help visualize the symmetry
of the blades and the footprint of the turbine, which
will be important in determining its aerodynamic
performance.

The image is a side profile of the turbine and its

structural framework, particularly the proportionality
of the blades to the supporting tower. Again, the
design relative to the scale of the human figure gives
a clear perspective of the blade height.

This image showed a magnified view of the turbine's

generator part and how blades were attached to the
generating mechanism. Emphasis would have been
made on how rotational energy from the blades is
transferred to the generator to create electricity.
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