Abstract

This project (Design of Aeroleaf Wind Turbine) is about designing and

manufacturing a Vertical Axis Wind Turbines VAWT to transfer the wind speed
to a rotational motion using these turbines. These turbines will be attached to a
manufactured tree that will look like a modern design, which can be installed in
and around any public area such as parks, roads, public facilities, or business
offices. Aeroleaf Wind Turbines are designed to produce power up to 5000
watts.

This project presents a review on the performance of Savonius wind turbines.

This type of turbine is not commonly use and its applications for obtaining
useful energy from air stream is still considered as an alternative source. Low
wind speed start-up, working with any wind direction, and the less noise are
some advantage of VAWT- Savonius model.

This project consists designing. An actual of gained power is reported to be

31~35% relative to the theoretical gained power due to the instability and
inefficient of the wind speed.
 Table of CONTENTS

Abstract

Acknowledgment
Introduction
1. 03

1.1 Project Definition

1.2 Project Objectives

1.3 Project Specification

1.4 Product Architecture and Components

1.5 Applications
Literature Review
2. 05

2.1 Project background

2.2 Previous Work

Product Subsystems and Components
3 09
4. System Testing and Analysis
18
5. Conclusions and Future
Recommendations
21
 5.1 Conclusions

5.2 Future Recommendations

References
23
 Chapter 1
INTRODUCTION

1.1 PROJECT DEFINITION

This project is about designing and manufacturing an Aeroleaf Wind Turbine
that can convert wind by using Vertical Axis Wind Turbines (VAWT) to a useful
energy.
The current power demanding in India is very high compared to power
consumption world average; India consume three times more electricity than
the world average [1]. This high demanding should take the focus of attention
in thinking in different sources of energy.
One of the best sources of energy that can apply the concept of sustainability
is renewable energy such as sun, wind, and rivers. The positive point of wind
energy is that unlike solar energy that only used with sunlight, wind turbine can
be useful all the 24 hours all the year.
Another concept of sustainability is the way that we should use in utilizing this
renewable energy
Efficiently, and environmentally friendly. This, in turn will eliminate the
environment hazard and
Improve Indain communities’ health and life style.
Streets, public parks, schools, and public facilities are consider as main power
consumers, these
Consumers should be vulnerable to wind from time to time. The idea of this
project is to convert
This wind by using Vertical Axis Wind Turbines (VAWT) to a useful energy by
using it as a
Power source that can serve these consumers.
1.2 PROJECT OBJECTIVES
The main objective of this project is gaining power from wind. Therefore, this
project is green source of energy and has no effect on the life of earth. These
wind energy turbines are small and can produce up to 100 watts for each
turbine.
Another objective of this project is gaining and exercising some engineering
concepts such as:
 Learn about wind energy and different ways of convert it to a useful
power
Learn the different between Vertical Axis Wind Turbines (VAWT) &
Horizontal Axis Wind Turbines (HAWT).
Learn the impact of energy & our rules as engineering students to
provide alternatives.
1.3 PROJECT SPECIFICATIONS
This project is 10 meter high (tree & turbine), it is expected to produce total of
up to 2400 kwh. The material that the tree is made of is galvanized carbon
steel and the turbine blades are made of aluminum alloy. The turbines can start
working under low wind speed and can cut-off if the speed is too high

1.4
PRODUCT ARCHITECTURE AND COMPONENTS
The project main components are wind turbines which include (blades, shaft
bearings) for each turbine, electrical generator attached to the end of the shaft
for each generator. The generators are connecting through wires to the control
banal, which include (converter, controller and battery connected from and to
the banal for the popups of changing from and to DC & AC).
1.5 APPLICATION
 This
project idea is very simple, where it focuses on utilizing the wind energy by
designing and manufacturing two VAWT and attach them to a manufactured
tree. This tree can be installed across the public facilities. Facilities such as public
parks, in the top of the stadiums where wind is very high and around the stadiums,
services’ buildings, and over the roads and streets.
Below figure1.1, identifying the initial functional diagram that shows the
expected project outlook. And initial real photo of the project is in the below
figure 1.2.
 Chapter 2
LITERATURE REVIEW
2.1PROJECT BACKGROUND
Energy is the main economy base of any country. Sources of energy are not
easy to have. Having multiple sources of energy is extremely important to
secure the basic living requirement of any country. Utilizing the nature could
help in converting some of the natural phenomenons such as sun, wind,
sea and oil into useful energy. This kind of energy called renewable energy.
Science Daily Research Newspaper has defend renewable energy as
“The most common definition is that renewable energy is from an energy
resource that is replaced rapidly by a natural process such as power
generated from the sun or from the wind.” [2].
Recently, the increasing demand of renewable energy is very well noticed.
According to a report by the International Energy Agency, the increase of
amount of electricity produced from renewable sources increased from just
over 13% in 2012 to 22% the following year. They also predict that that
figure should hit 26% by 2020 [3].
The traditional power plants in India are mainly working on the fuel either
gas or oil which are not environmental friendly. EcoSpark environmental
charity [4] has considered oil power plants as one of the most contributors
of environment pollution. EcoSpark environmental charity has listed the
below most significant environmental impacts:
Oil causes air pollution and greenhouse gas emissions.

Oil uses large amounts of water, and creates water pollution and
thermal discharge.

Oil creates hazardous sludge and solid waste.

Extracting and refining oil is environmentally destructive.

Transporting oil is risky and can harm the environment.

Oil is a non-renewable electricity source.

Such of the above environment affects lead us to think seriously about the
renewable energy sources, which will eliminate the environment hazard and
improve health and life style.
Wind energy is one of the most important energy sources. The concept of wind
energy is transforming the wind’s kinetic energy into mechanical energy.
This energy drive blades that turn generators that produce electricity. Our
project is fitting with wind energy source. The idea of this project is to convert
the wind by using Vertical Axis Wind Turbines (VAWT) into power.
They are two types of wind turbines, Horizontal Axis Wind Turbines (HAWT) as
shown in figure 2.1 that is more commonly used across the world and they are
used as a power plants.
 Figure 2.1

HAWT overview layout

These kind of turbines are the most efficient of wind turbine. Cole Gustafson
from Dakota State University has mentioned the advantages and
disadvantages of horizontal axis vs vertical axis wind turbines, “In research
studies evaluating wind turbine performance,horizontal axis machines have
been shown to be more efficient than vertical axis machines. However, the
blade span of horizontal wind turbines is larger than vertical axis machines
which limits placement confined spaces. Some people also find the large blade
area of horizontal axis machines objectionable” [5]. The other type of wind
turbine is the Vertical Axis Wind Turbines (VAWT) as shown in figure 2.2.
VAWT is the most popular of the turbines that people are using to make their
home a source of renewable energy.

Figure 2.1
VAWT overview layout
VAWT is not as commonly used as the Horizontal Axis Wind Turbine. The
reason behind that is that VAWT is less efficient than HAWT when considered
as a power plant generator. However, for the small scales like homes, parks, or
offices VAWT is more efficient.“Vertical axis turbines are powered by wind
coming from all 360 degrees, and even some turbines are powered when
the wind blows from top to bottom. Because of this versatility, vertical axis wind
turbines are thought to be ideal for installations where wind conditions are not
consistent, or due to public ordinances the turbine cannot be placed high
enough to benefit from steady wind.” [6]. Figure 2.3 shows the configuration of
HAWT vs VAWT.

Figure 2.3
Configuaration og HWAT and VWAT

2.2 PREVIOUS WORK

There are two different styles of vertical wind turbines. One is the Savonius
model, which is our project is based on, and the other type is the Darrieus
model. The first model looks like a gallon drum that is been cut in half with the
halves placed onto a rotating shaft. The second model is smaller and looks
much like an egg beater. Most of the wind turbines being used today are the
Savonius models.
Renewable Energy UK website provided some information about these two
model. “A Savonius is a type of vertical axis wind turbine (VAWT) generator
invented in 1922 by Sigurd Johannes Savonius from Finland though similar
wind turbine designs had been attempted in previous centuries."[7].
“A Darrieus is a type of vertical axis wind turbine (VAWT) generator. Unlike the
Savonius wind turbine, the Darrieus is a lift-type VAWT. Rather than collecting
the wind in cups dragging the turbine around, a Darrieus uses lift forces
generated by the wind hitting aerofoils to create rotation.” [8].
In Jun 2.15, International Research Journal of Engineering and Technology
(IRJET) has published a research titled “DESIGN, ANALYSIS AND
FABRICATION OF SAVONIUS VERTICAL AXIS WIND TURBINE” [9].
This research discussion was to showcase the efficiency of Savonius model in
varying wind conditions as compared to the traditional horizontal axis wind
turbine. It evaluated some observation that showed that at low angles of attack
the lift force also contributes to the overall torque generation. Thus, it can be
concluded that the Savonius rotor is not a solely drag-driven machine but a
combination of a drag-driven and lift-driven device. Therefore, it can go beyond
the limit of Maximum power coefficient Cp established for the purely drag-
driven machines.
Some of this researched conclusions are that The vertical axis wind turbine is
a small power generating unit with the help of free source of wind energy. It is
designed under consideration of household use. Generally, At least 10% power
of the consumption can be fulfil by the Savonius model.
The research has also resulted that this turbine is generally suitable for 8 to
10m of height above ground level. Because at ground level velocity of air is
very less. And finally the alternate option for turbine blade material is
reinforced glass fiber because of its more elastic nature but it is costlier than
aluminum alloy.
To have the best efficiency of the power output from our turbine, the team has
done some brainstorming in what are the most significant factor that affect the
turbine, the blade angle was agreed to be the most significant one.
By doing some researches, we fined an article that focusing in the turbine
blade angle.
A research article published by Advances in Mechanical Engineering (AIME)
with a title of “EFFECT OF THE BLADE ARC ANGLE ON THE
PERFORMANCE OF A SEVONIUS WIND TURBINE” [10].
This article is focusing on how to improve the efficiency of the turbine by
selecting the best blade angle.
The effect of the blade arc angle on the performance of a typical two-bladed
Savonius wind turbine is investigated with a transient computational fluid
dynamics method. Simulations were based on the Reynolds Averaged Navier–
Stokes equations, and the renormalization group turbulent model was
utilized.
The numerical method was validated with existing experimental data.
The results of this article indicate that the turbine with a blade arc angle of
160° generates the maximum power coefficient cp 0.2836, which is the highest
that gain from the experiment.
The article provided the below table 2.1, which shows the maximum coefficient
of power for different cases. Figure 2.1 shows the blade dynamic torque
coefficient for different blade arc ang
 Chapter-3
PRODUCT SUBSYSTEMS & COMPONENTS

Vertical axis wind turbine VAWT are one whose axis of rotation is vertical with
respect to ground. Generally as shown in figure 3.3, the main components of
this turbine are:
Blades

Shaft

Generator
 Figure 3.3

Main components of VAWT

3.3.1 ROTOR BLADES

Savonius blades are a crucial and basic part of a wind turbine figure 3.4. They
are mainly made of aluminum, fiber glass or carbon fiber. We selected the
aluminum alloy as recommended in the study mentioned in chapter 2.2
because they provide batter strength to weight ratio.
The design of the individual blades also affects the overall design of the rotor.
Rotor blades take the energy out of the wind; they capture the wind and
convert its kinetic energy into the rotation of the hub. The arc angle was
selected based on the pervious study mentioned in chapter 2.2, which
recommended an angle of 160°
3.3.2 SHAFT
The shaft is the part that gets turned by the turbine blades. It in turn is
connected to the generator within the main housing.
A solidworks tools have been used in designing the blades and the shaft as
shown in the below figure 3.5

3.3.3 Radial & Thrust Bearings

The bearing is integral part of the overall system. The lubricant and sealing
elements also play a crucial role. To enhance bearing effectiveness in the
system, the right type should be selected. However the procedure of the
selection is a science but we restricted on three simple steps:
1-Confirm operating conditions and operating environment.
2-Select bearing type and configuration.
3-Select bearing dimensions.
The correct amount of an appropriate lubricant must be present to reduce
friction in the bearing was consider. As long as the sealing elements are
important because of the environment surrounding our project and keep the
lubricant in, and away from the dust and contaminants. On another side, the
low speed of the system was consider too in the selection with axis and radial
forces which is the weights of upper system.
3.3.4Electrical Parts
The turbines are connected to electrical parts in order to get the required
power.
 3.3.5
GEN
ERAT
Part Function OR
The
Electrical conv
Generator Converting the rotating speed to an electrical ersio
n of
rotati
Turbine
onal
Controller
mech
anical
Combining the earned power from each turbine to energ
Combiner one output power y to
electr
Charged electrically to provide a static potential for ical
power or energ
y is
Battery perfor
released electrical charge when needed.
med
by
an electrical device that can interrupt the flow of gener
electrical current ator.
Fuse Differ
when it is overloaded ent
types
Converting DC current to AC current of
Converter
gener
ator
Turbine Sensors Braking overload have
been
Consumption used
reading Reading battery percentage in
wind
energ
y system over the years. For large, commercial size horizontal-axis wind
turbines, the generator is mounted in a nacelle at the top of a tower, behind the
hub of the turbine rotor. Typically wind turbines generate electricity through
asynchronous machines that are directly connected with the electricity grid.
Usually the rotational speed of the wind turbine is slower than the equivalent
rotation speed of the electrical network - typical rotation speeds for wind
generators are 5-20 rpm while a directly connected machine will have an
electrical speed between 750-3600 rpm. Therefore, a gearbox is inserted
between the rotor hub and the generator. This also reduces the generator cost
and weight.
The generator used for the prototype is the Low RPM permanent magnet DC
generator created by Wind Stream Power and is a 12-volt step generator. The
generator has an internal resistance of 21Ω.
The current generator can only operate continuously with a current of 1.5
amperes and at a max of 1.5 minutes with a current of 3 amperes the below
figures 3.6 and 3.7 are explaining the generator parts.

3.3.6Battery
The battery that we used in our project is The Long WPL150-12N rechargeable
power guard sealed lead acid battery as shown in the below figure 3.8, and
table 3.2

Figure 3.8

3.3.7 Bottom Pipe

Considering the total weight of the so far construction and the desirable
design of the wind turbine three support bases will be used. These three
levels are connected and supported, the material we used for the bases
was metal as shown in simulation figure 3.9.

3.4 Implementation
3.4.1 Turbine design & sketch
After compiling background research, we started the planning for the project.
We reached a point where we started the initial drawings of the design.
Basically, we drew the overall project outlook, which is a tree, turbine(s),
electrical generator, and light as shown in figures 3.10, 3.11.
Figure 3.11
As shown in figure 3.11, the turbine design was made using the SolidWorks
tools which we used at the beginning to identify the design initial parameters
for better understanding.
3.4.2 Designing tree Model
At this stage, we reached to a point where we need to start planning for
designing the tree. This planning starting from defining the high and width of
the tree, which we agreed leader to be 2.8 meter high to achieve as much wind
as possible and 2 width.
A goal for defining a tree branches was to have the most popular design and
material that would be able to provide realistic results. Initially, we tried to use
aluminum material for the tree branches. But, this marital will not hold the
turbines easily, and if it did it will not hold them for long time.
We finally came to the conclusion that a carbon steel galvanizing materials
(Pipe, flanges & blade) for the tree would satisfy our requirements. Figure
12.13 shows initial tree design. And figure 3.13 shows the solidworks drawing.
3.4.3 Manufacturing of turbine blades and rod.
The vertical shaft that held the turbine was manufactured out of quarter inch
stainless steel with press fits designed to attach to the generator. It also had
two set screws which kept the shaft connected to both instruments as well as a
set screw in the middle to lock turbine in place.
The blade manufacturing was assigned to a workshop plant in Jubal using the
solid work drawings and the given requirements and specifications.
The top and bottom pieces were cut out of 3/8th inch acrylic and then glued
together.
The metal rods used to lock the adjustable blade to the top and bottom pieces
were glued together with epoxy.
In the below figures 3.14 & 3.15 pictures of the tree and blades manufacturing
respectively.
Chapter 4
 SYSTEM TESTING AND ANALYSIS

4.1 THEORETICAL WIND TURBINE POWER CALCULATION

Wind Power depends on:
• amount of air (volume)

• speed of air (velocity)

• mass of air (density)

Kinetic Energy definition KE= 1/2×m×v2 Equation 4.1

Where:
M=Mass ,V=Velocity
Since Power is Energy per time, we can formulate equation 4.1 to be
P= 1/2×m×v2
Fluid mechanics gives mass flow rate (density volume flux):
Thus, power of the wind is P= 1/2×ƥ×A×v3

Taking in consideration the turbine Power coefficient, power in the wind is

calculated using this formula:

P= 1/2×ƥ×A×v3 ×Cp Equation 4.2

Power coefficient, usually varies according to wind turbine design, ranging
between 0.05 and 0.45. In this case, referring to the previously mentioned
study in chapter 2, we are taking 0.2836 based on the selected angle 160°.The
only variable in this equation is the wind speed. Table 4.1 and graph 4.1 are
reported the Theoretical gained power at different wind speeds.
4.2 EXPERIMENTAL READINGS
After designing the components and structures desired for testing power output
for wind turbine designs and the structures desired to be tested, we created the
experimental set-ups required to test the prototypes and structures.
In order to determine the effectiveness of the products that were manufactured,
we performed tests to evaluate them. The test set up was in Half Moon (open
area). We also tested the power output of the turbine blades and evaluated
how the vibrations from the turbine affect the stress and strain on a tree
structure.
Two experiments have been conducted; the procedure of calculating the power
is counting the voltage & current that feeding the battery. The power gained
can be calculated using the below equation.
 Chapter 5
CONCLUSIONS AND FUTURE RECOMMENDATIONS
5.1CONCLUSION
From our research we were able to come up with many important conclusions
and suggestions which will profit the future advancement of individual vertical
pivot wind turbines. We could outline a VAWT framework that enhanced power
yield when contrasted with the past projects. From our results we were able to
recommend new design aspects to improve the system and efficiency.
Inefficient wind speed was the huge impact getting the required power output,
minimum speed of 12 m/s is required to have acceptable output power taking
in consideration 31~35% of efficiency between theoretical and experimental
results.
Even though we were able to make this design of Vertical Axis Wind Turbine
but there is a never ending process to always improve upon inventions and
new designs. Wind turbines are a start for society to lessen the damage done
to the earth by not using energy sources that produces pollution. Hopefully the
project could propel research and testing on VAWT frameworks and give
knowledge for different gatherings to finish additionally testing and enhance
productivity and execution of vertical pivot wind turbines.
5.2FUTURE RECOMMENDATIONS
Using the data received we made recommendations for future studies
regarding the potential of commercial tree wind turbines. These
recommendations will hopefully aid in the development of a technology that
would allow green energy to reduce energy costs in the average household
and better the environment. Future tests could help determine the feasibility of
houses, neighborhoods, or cities powered by wind turbines and being able to
run off of renewable energy.
The turbine performance testing and results from the research in this venture
demonstrated that the split Savonius is the best plan that has been tried to this
point at WPI. The reason is because of the expansive surface range of the split
Savonius which empowers it to catch most maximum amounts of wind. We
trust that further research ought to be finished with different Savonius
To gain the best power gain in the concept of green energy, we strongly
recommend having some solar panels attached to the tree. These panels will
add more power and they are easy to install and connected to the electrical
components that are already added to the system. Below figures are some
recommended design sketches having the solar panels.
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Retrieved from http://duth.gr/index.en.shtml Department of Production Engineering &
Managemen