Vortex Wind Systems - Weebly

Memorial University of Newfoundland

ENGI 8926: Mechanical Design Project II

Final Report

Vortex Wind Systems

H.A.W.T Rotor Detailed Design

April 4th, 2014

Dan Follett - 200559359

Scott Guilcher - 200915585

Jeremy Tibbo - 200902690

Group M9

i

Contents TABLE OF FIGURES .......................................................................................................................... iii

Table of Tables ................................................................................................................................ iv

List of Acronyms ............................................................................................................................... v

Acknowledgments ........................................................................................................................... vi

1 Introduction ............................................................................................................................. 1

2 Project Definition ..................................................................................................................... 2

3 Project Management Plan ....................................................................................................... 2

4 Market Analysis ....................................................................................................................... 2

5 Environmental Analysis ........................................................................................................... 3

6 Tool Evaluation ........................................................................................................................ 5

7 Prototyping Methods .............................................................................................................. 6

8 Testing Options ........................................................................................................................ 7

9 Blade Design Theory ................................................................................................................ 8

9.1 Blade Element/Momentum Theory ................................................................................. 8

9.2 Iterative process ............................................................................................................. 10

9.3 Stall Regulated Turbines ................................................................................................. 11

9.4 Tapered Blade Design ..................................................................................................... 11

10 Airfoil Polar Data Evaluation .............................................................................................. 11

10.1 Airfoil Selection and Evaluation .................................................................................. 11

10.2 Airfoil Selection Caveats ............................................................................................. 12

10.3 Root Airfoil S814 ......................................................................................................... 12

10.4 Mid-Span Airfoil S812 ................................................................................................. 13

10.5 Tip Airfoil S813 ............................................................................................................ 14

11 Design Considerations ....................................................................................................... 15

11.1 Betz Law ...................................................................................................................... 15

11.2 Justification for 3 Blades ............................................................................................. 15

11.3 Preliminary Theoretical Blade Length ........................................................................ 16

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11.4 Theoretical Power Output and Demand .................................................................... 16

12 Blade Design Analysis ......................................................................................................... 17

12.1 Geometry .................................................................................................................... 17

13 Performance Analysis ........................................................................................................ 19

13.1 Solid Mechanics .......................................................................................................... 20

14 Finite Element Analysis ...................................................................................................... 23

15 Optimization ...................................................................................................................... 26

15.1 Approach .................................................................................................................... 26

15.2 Weibull Distribution ................................................................................................... 26

15.3 Method ....................................................................................................................... 27

15.4 Blade Geometry .......................................................................................................... 28

15.5 Power Output ............................................................................................................. 29

16 Prototype Model ................................................................................................................ 30

17 Prototype Testing ............................................................................................................... 32

17.1 Purpose ....................................................................................................................... 32

17.2 Materials ..................................................................................................................... 32

17.3 Procedure ................................................................................................................... 32

17.4 Results ......................................................................................................................... 33

17.5 Discussion ................................................................................................................... 33

18 Composite Drive Shaft Design ........................................................................................... 34

18.1 Product Description and Technical Requirements ..................................................... 34

19 Material Selection .............................................................................................................. 34

19.1 Design and Analysis .................................................................................................... 35

19.2 Process Selection for Manufacturing ......................................................................... 36

19.3 Cost Analysis ............................................................................................................... 37

19.4 Drive Shaft Recommendations ................................................................................... 38

20 Project Recommendations ................................................................................................. 39

21 Conclusion .......................................................................................................................... 40

22 Works Cited .......................................................................................................................... vi

iii

TABLE OF FIGURES Figure 1 - 30 Meter Elevation Wind Map of Newfoundland .......................................................... 3

Figure 2 – Wind Frequency Distribution for Newfoundland .......................................................... 4

Figure 3 - Annual Distribution of Wind Direction .......................................................................... 4

Figure 4 - Previously Fabricated Rapid Prototype ABS Blade ......................................................... 7

Figure 5 - Wind Tunnel Apparatus .................................................................................................. 7

Figure 6 - Sectional Blade Profile ................................................................................................... 8

Figure 7 - Vector Configuration ...................................................................................................... 9

Figure 8 - Propeller Disc and Stream Tube Area ............................................................................ 9

Figure 9 - Slipstream Model ......................................................................................................... 10

Figure 10 - S814 Normalized Profile ............................................................................................. 12

Figure 11 - Coefficient of Lift and Drag Ratio vs. Angle of Attack ................................................. 13





Figure 17 - Chord Distribution of Turbine Blade ........................................................................... 18

Figure 18 - Twist Distribution of Turbine Blade ............................................................................ 18

Figure 19 - Rotor Power Coefficient for Varying Wind Speeds ..................................................... 19

Figure 20 - Power Curve for Initial Wind Turbine Design ............................................................. 20

Figure 21 - Preliminary Stress Calculation Diagram ...................................................................... 21

Figure 22 – Simplified Blade Dimensions ...................................................................................... 22

Figure 23 - Von Misses Stress FEA Model ..................................................................................... 24

Figure 24 - Displacement Model FEA ............................................................................................ 25

Figure 25 - SolidWorks Fatigue Check ........................................................................................... 26

Figure 26 – Power Efficiency and Wind Distribution .................................................................... 28

Figure 27 - Normalized Chord Lengths for Final Design ............................................................... 29

Figure 28 - Twist Distribution for Final Blade Design .................................................................... 29

Figure 29 - Power Output for Optimized Blades ........................................................................... 30

Figure 30 - Prototype Power Output of Optimized Blades ........................................................... 34

Figure 31 – Radial Geometry of Drive Shaft ................................................................................. 36

Figure 32 - Schematic of Filament Winding Process ..................................................................... 37

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Table of Tables Table 1 - - Power Demand Yearly ................................................................................................. 17

Table 2 Prototype Component Breakdown .................................................................................. 31

Table 3 - Experimental Measurements ......................................................................................... 33

Table 4- Cost Comparison of non-Composite Materials ............................................................... 37

Table 5 - Differences in composite materials .............................................................................. 38

v

List of Acronyms Acronym Meaning

1D One dimensional

2D Two dimensional

3D Three dimensional

HAWT Horizontal Axis Wind Turbine

FEA Finite Element Analysis

Air Density (kg/m3)

Pitch Angle

Difference in Thrust and Lift Direction

Axial Flow Velocity Vector

Sectional Flow of Velocity Vector

Angular Flow Velocity Vector

B Number of Turbine Blades

Change in Momentum Flow Rate

Change in Angular Momentum Rate for Flow x Radius

Lift Coefficient

Drag Coefficient

TSR Tip Speed Ratio

vi

Acknowledgments

Vortex Wind Systems would like to give special thanks to project supervisors Dr. Sam Nakhla

and Dr. Kevin Pope. Without their continuous support and dedication to our team this project

would not have been possible. Don Taylor, for his guidance and help in machining and

development of the various mechanical components; as well as Steve Steele for his support in

the rapid prototype laboratory, your help has been greatly appreciated.

1

1 Introduction

The province of Newfoundland and Labrador has a strong connection to renewable energy with

hydro energy and wind energy assets developed all across the province. However, the island of

Newfoundland has large regions where this power supply does not reach. In some of these

areas residents own cabins or cottages for recreational purposes. There is an existing demand

to provide these off grid structures with electricity to supply essentials like radio, light, and

other small appliances. An isolated 500W rated wind turbine is sufficient to meet the power

demand.

Retreat locations have power commonly supplied through combustion generators with some

exceptions of some solar applications. Generators can be costly, due to rising fuel prices, and

inconvenient when having to transport fuel. Burning fuel also creates pollution harming the

environment of the cabin. Solar energy, while environmentally friendly, can pose high capital

costs in comparison to a small wind turbine. With a simple, robust, small horizontal axis wind

turbine [HAWT], owners can leave their cabin and return on weekends with the necessary

power already stored in batteries.

Vortex Wind Systems has completed the design for the blades of a small wind turbine to supply

the necessary power needed for a cabin. The turbine has been sized in accordance to the power

demands required for essential appliances. Heat, stove, oven and large appliances such as

washers and dryers are rarely found in a remote cabin therefore it is not necessary to

accommodate their power demands.

Using XFLR5 and Prop-ID, Vortex Wind Systems was able to design stall regulated wind turbine

blades. The blades will harness sufficient energy through their design based on annual wind

frequency data for Newfoundland and through the application of statistical models for optimal

performance. Using XFLR5, the blade airfoils have been evaluated and then incorporated into

PropID to reach the final design geometry.

This report will discuss in detail, the front end research, design, and prototype fabrication and

testing of the stall regulated wind turbine blades. Front end research includes an

environmental analysis, market study, tool evaluation, and prototyping options. Discussion on

design of the blades will incorporate the process and results that led to the initial geometry for

optimization. These results will be test by using scaled blades fabricated into a prototype for

concept validation. This report will endeavour to illustrate that this design meets all the

established requirements and is an efficient and competitive design.

2

2 Project Definition

The objective of the design project is to create a HAWT capable of providing power to a cabin to

operate lights, radio, and other small appliances. Targeted users would be located on the island

of Newfoundland and require the power only during the weekends. The HAWT will be a stand-

alone unit for power supply to off-grid structures. Optimization of the blades is a primary focus

to ensure that the unique wind characteristics of the island are used to their full potential.

Harsh weather conditions on the island impose a higher risk of structural and functional failure

that will be mitigated through a proper analysis and creative design. The final result will be

turbine blades designed to withstand and optimized for cabins of Newfoundland.

3 Project Management Plan

The project is separated into three phases: Front End Engineering and Design (FEED), Detailed

Engineering and Close Out. The Front End Engineering and Design is a comprehensive research

phase with the goal of developing initial design criteria. The primary tasks completed, as

highlighted by the Gantt chart in Appendix A1 are a Market Analysis, an Environmental Study,

Engineering Tool Development, and Prototype Method research. The research completed in

this phase allowed for a clear path forward allowing the team to successfully move from the

FEED and into Detailed Engineering. The Detailed Design stage involved the complete blade

design and analysis, prototype component design, fabrication and testing. The close out phase

is the reporting phase to conclude the project.

Fabrication of some prototype components was done in parallel with other tasks to give more

room for errors and mistakes. The additional time was used in the fabrication of the blades. A

software glitch caused the rapid prototyping machine to create defective parts that could not

be used. However, the PMP allowed time for this error to be absorbed and corrected. The

prototype fabrication remained on schedule.

4 Market Analysis

In an effort to narrow down the design scope and size of HAWT that the team would pursue, a

market analysis of existing HAWTs within the industry was conducted on both a local and

international scale. By first looking into the scale of various global projects it was concluded

that a 500W HAWT would best suit a small cabin or cottage with low power demands [1]. By

researching local contracts for HAWTs we were able to not only see how existing set-ups tie in

with a cabins electrical but were able to identify various challenges and obstacles that present

themselves given Newfoundland’s inclement wind conditions.

3

In establishing our preliminary market analysis a 500W HAWT is to be used, a market

comparison of current models being offered to establish a direction forward was conducted. As

shown in Appendix A2, we included six 500W turbines which we then compared against one

another.

With this information trends such as blade length and material were used to provide direction

in determining our prototyping and testing methods while taking the start-up, cut-in and max

wind speed in addition to the rotational speed to tie in with the environment analysis and again

our testing methods.

5 Environmental Analysis

RET Screen can be used to access a broad database of ground station and satellite data across

Newfoundland. Using the average annual wind speeds across twenty years of thirty cities, it

can be estimated that the average wind speed is approximately 6.5m/s [2]. However, wind

speeds have a very significant impact on the energy output of the turbine and therefore the

design; accuracy is paramount when optimizing a turbine. RET Screen has the capacity to link

information from high resolution wind resource maps. The Canadian Wind Energy Atlas

provides a detailed map of wind speeds on the island at elevations of 30 meters, as shown

Figure 1, 50 meters, and 80 meters.

Figure 1 - 30 Meter Elevation Wind Map of Newfoundland [3]

4

Utilizing a wind frequency distribution for Newfoundland can provide further insight into

predictions of power generation. Figure 2 – Wind Frequency Distribution for Newfoundland is

based on 5 years of annual data and allows for categorical estimations of power production at

discrete wind speeds when used in conjunction with turbine’s power curve.

Figure 2 – Wind Frequency Distribution for Newfoundland

Wind direction is an environmental factor that has design implications. It was found that wind

direction is completely variable which implies that a full scale prototype/design must include an

effecting yawing mechanism to place the blades in the optimal position. The variability of wind

direction can be seen in the below figure.

Figure 3 - Annual Distribution of Wind Direction [4]

0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

14.00%

0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00

Fre

qu

en

cy

Wind Speed (m/s)

Wind Frequency Distribution

Wind Freq. Data

5

6 Tool Evaluation

Due to the complexity of learning a new program it is important to establish which program will

be used to evaluate the optimal design of the blades based on our design criteria. Programs

which were evaluated and considered are:

Fluent

PROP-ID

WT-PERF

X-Foil

RET Screen

After evaluating the software capabilities it was decided that Fluent or PROP-ID would be

suitable for the design of the turbine blades. The final decision was to use PROP-ID due to its

relative ease of use in comparison to Fluent. PROP-ID is believed to have a shorter learning

curve. Also PROP-ID is based on the blade element momentum theory and incorporates stall

regulated designs. Due to the scope of the project and the attempt to keep the design simple,

the blades will act under stall regulation at high wind speeds for over speed protection. To

obtain and install Fluent can be difficult task, a Linux system is required to run the program.

However PROP-ID can easily be downloaded from the University of Illinois and is ran through

the command window of any computer. Due to these reasons, PROP-ID is the final selection

and is believed to be able to output all necessary information for an optimal blade design based

on design inputs. Some PROP-ID inputs are:

Tip loss effects

Air density

Stall regulation or non stall regulated options

Airfoil mode.

Number of blades

Airfoil polar data

Preliminary Geometry

Outputs for the program consist of:

Blade design (twist, pitch, chord length etc)

Torque

Relative angle of attack

Lift, drag

Power curve

6

These are just a few examples of useful inputs and outputs available when using PROP-ID. For

more an example of an input and output file refer to Appendix A3.

If needed for further evaluation of the blades, WT-PERF can be used for analysis purposes. This

has a limited amount of design capabilities in comparison to PROP-ID, however the analysis

functions may become useful if deemed necessary in future blade evaluations. WT-PERF is also

run through the command window of any computer and is free to download from the National

Renewable Energy Laboratory website. This will output torque, power curves and other forces

apparent on the turbine.

7 Prototyping Methods

In an effort to develop a model capable of withstanding the environmental elements in

Newfoundland while still operating efficiently, a multitude of prototyping processes must be

considered with a budget in mind. Considering Memorial University’s access and availability

when it comes to in house materials and equipment it’s was decided to stay in house for

prototyping. This is the result of considerations given to the schedule and budgetary concerns

involved in manufacturing a working prototype in such a small window for testing.

To create an accurate blade profile of the chosen design once created in SolidWorks, the rapid

prototyping machine was considered to fabricate the blade out of Acrylonitrile butadiene

styrene [ABS] in potentially multiple sizes due to restrictions of the machine.

ABS is a thermoplastic terpolymer created by polymerizing acrylonitrile and styrene in the

presence of polybutadiene. Due to a high enough glass transition temperature it is resistant to

unwanted deformation at elevated temperatures.

7

Figure 4 - Previously Fabricated Rapid Prototype ABS Blade

Once complete multiple, sections can be mated together to form one master model for

reproduction through the utilization of a reusable silicon injection mold using resin as our

material. The intention for this is that the cost of using the rapid prototyping machine at

roughly $10/hr for all three blades would go well beyond the budget. Silicon can be purchased

and cast around our master model with relative ease while injecting resin into the mold for a

lightweight supplicate at a much lower cost than ABS [5].

8 Testing Options

Two preliminary testing options were considered, wind tunnel testing or creating an outdoor

prototype. It is important to evaluate the pros and cons of both of these to understand which

option is appropriate in the short time frame given and limited budget.

Figure 5 - Wind Tunnel Apparatus

Testing in the wind tunnel would be a cost effective option. It would also allow for the testing

to be performed at controlled wind speeds. The ability to control the wind speed would a

greater level of accuracy for the data points needed. However testing in this manner is limited

due to the size restriction. The wind tunnel only consists of a 4’ by 3’ cross sectional area which

would limit the size of the blade design. See Figure 5 - Wind Tunnel Apparatus Figure 5 for the

wind tunnel setup.

8

The fabrication of an outdoor prototype would allow for a realistic evaluation of a potentially

full scale blade design. This option allows for the turbine to experience changing wind

directions and the yawing action of the turbine could then be observed. It would also allow for

the turbine to experience the harsh Newfoundland weather environment. However, creating

this type of prototype on a limited budget may prove to be difficult. Also with a limited time

restriction on the project it may be time consuming to implement a prototype of this nature.

Careful consideration was given to which method to pursue. It was decided to develop a scaled

model of the turbine blades to be tested within the wind tunnel. This method will simplify the

prototype design as no yawing mechanism needs to be in place to align the wind stream. A

reduced size also means a reduced cost in fabrication of the blades.

9 Blade Design Theory

9.1 Blade Element/Momentum Theory

In considering our blade design Vortex Wind Systems chose to utilize Prop-ID for the design and

analysis of the turbine blade. Blade element and momentum theory are used in predicting the

performance parameters and are the supporting theories behind the Prop-ID software package.

Blade element and momentum theory involve the division of the blade into multiple sections

while lift, drag, thrust and torque are represented in a two dimensional plane as illustrated in

Figure 6.

Figure 6 - Sectional Blade Profile [6]

In addition, axial and angular momentum is applied to the model producing a non-linear set of

relationships.

9

Figure 7 - Vector Configuration [7]

By analyzing both circumferential and axial directions, the governing principle behind the

conservation of flow momentum can be analyzed. It is by the consideration of the momentum

theory that the change in flow momentum in the axial direction can be observed. This means

that any change in flow momentum observed upstream that subsequently passes through the

blade must in turn equal the thrust produced by this element of the blade. [8]

Figure 8 - Propeller Disc and Stream Tube Area [6]

10

In an effort to eliminate any unsteady effects resulting from our blades rotation, it is assumed

the horizontal axis wind turbine (HAWT) is covered around its sweep area as shown below in a

slipstream model.

Figure 9 - Slipstream Model [7]

9.2 Iterative process

Equations [7]:

1 -

2 –

3 -

4 -

5 -

6 -

The iterative process that Prop-ID uses to better define various desirable properties begins with

some initial guess inflow factors. These inflow factors are then used to find the flow velocity

and flow angle on the blade as shown in equations 3 and 4. This is then used to determine

blade section properties to estimate the thrust and torque as shown in equations 1 and 2.

With these approximations in place equations 5 and 6 can be used to better define the values

of the initial inflow factors. This process in executed repeatedly until the inflow factors have

converged within an acceptable tolerance.

11

In using the Prop-ID software package this iterative process can be repeated continually until a

value for both thrust and torque can be predicted for the overall performance.

Some limitations to the theory and the software Prop-ID include:

Negates 3D Flow Velocities

Over Predicts Thrust

Under Predicts Torque

Overshoots Actual Efficiency by 5-10%

The objective is to use this software to create comparative results considering environmental

conditions. In turn these comparative results act as a tool to help optimize the blade pitch given

the rated wind speed in addition to optimizing our blade solidity aiding in the material selection

process.

9.3 Stall Regulated Turbines

Constant-speed, stall-regulated wind turbines have blade designs that passively regulate the

produced power. The fixed-pitch blades are designed to operate near the optimal tip speed and

lift to drag ratio at low wind speeds. When the wind speed increases, the angle of attack

increases and parts of the blade, starting at the blade root, begin to enter the stall region. [9] As

blades move into a stall region they begin to produce less lift, reducing the tip speed and power

output. A stall controlled blade will not spin at excessively high rates and damage the turbine.

This is a main design focus for Vortex Wind Systems.

9.4 Tapered Blade Design

Blades which are designed for optimum power production will have a tapered blade design

with an increasingly larger cross section at the root of the blade and much smaller at the tip of

the blade. The pressure on the suction side of the blade is lower than the high pressure side;

therefore the air will flow around the tip from the lower side toward the upper side. This

reduces the lift of the blade and decreases the power production near the tip of the blade. With

a tapered blade design moving from a larger cross section at the root, to a smaller cross section

at the tip, these tip loss effects can be reduced [9]. A tapered blade design will be utilized by

Vortex Wind in attempt to maximize the power output.

10 Airfoil Polar Data Evaluation

10.1 Airfoil Selection and Evaluation

The properties of incoming wind vary when moving radially along the blade section from root

to tip. That is, the root blade section experiences lower relative wind speeds than the tip due to

12

its position from the center. The profile of an airfoil dictates the aerodynamic properties of the

blade and is critical in designing and evaluating the turbine. For this reason, the blade is

sectioned into three distinct regions: the root, mid-span, and tip. Three airfoils were selected

for these regions. An analysis of their lift and drag data across varying angle of attacks and a

range of Reynolds numbers were conducted using the XFLR5 program for the integration into

Prop-ID.

10.2 Airfoil Selection Caveats

It should be noted that Prop-ID requires the lift and drag data to be evaluated up to an angle of

attack of 27.5°. While angles this high may not be present in the design, the program will not

operate without data in this region. As a result, some airfoils cannot be selected as it is not

possible to calculate data with the XFLR5 program. The airfoils selected are recommended for

wind turbines and all reached converged solutions for the required range.

10.3 Root Airfoil S814

The S814 airfoil, shown in Figure 10, is specifically designed to operate in the root region of the

blade. The primary purpose of its design is to create high maximum lift and low drag for the

lower airspeed region. This profile also has a thicker cross-section to provide greater strength to

the blade structure. The profile coordinate data was directly imported into XFLR5 where a

batch analysis was completed to obtain comprehensive lift and drag information suitable for

integration into Prop-ID.

Figure 10 - S814 Normalized Profile

Figure 11 shows the lift and drag ratio for a series of Reynolds numbers across a range of angles

of attack. This plot shows the set of attack angles where the foil can productively capture wind

energy. The pitching moment coefficient plot and a lift versus drag plot for this foil were also

completed and are contained in Appendix A4.

13

Figure 11 - Coefficient of Lift and Drag Ratio vs. Angle of Attack

10.4 Mid-Span Airfoil S812

The mid-span section of the airfoil is considered to be the main power generating section of the

blade [9]. Its profile can be seen in Figure 12. A higher lift to drag ratio is desired for the range

to attack angles it is to be operating, this is observed in Figure 13. The pitching moment

coefficient plot and a lift versus drag plot for this foil were completed and are contained in

Appendix A4.


14


10.5 Tip Airfoil S813

The highest relative wind velocities occur in the tip section of the blade. As the relative angle of

attack increases with an increasing wind velocity, this section of the blade experiences the

highest drag forces. Minimizing the effects of drag is the primary consideration for the foil [10].

The profile can be seen in Figure 14 and drag ratio in Figure 15. The pitching moment

coefficient plot and a lift versus drag plot for this foil were completed and are contained in

Appendix A4.


15


11 Design Considerations

11.1 Betz Law

Betz Law states that the design can only convert approximately 59% of kinetic wind energy into

mechanical energy. Efficiency is determined by the rotor blade where the maximum efficiency

is maintained at the optimal rotational speed (aerodynamic power coefficient) for the given

blade.

In generators, when converting rotational mechanical energy to electric energy the resistance

to the rotor provides a form of friction that can only be overcome with a specific start up wind

speed that must be reached to overcome these forces.

Another source of inefficiency is when yawing each blade experiences cyclic loading at its root

depending on its position. These loads combined with the drive train shaft can be balanced

symmetrically for three blades yielding a smoother operation for turbine yaw [9].

11.2 Justification for 3 Blades

In considering the number of blades and the optimization of the model, aerodynamic efficiency,

component costs and system reliability need to be taken into account. Aerodynamic efficiency

increases by 6% [9] when moving from one to two blades, while moving from two to three

blades provides an increase of 3% [9]. Any additional blades beyond three provide minimal

returns in efficiency. In addition, as the blades would need to be much thinner and unstable

causing interference with the tower; it sacrifices too much blade stiffness when considering

interference with the tower. Adding additional blades would also lead to a higher

manufacturing cost and would decrease the overall rotational speed. Fewer blades with higher

16

rotational speeds result in reduced peak torques in the drive train lessening the probability of

gearbox and generator failure.

11.3 Preliminary Theoretical Blade Length

[10]

Power Output – 500W

PC - Power Coefficient (Efficiency of the rotor to convert energy) (35%)

A - Sweep Area of the Blade ( (Units in )

r – Radius of Sweep Area (Units in m)

PA - Power Density of the Wind = 0.6125x (S - Wind Speed in m/s)

G - Generator Efficiency (90%)

With the output and rated wind speed taken from the market analysis, solving for r to get the

following:

r = 1.202 m

This gives an initial guess from which to compare with the Prop-ID model. Appendix A5 contains

detailed calculations.

11.4 Theoretical Power Output and Demand

In maintaining an average run time of 66%, a theoretical power output both in Watts (W) and

Kilowatt Hours (kWh) for the turbine per year can be estimated. This can then be used for

various comparisons. Calculations for the following section are included in Appendix A5.

The yearly kWh for Vortex Wind System’s 500W wind turbine is found to be 1848 kWh/yr at

40% capacity [11]. In order to produce this much power by use of a gas generator, 3696

generator operating hours would be required. This operation time and gas consumption rate of

4.2 liters of fuel for 5.8 hours of operation yields a total of 2,676.41 liters per year [11]. From

the current gas prices ($1.35 per liter) it would cost $3,613.16 to run a generator for the

equivalent output of the wind turbine per year [12].

These are rough calculations but with an expected life of around twenty years, the financial

benefits of using a horizontal axis wind turbine add the primary source of energy are evident

even during the first year.

Considering power consumption, the daily kWh usage rates for the appliances below for the

associated average usage length trends are provided [12][13].

17

Table 1 - - Power Demand Yearly [7][8]

It can be seen from the above summation that at 13.2 kWh per day for 52 weekends per year

that the 1372.8 kWh/yr power demands falls just below the estimated output of 1848 kWh/yr.

12 Blade Design Analysis

12.1 Geometry

The variables assessed for the geometric design and optimization within Prop-ID are: rotor

diameter, chord length, twist and pitch. An initial geometry with preliminary values was

entered as a starting point for the programs iteration methods. To perform the analysis, a

preliminary design point was specified. The required 500W output with a target wind speed of

7m/s was used. Using data from the market analysis, the HAWT was set to operate at 300 rpm,

comparable to existing designs. Aerodynamic data calculated from the family airfoils discussed

was integrated into Prop-ID. The S814 airfoil was set to exist at the first 30% of the blade

length, S812 from 30% to70%, and S813 for the remainder of the blade. Applying this design

point to the base geometry, with the integrated foil data, Prop-ID functions were executed to

manipulate the rotor radius, and chord lengths to reach the specified design point.

Prop-ID concluded that the optimal rotor radius to meet the design point with the given airfoil

data was 4.3 feet. This is a realistic result as the simplified initial calculations expected a radius

of 3.9 feet. Figure 16 illustrates the optimized chord length across the new length of the blade.

This plot shows the tapering of the chord expected of this type of airfoil.

18

Figure 16 - Chord Distribution of Turbine Blade

Figure 17 (twist distribution for the blade) follows the typical profile for a stall regulated

turbine; however, these angles need further optimization as the functions for this procedure

have not yet been successfully run. The twist angles shown represent a typical distribution of

this class of turbine [10]. Example input and output geometry can be seen in Appendix 6.

Figure 17 - Twist Distribution of Turbine Blade

19

13 Performance Analysis

From the results of the geometric analysis, the 2D-Sweep and 1D-Sweep functions were used to

perform an analysis on the rotor performance and aerodynamic characteristic of the blade.

Figure 18 shows that the maximum rotor power coefficient of 46% to occur at 5.6m/s and the

target wind speed of 7 m/s to have an efficiency of 39%. Ideally the peak efficiency should

occur at the target wind speed to maximize the energy captured as wind at 5 m/s does not hold

a significant amount of harvestable energy as illustrated in the Power Curve of Figure 19.

Figure 18 - Rotor Power Coefficient for Varying Wind Speeds

The target is to design the blades to produce 500W at a wind speed of 7 m/s, but the turbine

has an estimated 497 W peak power production at 9.8 m/s. At 7m/s it is estimated that power

production is 415W, 17% lower than required. Further optimization of the design parameters

will be necessary to shift the power curve into the correct position. It is evident that after peak

power is reached, power efficiency and production decrease as wind speeds continue to

increase – this is the result of stall regulation. The power curve does continue to climb but does

not achieve comparable production at high wind speeds.

0.000

0.100

0.200

0.300

0.400

0.500

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r C

oe

ffic

ien

t

Wind Speed (m/s)

Cp vs. Wind Speed

20

Figure 19 - Power Curve for Initial Wind Turbine Design

The tip speed ratio (TSR) is the fraction between the tip speed of the blade and the wind speed.

The TSR versus rotor power coefficient plot shows the range of tip speeds observed by the

blade. Peak efficiency is achieved with a tip speed ratio 6.98 but values of as high as 15 are

seen. Values above 10 are considered high and consideration should be given to centripetal

effects and potential fouling of the blade at the leading edge. Further optimization should

attempt to reduce high TSR values and minimize any detrimental effects.

13.1 Solid Mechanics

Before performing a finite element analysis (FEA) on the actual blade design, it was decided to

perform preliminary stress calculations. This is to gain an approximate estimate of values and to

give a starting point for the finite element analysis evaluation which will be performed in the

coming months. The first step to finding a rough maximum stress value is calculating the lift and

drag forces that will occur on the blade. The maximum coefficient of lift (CL) as specified from

Prop-ID is 1.6 while the maximum coefficient of drag (Cd) was found to be 0.39. These values

are directly proportional to their respective lift and drag forces. The lift and drag forces were

solved using the following formulas:

(Lift Force per unit length) [9]

(Drag force per unit length) [9]

Where:

Ρ = density of air (1.225 kg/m3)

21

U = wind speed (12.5 m/s)

c = chord length (0.22552 m)

This yielded the following lift and drag forces:

The blade has been modeled as a uniform beam cross section which is fixed at one end as

shown in Figure 20Figure 20. Using the distributed loads (Lift and Drag) previously calculated we

can gain a rough estimate of the stresses at the root of the blade. The width and height values

of the beam simulate the initial size of a spar like beam which will run the length of the beam to

act as support for the outer layer. Here it is assumed that this beam will take all of the force

due to lift and drag.

Figure 20 - Preliminary Stress Calculation Diagram

Two moments will occur in this stress evaluation. A moment will occur about the Y-axis in a

negative manner, while a second moment will occur about the Z- axis in the positive direction.

These are calculated by:

22

This yields a Mz = 7.16 Nm and My = -29.38 Nm. Now the moments the maximum stress can be

evaluated using the simplified equation below:

Solving this expression yields a maximum stress of 1.297 MPa. Using similar equations, an

analysis was performed in the event the blades are parked and winds reach 160 km/h. Here the

blades were assumed to be flat plates with the wind acting perpendicular to the blade surface.

The maximum stress at this point was found to be 18.4 MPa. This will be the value we will

use moving forward as it is worst case scenario and Vortex Wind Systems believes that

designing to suit these stress values will provide safe operation of the turbine. For more

information on these calculations please refer to Appendix A5.

It is also important to understand the centripetal force. This is an external force that is required

to make a body follow a curved path. This force acts inwards, towards the centre of curvature

of the path. Figure 21 shows the simplified blade dimensions used in this analysis.

Figure 21 – Simplified Blade Dimensions [14]

The centripetal force can be calculated by:

[14]

23

The area will be an estimation of the area of the airfoil at the root section of the blade. The

rotations per minute (rpm) used is the design rpm which will be the maximum. This is to gain

rough estimate of values and to give a starting point for the finite element analysis evaluation

which will be performed in the coming months. In this case:

A = 1.17x10-2 m

ρ = 1.225 kg/m3

r2 = 1.46 m

r1 = 0.15 m

= 31.41 rad/s

This gives a centripetal force of the blade is found to be F = 14.9 N. So as stated previously the

force due to max winds and assuming the blades are stationary will be used to move forward

with a rough estimate to begin FEA.

14 Finite Element Analysis

Although preliminary stress calculations were performed to evaluate the approximate forces

that will occur during testing of the prototype, it is necessary to take a closer look into the

Finite Element Analysis using SolidWorks. Using the maximum force due to lift and drag, we are

able to find the maximum stress and deflection of the blades. Although the maximum lift and

drag forces do not occur at the same time, it was decided to use both simultaneously as a

safety factor to ensure safety and reliability. The forces used during the analysis were as

follows:

Maximum lift force as pressure: 140 N/m2

Maximum drag force as pressure: 40 N/m2

Aerodynamic moment: 0

Material Yield Strength (ABS M30): 36 MPa

As Figure 22 shows, the base of the blade is fixed on each side. This will be a rigid connection to

the rotor hub. The lift force is then applied to the upwind side of the bald as shown, while the

drag force is shown on the leading edge of the blade.

It was decided to neglect the aerodynamic moment as it was deemed to be very minimal and

would not play a large factor in the Finite Element Analysis. After implementing the above

forces, the maximum von misses stress was found to be 1.149 MPa as shown in Figure 22

below. This value proved to me very close to the initial estimated value calculated which

provided assurance that the blades can withstand the forces witnessed during testing.

24

Figure 22 - Von Misses Stress FEA Model

With a yield strength of 36Mpa the blades have a minimum safety factor of 31. This means at

the highest stress concentration the safety factor will be 31 while all other points along the

blade have even much higher safety factors.

In order be sure the material would withstand the wind forces as previously mentioned, it is

important to understand the deflection of the blades during testing. As shown in Figure 23 the

maximum displacement expected at the given lift and drag forces will be 2.907 mm. This means

the blades should produce with minimal deflection.

25

Figure 23 - Displacement Model FEA

Lastly in order to ensure the safety of Vortex Wind Systems testing team, a fatigue model was

examined. This was a quick examination as it was purely to ensure testing safety therefore an in

depth model was not deemed necessary for prototyping purposes. However as shown in Figure

24 there are no fatigue issues. When the model shows all blue, it means that no fatigue is

present in the model. If there were to be red, yellow or green colours present, further

evaluation would be necessary as this would suggest fatigue issues. For more details on the FEA

report please refer to Appendix A6.

26

Figure 24 - SolidWorks Fatigue Check

15 Optimization

15.1 Approach

The original design approach was to develop a blade that would produce 500W at the average

wind speed. It was decided that this approach would not meet the energy demand of the cabin

– it does not need 500W of power, but a minimum of 1825 kWh. For Vortex Wind Systems,

optimization means that for the given wind distribution the blades should be designed to

harness a minimum 1823 kWh after storage. To do this an accurate statistical model of

Newfoundland wind frequencies was required.

15.2 Weibull Distribution

To develop a more accurate prediction of wind patterns, a probability distribution of wind

speeds based on geographic information was needed. There are two probability distributions

commonly used in wind data analysis: the Rayleigh and the Weibull. The Weibull distribution

uses two parameters and can represent a wider variety of wind distributions (Rayleigh uses one

parameter), and for this reason was used in the analysis.

27

The Weibull probability density function requires the use of the two parameters: k – the shape factor,

and c - the scale factor. The shape factor is approximated as:

[15]

Where:

= standard deviation of wind = mean wind speed

The shape factor is found using:

[15]

The gamma function is defined as:

[15]

These parameters are then applied to the Weibull function:

[15]

Using the built in gamma Weibull functions in excel, the resulting wind distribution can be seen

in Figure 25.

15.3 Method

To effectively optimize the design, it was decided the power coefficient curve should follow the

shape of the wind distribution. The blade was design so peak efficiency would occur near the

most probable wind speeds and place more efficiency on the higher wind speeds as the energy

density has a cubic relationship to wind speed:

28

Where:

ρ = air density

PROPID was used to perform geometry iterations until the power coefficient curve aligned with

the desired characteristics as illustrated in Figure 25.

Figure 25 – Power Efficiency and Wind Distribution

15.4 Blade Geometry

The final blade geometry selected through iterative use of PROPID can be seen in Figure 26 and

Figure 27. The final radial length of the blade is 3.13 feet mounted with a fixed pitch of 2°.

0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

14.00%

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.50

0.00 5.00 10.00 15.00

Win

d F

req

ue

ncy

Cp

Wind Speed (m/s)

Rotor Performance and Wind Distribution

Weibull Wind Distribution

Wind Freq. Data

Previous Model

Current Model

29

Figure 26 - Normalized Chord Lengths for Final Design

Figure 27 - Twist Distribution for Final Blade Design

15.5 Power Output

Using the optimized geometry a new power curve, illustrated in Figure 28, was generated.

Using the derived Weibull distribution, the amount of time per year the blades experienced

each wind speed can be estimated through:

0.00

0.10

0.20

0.30

0.40

0.50

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

No

rma

lize

d C

ho

rd,

c/R

Normalized Radial Position, r/R

Normalized Chord Distribution

-10

-5

0

5

10

15

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Tw

ist

(de

g)

Normalized Radial Position, r/R

Twist vs Normalized Radial Position

30

Figure 28 - Power Output for Optimized Blades

This allows for the annual kWh produced by the blades to be estimated by:

The total annual kWh for the optimised design was estimated to be 4620 kWh. However, this

energy is only useful if it can be stored and utilized later through batteries. It is necessary to

apply a capacity factor to estimate losses associated with the ability to store the energy

effectively. If 40% of the generated energy can be stored, 1848 kWh can be utilized. This value

meets the estimated power demand requirements.

16 Prototype Model

Vortex Wind Systems decided a solid prototype was necessary for testing purposes. The design

philosophy behind the prototype was to meet the following criteria:

Simple to assemble

Strong and reliable

Cost effective

0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

0

100

200

300

400

500

600

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Fre

qu

en

cy

Po

we

r (W

atts

)

Wind Speed (m/s)

Power Output

Weibull

Power Curve

31

Fit within the wind tunnel constraints

It was necessary to create a prototype which can easily be put together, or taken apart as

testing can often be a learning experience. If quick changes were needed, the simplicity of the

assembly proved to be instrumental in minimizing the testing time. This was extremely

important as multiple groups needed to wind tunnel for their testing and wind tunnel time was

not infinite. In order to create a simple model, easy to work with materials such as PVC plastic,

double sided tape as well as rapid prototyping materials was utilized.

The strength and reliability were integral to reduce time in fixing components. This also allowed

for a cost effective solution as no components needed replacement due to failure. The

prototype was designed as a 25% scale of the actual wind turbine design in order to meet the

size restrictions of the wind tunnel.

The prototype consisted of the following components:

Shaft

Bearing and Seat

Generator

Nacelle

End Cap

Rotor Hub

Blades

Tower

Each of components associated cost is provided in following table. Vortex Wind Systems

believes that the prototype was a simple cost effective solution that follows closely to the goals

outlined above.

Table 2 Prototype Component Breakdown

Prototype Part Material Cost

½” Shaft Steel $0.99 ½” Bearing Steel $4.00

12V DC Generator N/A $9.99 Nacelle PVC Plastic $0.33 End Cap ABS-M30 $16.50

Rotor Hub ABS-M30 $47.30 Blades (3) ABS-M30 $59.1

Tower Steel N/A Bearing Seat (2) ABS-M30 $39.00

Total Cost $177.21

32

The end cap, rotor hub, bearing seat and blades were all designed specifically for this prototype

and made using ABS-M30 in the rapid prototyping machine at Memorial University of

Newfoundland (MUN). The ½” shaft was manufactured by Vortex Wind Systems using

equipment provided in the production laboratory at MUN. All other components were

purchased from outside sources. For more information regarding the design of these

components please refer to Appendix A7 where a detailed drawing package can be found.

At this point a full scale cost model is out of the scope of work. Due to design changes that

would occur when moving from a prototype to a full scale model, a cost analysis would be very

inaccurate.

17 Prototype Testing

17.1 Purpose

The purpose of testing a scaled prototype is to validate the theoretical optimized design by

proving that it is capable of producing a predicted power output at a given wind speed.

17.2 Materials

The following materials we used to perform the testing of the wind turbine:

Multimeter

Anemometer

Optical Tachometer

Wind Tunnel

Wire

Electrical Tape

Reflective Tape

17.3 Procedure

A digital anemometer was used to take wind speed measurements. Reflective tape was placed

on one of the blade for the optical tachometer to take RPM measurements. The prototype

generator was connected to a digital multimeter to measure current and voltage outputs to

determine the power being produced at the varying wind speeds.

The prototype was placed in a downstream position aligned with the wind stream inside the

wind tunnel. After activating the wind tunnel, wind speeds were incrementally adjusted by

opening vanes through the wind tunnel’s control mechanism. Wind, voltage, current, and RPM

measurements were taken after each adjustment of the vanes.

33

17.4 Results

Table 3 - Experimental Measurements

Wind Speed Voltage (V) Current (mA) RPM Power (W)

6.35 0.12 8.00 23 0.001 7.70 0.20 20.00 76 0.004 8.25 1.12 70.00 313 0.078 9.00 1.85 163.00 516 0.302 9.70 2.24 194.00 625 0.435

10.10 9.10 5500.00 2553 50.050

17.5 Discussion

Table 3 shows the results from the prototype testing. It was observed that the power output at

the lower wind speeds and lower RPM values results in low power outputs. This is due to the

nature of the generator obtained as it will only produce usable power outputs 1000 and 3300

RPM. However, 50.05 W was generated by the prototype when the wind speed reached 10.10

m/s at 2553 RPM. It can be seen in Figure 28 that this is also the theoretical maximum output.

However, at this rotational speed the TSR is high with a value of 62.93. Cp is inversely related to

the TSR and has a significant effect on expected power when the TSR is high. An estimate of Cp

= 0.05 was used based on observations from PROPID results. The theoretical output of 90 W for

the scaled blades was calculated through:

[15]

From the data table obtained for the generator used it is estimated that it is 65% efficient at

2553 RPM. Other losses can be contributed to fabrication issues: surface finish, bearing friction,

transmission efficiency, and alignment. Combining the losses from the generator and

fabrication as shown in Figure 29 is shown that they can close the gap between the theoretical

output and the measure experimental results. These results show that at this wind speed the

prototype validates the theoretical model.

34

Figure 29 - Prototype Power Output of Optimized Blades

18 Composite Drive Shaft Design

18.1 Product Description and Technical Requirements

To deliver the wind energy harnessed by the blades to a generator, a drive shaft must be

engineered to transmit the energy. The turbine has been shown to generate 12 Newton meters

(N*m) of torque. With a known torque it is possible to design a shaft composed of a composite

material to deliver energy captured without failure from the induced shear stresses. The goal is

to determine a minimum wall thickness for a given diameter shaft that is large enough to

withstand the induced load. This drive shaft should also provide resistance to the outdoor

environmental operating conditions while also being cost effective as this component will affect

the product cost.

19 Material Selection

For the purposes of this project, the material selection was limited to three composite

materials: Glass, Kevlar, and Carbon Fiber Epoxies. Considering the constraints of problem

(shear stress tolerance, cost, and weather resistance) the Glass Epoxy was selected for its

stiffness in shear, it’s resistance to weather elements (low corrosion rate), and is the most cost

effective of the three. Other advantages of choosing E-glass are that it is light weight and easily

shaped. The following are the material properties used in the analysis of the shaft:

El= 1250 MPa

Ey = 35 MPa

0

10

20

30

40

50

60

70

80

90

100

Experimental Theoretical

Po

we

r (w

atts

)

Prototype Power Output

Other Losses

Generator Efficiency

Measured

35

Glt = 4500 MPa

Vxy = 0.3

It has been recommend that for the stacking sequence of the composite layers it should contain

10% of 0 and 90 degree laminate, and 80 percent of ±45 degree angle-ply. Also, to minimize

coupling effects and to simplify calculations the stacking sequence should be symmetric. The

±45 degree angle-ply E-Glass laminates provide the greatest resistance to shear; these will be

place on the inside and outside of the stacking sequence to resist the maximum shear stress

due to the torsional moment.

19.1 Design and Analysis

The primary concern for the drive shaft is the failure of the shaft due to shear stress. The shear

stress experienced by the circular shaft a function of the enclosed cross sectional area. For this

reason, the shaft will be designed to be hollow. The allowable shear stress in a hollow shaft is:

(1)

Where:

T = Applied Torque

r = Shaft Radius

t = Wall Thickness

The maximum allowable shear stress for a [010%, 9010%, ±4580%] configuration is 86 MPa [16] and

applying a factor of safety of 8, the τall becomes 10.75 MPa.

From a separate study, the torque delivered by a 500W wind turbine’s rotor is 12N*m, and to

match relative sizes of the rotor’s hub the shaft diameter was selected to be one inch. Using

equation (1) the minimum required wall thickness is 1.1015 mm. Each layer is 0.13 mm thick

[16] so a minimum of 9 layers is required. However, due to the necessary minimums of each

layer type and the need for symmetry, 12 layers in a [±454, 90, 0]s will be used.

36

Applying Classical Lamination Theory, and employing MATLAB code to perform the calculations

to determine the shear strain, the layers were evaluated for failure. The results showed that

the stresses observed by each laminate are well below the allowable stresses. The thickness

and stacking sequence are adequate and final geometry can be seen Figure 30. Calculations

and MATLAB code can be found in Appendix A8 and Appendix A9 respectively.

19.2 Process Selection for Manufacturing

There are two methods that can be used to produce the necessary drive shaft, Pultrusion and

Filament Winding. A primary disadvantage of Pultrusion its high cost, so it is eliminated as an

option for fabrication due to the design constraint of cost efficiency. Filament winding can be

used to produce cylindrical products such as drive shafts. Continuous, resin-impregnated fibers

are wound on a rotating mandrel in a predetermined pattern; this provides a high level control

over fiber placement. Fiber tension is controlled using the fiber guides or scissor bars located

between each strand roving and the resin bath. In the wet method, the fiber picks up the low-

viscosity resin either by passing through a resin bath. In the dry method, the reinforcement is

impregnated with resin prior to winding. Integral fittings and vessel closings can be wound into

the structure if necessary. When sufficient layers have been applied, the composite is cured on

the mandrel and the mandrel is removed [17]. This process is illustrated in Figure 31.

Figure 30 – Radial Geometry of Drive Shaft

37

Figure 31 - Schematic of Filament Winding Process

19.3 Cost Analysis

It is important to perform a cost comparison in order to understand the cash benefit to

choosing E-glass over conventional shaft materials such as steel. Figure 1 shows the cost

differences between several materials with the sizing of 1” diameter, 12” length and 1.56 mm

thickness in the case of the composite materials. For the case of non-composite materials a

solid driveshaft was considered.

Table 4- Cost Comparison of non-Composite Materials

Material Type Cost of Shaft

Black Oxide Coated Steel Shafts [18] $22.65 Steel Shafts [18] $14.65 Nitride Coated Steel Shafts [18] $19.23 Chrome Plated Steel Shafts [18] $17.87 Type 303 Stainless Steel Shafts [18] $76.13

The composite shaft has a volume of 3.56x10-5 m3. Therefore at an approximate at a density of

2080 kg/m3 and a cost of approximately 3.03$/kg [19]:

*0.6

38

The volume of the fiber is 60 percent of the total volume while the volume of the resin is the

remaining 40 percent. Now using the cost of 105A – Epoxy Resin ($41.29/qt,

$43,630.65/m^3)[20] we get the cost of resin for our shaft:

Although not taking into account the manufacturing cost at this point, the cost of material for

E-glass fiber is much cheaper than any option. As you can see from Error! Reference source not

ound., E-Glass is the cheapest option in the realm of composite materials therefore this choice

proves to be the most cost effective.

Table 5 - Differences in composite materials [21]

19.4 Drive Shaft Recommendations

It was successfully shown that the 1 inch diameter driveshaft with a 12 layer, 1.56mm thick

wall, can easily support the induced stress. The observed stress in each laminate is much

smaller than the allowable stress probably as a result of the additional layers to achieve

symmetry and thus increase the thickness of the wall more than required. The disadvantage of

using this method is the increase in the volume of the final product. However, the weight and

cost of the shaft is very low so the over design of the wall thickness is negligible.

39

Another aspect important to drive shafts, outside of the scope of this project is its fatigue life.

Consideration should be given into determine the life of the shaft. This is typically done

through a series of experiments; however, there may be existing data that could be used to

estimate the life. Also not within the scope of this design are the end fittings that would be

required to attach the drive shaft to the generator and rotor assembly. Depending on the

design, stress concentration can occur and further analysis on the stresses at these locations

would have to be conducted.

20 Project Recommendations

Future work recommended is the implementation of a gearbox. This design could reduce the

TSR while increasing the RPM to the generator. This would create higher power output of the

wind turbine at lower wind speeds and keep the TSR of the turbine blades to lower values to

prevent fouling. It is also recommended that a full scale model be testing in a setting similar to

that mentioned as the cabin setting Vortex Wind Systems is targeting. Before moving to this full

scale it is important to gain further knowledge of the appropriate gearbox, bearing and yaw

mechanisms needed for the full size actual model. None of these were considered for testing

purposes therefore before implementing in an environment with changing wind directions all of

these become important aspects to the wind turbines success. After testing in a realistic setting,

testing data then can be compared to theoretical data and further adjustments to the model

can be made if deemed necessary.

It is also recommended that after design of the full scale model, a total cost to each component

(material, labor, etc) should be found and a market cost of the entire turbine calculated. Using

this cost value a market comparison can be drawn comparing Vortex Wind to other turbine

costs in the range of 500W. If deemed necessary, costs can be re-evaluated and cheaper

methods of production and manufacturing may be needed for blades and other turbine

components.

Lastly, Vortex Wind Systems suggests that a market or seller must be approached and

evaluated. The final design would be recommended to be in the nature of a setup which the

buyer themselves can set up at their cabin or desired location. Therefore a market such as Kent,

Rona or a store of that nature may be the best approach at getting this product distributed.

40

21 Conclusion

Vortex Wind Systems believes that the project was an overall success. During testing, Vortex

found that the prototype produced very close to the estimated value while taking into account

generator efficiency and minor losses. The main goal of the project was the design and testing

of turbine blades and this was successfully completed.

Through the project, stress calculations and finite element added further confidence that the

blade design can withstand loads which may occur during testing. It is believed that when

scaled to the full size model these forces and stresses would scale appropriately and the blades

would still prove to be strong and durable.

The prototyping phase went smoothly and the goals of creating a strong, reliable and easy to

assemble machine were achieved. Testing results were taken and evaluated while changing the

wind speeds in the tunnel to develop as many possible data points.

Vortex Wind Systems believes that with further progress and time allocated towards this

project, a full scale model could be designed and implemented. Strong belief and confidence in

the product has been developed through vigorous calculations, testing and blade optimization.

The Vortex 500W turbine is believed to be an optimal design which could be proved with a full

scale model to make an impact to the cabin turbine market in St. John’s, Newfoundland.

vi

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http://weatherspark.com/. [Accessed 5 02 2013].

[5] "Prototyping Processes," 2010. [Online]. Available: http://www.freemansupply.com.

[6] D. M. Cavcar, "http://home.anadolu.edu.tr/~mcavcar/hyo403/Blade_Element_Theory.pdf," Anadolu

University, School of Civil Aviation , 2004. [Online]. [Accessed 2014].

[7] "Multidisciplinary Design Project," University of Sydney, 1996-2006. [Online]. Available: http://www-

mdp.eng.cam.ac.uk/web/library/enginfo/aerothermal_dvd_only/aero/propeller/prop1.html.

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"http://www2.eng.cam.ac.uk/~hemh/climate/P8_Blade_Design_Student_Handout_2009.pdf,"

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[10] J. McCosker, "Design and Optimization of a Small Wind Turbine," Rensselaer Polytechnic Institute,

Hartford, 2012.

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209804414/Mini_portable_gasoline_generator_500w_4_stroke_with_CE_ISO_EPA.html. [Accessed

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vii

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http://www.concordiaelectric.com/forms/kWh_Usage.pdf. [Accessed 2014].

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power-use. [Accessed 2014].

[15] T. R. A. o. Engineering, "Forces on Large Steam Turbine Blades," [Online]. Available:

https://www.raeng.org.uk/education/diploma/maths/pdf/exemplars_advanced/22_Blade_Forces.pdf.

[Accessed 2014].

[16] J. F. Manwell, J. G. McGowen and A. L. Rogers, Wind Energy Explained, Chichester: Wiley and Sons Ltd,

2009.

[17] S. V. Hua and d. Gay, "Composite Materials: Design and Applications, Second Edition," CRC Press,

2007.

[18] P. Mallick, Fiber-Reinforced Composites, Boca Raton: CRC Press, 2008.

[19] "McMaster Carr," [Online]. Available: http://www.mcmaster.com/#rotary-shafts/=ra66vx . [Accessed

27 March 2014].

[20] "Net Composites," [Online]. Available: http://www.netcomposites.com/guide/glass-fibrefiber/32.

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APPENDIX A1

ID Task Name Duration Start Finish

1 HAWT Development 83 days Sun 1/12/14 Fri 4/4/14

2 Front End Engineering and Design (FEED) 27 days Sun 1/12/14 Fri 2/7/14

3 Website Development 15 days Sun 1/12/14 Sun 1/26/14

4 Scope Definition 1 day Thu 1/16/14 Thu 1/16/14

5 Publish Website 0 days Sun 1/26/14 Sun 1/26/14

6 Project Management Plan (PMP) 4 days Sat 1/18/14 Tue 1/21/14

7 Issue PMP 0 days Tue 1/21/14 Tue 1/21/14

8 Research and Development 15 days Tue 1/21/14 Tue 2/4/14

9 HAWT Market Analysis 15 days Tue 1/21/14 Tue 2/4/14

10 Environmental Study 15 days Tue 1/21/14 Tue 2/4/14

11 Tool Development 15 days Tue 1/21/14 Tue 2/4/14

12 Prototype Methods 15 days Tue 1/21/14 Tue 2/4/14

13 Existing Blade Design Technology 15 days Tue 1/21/14 Tue 2/4/14

14 Presentation and Report 1 Development 9 days Wed 1/29/14 Thu 2/6/14

15 Present and Submit Report 1 1 day Fri 2/7/14 Fri 2/7/14

16 Detailed Design 47 days Sat 2/8/14 Wed 3/26/14

17 Blade Elemental Theory 26 days Sat 2/8/14 Wed 3/5/14

18 FLUENT Analysis 26 days Sat 2/8/14 Wed 3/5/14

19 Power Ouput Evaluation 23 days Tue 2/11/14 Wed 3/5/14

20 Presentation and Report 2 Development 10 days Tue 2/25/14 Thu 3/6/14

21 Present and Submit Report 2 0 days Fri 3/7/14 Fri 3/7/14

22 Rotor Hub Design 10 days Sat 3/8/14 Mon 3/17/14

23 Drive Train Design 10 days Sat 3/8/14 Mon 3/17/14

24 Main Frame Design 10 days Sat 3/8/14 Mon 3/17/14

25 Prototyping and Testing 26 days Sat 3/1/14 Wed 3/26/14

26 Project Close Out 9 days Thu 3/27/14 Fri 4/4/14

27 Final Report and Presentation Development 8 days Thu 3/27/14 Thu 4/3/14

28 Present and Submit Final Report 1 day Fri 4/4/14 Fri 4/4/14

1/26

1/21

2/7

3/7

4/4

F T S W S T M F T S W S T M F T S W S T M F T SJan 5, '14 Jan 19, '14 Feb 2, '14 Feb 16, '14 Mar 2, '14 Mar 16, '14 Mar 30, '14

Task

Split

Progress

Milestone

Summary

Project Summary

External Tasks

External Milestone

Deadline

Page 1

Project: Vortex Wind Inc PMPDate: Sun 1/26/14

APPENDIX A2

BrandWind Power

UK

H2.7-500W Wind

Turbine

Wuxi Naier Wind Power

Tech

Guangzhou HY Energy Tech

Rated Power (W) 500 500 500 500Max Power (W) 700 570 550 600Rated Current (A) N/A N/A N/A 10.4KWH/Year N/A N/A N/A 1049Rotor Diameter (m) 2.7 2.7 1.6 1.55

Blade Material Reinforced Fibreglass

Fibreglass Reinforced Composite

Nylon FiberStrengthened LFT-

PP Glass Fiber

# of Blades 3 3 N/A 5Starting Wind Speed (m/s) 3 3 2.5 2.5Rated Wind Speed (m/s) 8 11 10 12Rated Rotational Speed (r/min) 400 600 400 N/AMax Wind Speed (m/s) 40 50 35 50Output Voltage 24V 110/220Vac 24V DC48

Generator Type

3 Phase Permanent

Magnet Alternator

Permanent Magnet

AlternatorN/A

3 Phase Permanent

Magnet

Weight (kg) 131 N/A 11.5 22

Overspeed Protection Auto FurlPassive

Furling Tail Design

N/AElectromagnetic

Brake

Type Up-Wind Up-Wind Up-Wind Up-Wind

HAWT Market Comparison

500W Wind Turbines

600

800

1000

1200 1054.3

699 699

429 95 ice

Price Comparison

0

200

400

1 - Wind power UK

3 - HY Energy 3 - Windmax 4 - Wind Ghost 5 - K P

429.95 Pri

Vortex Wind Systems vs. Com

Shandong HuayaSonar Plus MG-

4540

500 500800 600N/A N/A

500-1500 N/A 1 - http://wind2.5 2.5 2 - http://www

Polyester Resin Fibreglass3 - http://www

3 3 4 - http://www8 3 5 - https://ww

10 8 6 - https://wwN/A 400 7 - https://ww40 20

12-48VDC 24V

Three Phase Permanent

Magnet

Three Phase Permanent

Magnet

45 15

Electromagnetic Brake + Yawing

Auto Furl

Up-Wind Up Wind

Model

Price ($)

437 7 439 08

Komplet Parket

6 - Black Eidtion

7 - White Edition

437.7 356.75

439.08

mpetitors

dandsolarpoweruk.com/wind-turbines/500w-wind-turbine/ w.amazon.com/Home-Wind-Turbine-Generator-5-Blade/dp/B0012L0A5G

w.amazon.com/Windmax-HY400-12-Volt-Residential-Generator/dp/B001CZIHH0/ref=pd_sim_sbs_ w.ebay.com/itm/WIND-GHOST-500W-LOW-WIND-10-BLADES-CLEAR-PROPS-TURBINE-24-Volt-DC-N ww.istabreeze.com/online/index.php?route=product/product&product_id=69 ww.istabreeze.com/online/index.php?route=product/product&path=59&product_id=60 ww.istabreeze.com/online/index.php?route=product/product&path=59&product_id=65

7 - White Edition

439.08

6 - Black Eidtion

1 - Wind power UK

3 - HY Energy

3 - Windmax

6991054.3

Price Comparison

699

4 - Wind Ghost

5 - Komplet Parket

429.95 437.7 356.75

ac_3?ie=UTF8&refRID=0A35NDC6MBA5TVJWG10E NONCOG-PMA-/300982463815

APPENDIX A3

PROP-ID Input file # Stall Regulated Turbine 500W Input File # Basic input MODE 1.0 # wind turbine INCV 0.0 # wind turbine mode LTIP 1.0 # use tip loss model LHUB 1.0 # use hub loss model IBR 1.0 # use brake state model ISTL 1.0 # use viterna stall model USEAP 1.0 # use swirl suppression WEXP 0.0 # boundary layer wind exponent NS_NSEC 10.0 1.0 # number of blade elements/number of sectors IS1 1.0 # first segment used in analysis IS2 10.0 # last segment used in analysis BE_DATA 1 # printout blade element data SH 0.0 # shaft tilt effects RHO 0.0023769 # air density (slug/ft^3) # Geometry HUB 0.04 # normalized hub cutout HH 3.333 # normalized hub height BN 3 # blade number CONE 0 # cone angle of rotor (deg) RD 4.279492 # radius(ft) CH_TW # Normalized chord and twist distribution 0.172918 13.0000 0.155626 8.0000 0.103751 6.0000 0.086459 6.0000 0.064258 4.0000 0.056225 1.0000 0.064258 -1.0000 0.056225 -3.0000 0.048193 -4.0000 0.043229 -5.0000 AIRFOIL_MODE 4 4 s814.pd .24 13. 3 1.600 6 s814.pd .24 13. 3 1.600 6 s812.pd .21 14.3 3 1.180 6 s813.pd .16 9. 3 1.100 6

# airfoil family 1 with 2 airfoils # r/R-location and airfoil index AIRFOIL_FAMILY 4 0000 1 .3000 2 .7500 3 1.0000 4 USE_AIRFOIL_FAMILY 1 # Enforce tip loss model to always be on TIPON # Use the Prandtl tip loss model, # not the original modified model. TIPMODE 2 # Design point: 300rpm, 2 deg pitch, 16 mph DP 1 300 2 16 2 #Specify the peak power (500W) and iterate on the rotor scale NEWT1ISWP 300 0.50 1 40 .1 1 1 999 1 7 999 .3 IDES # Specify the peak power (500W) and iterate on the chord #NEWT1ISWP 300 0.5 1 25 .1 1 1 999 2 1 999 .05 #IDES #NEWT1ISWP 300 0.5 1 25 .1 1 1 999 3 2 999 #IDES #NEWT1ISWP 300 0.5 1 25 .1 1 1 999 3 3 999 #IDES #NEWT1ISWP 300 0.5 1 25 .1 1 1 999 3 4 999 #IDES #NEWT1ISWP 300 0.5 1 25 .1 1 1 999 3 5 999 #IDES #NEWT1ISWP 300 0.5 1 25 .1 1 1 999 3 6 999 #IDES #NEWT1ISWP 300 0.5 1 25 .1 1 1 999 3 7 999 #IDES #NEWT1ISWP 300 0.5 1 25 .1 1 1 999 3 8 999 #IDES #NEWT1ISWP 300 0.5 1 25 .1 1 1 999 3 9 999 #IDES #NEWT1ISWP 300 0.5 1 25 .1 1 1 999 3 10 999 # Initiate design (does some required preliminary work before analysis) #IDES

# Determine the rotor power, Cp, and thrust curves (2D_SWEEP) # # use pitch setting from design point (DP) 1 PITCH_DP 1 # use rpm from design point (DP) 1 RPM_DP 1 # sweep the wind from 5 to 50 mph in increments of 1 mph WIND_SWEEP 1 50 1 2 # perform the sweep 2D_SWEEP # write out data to files # 40 - power curve (kW) vs wind speed (mph) # 45 - Cp vs TSR # 51 - rotor thrust curve WRITE_FILES 40 45 51 # Compute the gross annual energy production # Output the data to file: gaep.dat # # Initial avg wind speed - 14 mph # Final avg wind speed - 18 mph # Step - 2 mph # Cutout - 45 mph # # 100% efficiency # GAEP 14 16 .2 45 # # 15 mph only, 85% efficiency GAEP 14 16 1 45 .85 Report_Start # Report the last GAEP analysis case REPORT_SPECIAL 8 999 999 REPORT_END # Obtain aero distributions along the blade (1D_SWEEP) # PITCH_DP 1 RPM_DP 1 WIND_SWEEP 5 30 5 2 1D_SWEEP # write out # 75 - blade l/d dist # 76 - blade Re dist # 80 - blade alfa dist # 85 - blade cl dist # 90 - blade a dist WRITE_FILES 75 76 80 85 90

# Write out # 95 - chord dist (ft-ft) # 99 - alfa dist (ft-deg) WRITE_FILES 95 99 #REPORT_BE_DATA 14 0 #REPORT_BE_DATA 14 .25 #REPORT_BE_DATA 14 .5 #REPORT_BE_DATA 14 .75 # Write out the rotor design parameters to file ftn021.dat DUMP_PROPID *

Prop-ID Geometry Output File RHO 0.002377 HUB 0.034584 RD 4.279492 CH_TW 0.172918 13.0000 0.155626 8.0000 0.103751 6.0000 0.086459 6.0000 0.064258 4.0000 0.056225 1.0000 0.064258 -1.0000 0.056225 -3.0000 0.048193 -4.0000 0.043229 -5.0000 AIRFOIL_MODE 4 4 s814.pd 0.240 13.000 3.000 s814.pd 0.240 13.000 3.000 s812.pd 0.210 14.300 3.000 s813.pd 0.160 9.000 3.000 AIRFOIL_FAMILY 4 0.0000 1 1.0000 0.3000 2 0.7000 0.7500 3 0.2500 1.0000 4 0.0000 USE_AIRFOIL_FAMILY 1 DP 1 250.0000 2.000 16.000 2

APPENDIX A4

Figure A2.1 - Cl Vs. Alpha S812



Figure A2.4 - Cl Vs. Cd S812

Figure A2.7 - Cm Vs. Alpha S812



Figure A2.9 – Cl Vs. Alpha Prop-ID Blade Segments

APPENDIX A5

APPENDIX A6

Simulation of BladeTwist03292014SW2013 Date: Friday, April 04, 2014 Designer: Solidworks Study name:Study 2 Analysis type:Static

Table of Contents Description ........................................... 1

Assumptions ......................................... 2

Model Information .................................. 2

Study Properties .................................... 3

Units .................................................. 3

Material Properties ................................. 4

Loads and Fixtures .................................. 5

Connector Definitions .............................. 5

Contact Information ................................ 6

Mesh Information ................................... 7

Sensor Details ....................................... 8

Resultant Forces .................................... 8

Beams ................................................ 9

Study Results ....................................... 10

Conclusion .......................................... 13

Description No Data

Analyzed with SolidWorks Simulation <Label_Simulationof/><Model_Name/> 1

Assumptions

Model Information

Model name: BladeTwist03292014SW2013

Current Configuration: Default Solid Bodies

<L_MdInf_SldBd_Nm/> Treated As Volumetric Properties Document Path/Date Modified

Boss-Extrude1

Solid Body

Mass:0.0329 kg Volume:3.22549e-005 m^3

Density:1020 kg/m^3 Weight:0.32242 N

H:\My Documents\Desktop\Desig

n Project II\25 Per Scale\Solidworks

Model\BladeTwist03292014SW2013.SLDPRT

Mar 30 17:08:14 2014

<L_MdInf_ShlBd_Nm/> <L_MdIn_ShlBd_Fr/> <L_MdInf_ShlBd_VolProp/> <L_MdIn_ShlBd_DtMd/> <L_MdInf_CpBd_Nm/> <L_MdInf_CompBd_Props/> <L_MdInf_BmBd_Nm/> <L_MdIn_BmBd_Fr/> <L_MdInf_BmBd_VolProp/> <L_MdIn_BmBd_DtMd/>


Study Properties Study name Study 2

Analysis type Static

Mesh type Solid Mesh

Thermal Effect: On

Thermal option Include temperature loads

Zero strain temperature 298 Kelvin

Include fluid pressure effects from SolidWorks Flow Simulation

Off

Solver type FFEPlus

Inplane Effect: Off

Soft Spring: Off

Inertial Relief: Off

Incompatible bonding options Automatic

Large displacement Off

Compute free body forces On

Friction Off

Use Adaptive Method: Off

Result folder SolidWorks document (H:\My Documents\Desktop\Design Project II\25 Per Scale\Solidworks Model)

Units Unit system: SI (MKS)

Length/Displacement mm

Temperature Kelvin

Angular velocity Rad/sec

Pressure/Stress N/m^2


Material Properties Model Reference Properties Components

Name: Custom Plastic Model type: Linear Elastic Isotropic

Default failure criterion:

Unknown

Yield strength: 3.6e+007 N/m^2 Tensile strength: 3.6e+007 N/m^2 Elastic modulus: 2e+009 N/m^2 Poisson's ratio: 0.394

Mass density: 1020 kg/m^3 Shear modulus: 3.189e+008 N/m^2

SolidBody 1(Boss-Extrude1)(BladeTwist03292014SW2013)

Curve Data:N/A


Loads and Fixtures Fixture name Fixture Image Fixture Details

Fixed-1

Entities: 5 face(s) Type: Fixed Geometry

Resultant Forces Components X Y Z Resultant

Reaction force(N) -0.617857 -1.82537 -0.000199124 1.9271 Reaction Moment(N·m) 0 0 0 0

Load name Load Image Load Details

Pressure-1

Entities: 1 face(s) Reference: Face< 1 >

Type: Normal To Plane Value: 140 Units: N/m^2

Pressure-2

Entities: 1 face(s) Reference: Face< 1 >

Type: Along Plane Dir 1 Value: 40 Units: N/m^2

Connector Definitions No Data


Contact Information No Data


Mesh Information Mesh type Solid Mesh

Mesher Used: Curvature based mesh

Jacobian points 4 Points

Maximum element size 0 in

Minimum element size 0 in

Mesh Quality High

Mesh Information - Details Total Nodes 13641

Total Elements 7864

Maximum Aspect Ratio 8.8328

% of elements with Aspect Ratio < 3 92.9

% of elements with Aspect Ratio > 10 0

% of distorted elements(Jacobian) 0

Time to complete mesh(hh;mm;ss): 00:00:03

Computer name: lenovo27


Sensor Details No Data

Resultant Forces

Reaction Forces Selection set Units Sum X Sum Y Sum Z Resultant Entire Model N -0.617857 -1.82537 -0.000199124 1.9271

Reaction Moments Selection set Units Sum X Sum Y Sum Z Resultant Entire Model N·m 0 0 0 0


Beams No Data


Study Results Name Type Min Max Stress1 VON: von Mises Stress 0.00013976 N/m^2

Node: 1359 1.1499e+006 N/m^2 Node: 647

BladeTwist03292014SW2013-Study 2-Stress-Stress1

Name Type Min Max Displacement1 URES: Resultant Displacement 0 mm

Node: 1 2.9068 mm Node: 83


BladeTwist03292014SW2013-Study 2-Displacement-Displacement1

Name Type Min Max Strain1 ESTRN: Equivalent Strain 1.49048e-007

Element: 2192 0.000398964 Element: 7047


BladeTwist03292014SW2013-Study 2-Strain-Strain1

Name Type Fatigue Check1 Fatigue Check Plot


BladeTwist03292014SW2013-Study 2-Fatigue Check-Fatigue Check1

Conclusion


APPENDIX A7

1.00 1.00

.25 #10-24

#10-24 .30

3.75

1.00

7.13°

.50

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OF<INSERT COMPANY NAME HERE>. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OF<INSERT COMPANY NAME HERE> IS PROHIBITED.

PROPRIETARY AND CONFIDENTIAL

NEXT ASSY USED ON

APPLICATION

DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONALANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL

INTERPRET GEOMETRICTOLERANCING PER:

MATERIAL

FINISH

Steel

Standard

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME Vortex Wind SystemsTITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: 2:1

UNLESS OTHERWISE SPECIFIED:

SJG 11-Mar-14

Tapered Shaft

SHEET 1 OF 1

VWS-001DO NOT SCALE DRAWING

R1.00

R.453

.547 TYP

.967 .467

1.41

.25

.30

NOTE:TWO OF THESE NEEDED IN ASSEMBLY, TOP AND BOTTOM.

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1



NEXT ASSY USED ON

APPLICATION



MATERIAL

FINISH

ABS-M30

Standard

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


SIZE

BDWG. NO. REV

WEIGHT: SCALE: 2:1


SJG 11-Mar-14

Bearing Seat

SHEET 1 OF 1


.22

.50

1.00

.50

.25

1.00 .31

.90 TYP 1.20 TYP

.47 TAPERED TO 0.22 OVER 1" THICKNESS

R.16 TYP

1.38

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1



NEXT ASSY USED ON

APPLICATION



MATERIAL

FINISH

ABS-M30

Standard

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


SIZE

BDWG. NO. REV

WEIGHT: SCALE: 1:1


SJG 11-Mar-14

Rotor Hub

SHEET 1 OF 1


R1.00 .18

2.36

6.00

1.18

NOTE:THE TOP AND BOTTOM PART OF NACELLE BOTH CONSIST OF THIS DESIGN.

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1



NEXT ASSY USED ON

APPLICATION



MATERIAL

FINISH

PVC Plastic

Standard

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


SIZE

BDWG. NO. REV

WEIGHT: SCALE: 1:2


SJG 11-Mar-14

Nacelle

SHEET 1 OF 1


R1.18

.25 .48

1.57

1.97

2.36

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1



NEXT ASSY USED ON

APPLICATION



MATERIAL

FINISH

ABS-M30

Standard

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


SIZE

BDWG. NO. REV

WEIGHT: SCALE: 1:1


SJG 11-Mar-14

Nacelle Cap

SHEET 1 OF 1


1.00 .50 .50

.57

.05

16.00°

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1



NEXT ASSY USED ON

APPLICATION



MATERIAL

FINISH

ABS-M30

Standard

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


SIZE

BDWG. NO. REV

WEIGHT: SCALE: 1:2


SJG 11-Mar-14

Blade

SHEET 1 OF 1


.75

23.00

2.00 7.80

5.50

6.00

.25 TYP

.75

C

1.20

.60

.125 TYP

DETAIL C SCALE 1 : 2

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1



NEXT ASSY USED ON

APPLICATION



MATERIAL

FINISH

Steel

Standard

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:


SIZE

BDWG. NO. REV

WEIGHT: SCALE: 1:8


SJG 11-Mar-14

Turbine Tower

SHEET 1 OF 1


NUMBERPART

Information in this drawing is provided for reference only.

http://www.mcmaster.com

1 3/8"

1/2" +0.005-0

+0 -0.0005 7/16" +0

-0.005

6384K74Steel

Double-Sealed Ball Bearing© 2010 McMaster-Carr Supply Company

http://www.mcmaster.com

APPENDIX A8

APPENDIX A9

Vortex Wind Systems - Weebly

Documents

Transcript of Vortex Wind Systems - Weebly