Design and Fabrication of Small Wind Turbine for Power Generation

This project involved designing and fabricating a small wind turbine for power generation. The project objectives included proposing a design for the turbine, identifying the correct blade shape, setting up experiments, determining size and efficiency, receiving external electrical connections, generating power, and comparing results. The project group consisted of multiple team members, and my responsibilities included designing the helical savonious rotors, connecting the turbine blades with the shaft, and fitting the DC generator. The project faced issues with blade shape and blade attachment, which were solved by using spiral involute blades and 120-degree dividing gaps. My contribution to the project was designing the smaller power turbine for proper generation of power.

CE 2.1 Project Information
Name of the project: Design and Fabrication of Small Wind Turbine to Generate
Electric Power
Location of the project: Please fill
Project Duration: Please fill
Organization: Please fill
Role and Designation during the time: Team Member of the project
CE 2.2 Project Background
CE 2.2.1 Characteristics of the project
This project was the second major project in my electrical engineering career. Small
wind turbine can be defined as the specific wind turbine that is being utilized for the micro
generation as being opposed to the larger commercial wind turbines. These are majorly found
in the wind farms with high output of individual power. The significant range from less than
1000 watt or 1 kW eventually turbines up to around 300 kW. During this project, I designed
and fabricated the small wind turbine for the purpose of generating power. I investigated that
the smaller scale turbines have their blades usually from 1.5 meters to 3.5 meters in diameter
and noticed that around 1 to 10 kW of electricity is being produced at the optimal wind speed.
Some of the units are subsequently designed for being extremely lightweight and hence
enabling sensitivity to the smaller wind movements as well as the rapid response to wind
gusts. In this particular project, I have undertaken the savonious wind turbine for designing as
well as generating power. I had to design an exhaust fan in my project, since I work in

commercial kitchen. I implemented safety precautions within the site and then developed
healthier atmosphere by the proper enforcement of rules, regulations and procedures.
Therefore, I have researched and documented the design and fabrication of a smaller wind
turbine with the type of vertical axis and having a potential to generate power. Moreover, in
this project work, I have taken the blade shape as spiral involute.
CE 2.2.2 Objectives developed for the project
Small wind turbine with vertical axis comprises of the main rotor shaft that eventually
run vertically. The most significant advantage of this type of turbine is that the gearbox and
the generator could be easily placed at the bottom and this helps the turbine in not requiring
any support from the wind. While working on this project, I have identified that the spiral
involute shape of the turbine blade is required for the proper power generation. Therefore, in
order to complete my project and generating power by designing a small wind turbine, I have
developed the following objectives:
 To propose a design for the small wind turbine with the help of designing software.
 To identify the correct shape of our turbine blade.
 To set up the experiment to be undertake by me and my team.
 To determine size and efficiency of the smaller wind turbine for providing perfect
output to the project.
 To receive external electrical connections from the project and utilize this in
designing the exhaust fan.
 To generate power with the help of my designed smaller wind turbine.
 To check the results with the by comparing with the other experiment results.

CE 2.2.3 My area of work
I had been appointed as an electrical engineer in this project. Since, I had to design a
small wind turbine within the exhaust fan, I researched and studied several books, conference
papers, journals and past researches, which are absolutely relevant to the vertical axis
savonious wind turbine. As I was experienced in electrical projects and had executed some of
the most important projects in my engineering career, I investigated that the savonious wind
turbines are considered as of the simplest and most utilized turbines that consists of a
savonious wind rotor. I even checked that the savonious wind rotor is one of those vertical
axis wind turbines. I also provided significant suggestion to use the spiral involute shape of
the turbine blade for getting a better solution during the generation of power. Moreover, I was
also responsible for checking the power required in this project, which was of 300 kW and
even carried out the significant experimental investigation to study about the vertical axis
wind turbine or savonious wind turbine. My other area of work was to calculate the design
results of my exhaust fan in each and every dimension. Being a skilled electrical engineer, I
even assisted my project leader in this project.

CE 2.2.4 Project Group
Figure 1: People involved in the project
CE 2.2.5 My responsibilities throughout the project
During the project, I was assigned for the designing of helical savonious rotors within
any open jet wind tunnel. There is a lower aerodynamic efficiency present in these wind
rotors. I examined the previous results, and noted that the helical rotors with the shafts
comprise of low power coefficient than all the helical rotors that do not have any shaft. I was
also responsible for comparing the savonious rotor with separate geometries. I even gave
suggestion to use spiral involute for our turbine blade and to check that the optimum number
of blades is two for the savonious rotors whether it is single or in two or three stages. My next
responsibility involved connecting the three involute spiral wind turbine blades with the
respective turbine shaft at around 120 degree dividing gaps. I even fitted the smaller DC
generator to the supporting column.

CE 2.3 Distinctive Activity
CE 2.3.1 Comprehending the Theory of Project
The conventional savonious wind rotor comprises of blades that are formed from two
half cylinders within rotation in the vertical axis with or without the gaps in between.
Figure 2: Direction of torque affection on the rotor blades
This savonious turbine eventually works for the difference within forces that are being
exerted on every blade.
The height of the turbine blade was 786mm and the thickness was of 1.5mm. I have
used T-6 tempered aluminum material. For the shaft, the material was mild steel and diameter
was of 19mm. The outer circle diameter of my turbine was of 560mm and that of inner circle
was of 30mm.
CE 2.3.2 Engineering knowledge and skills applied in the project
The engineering skill of circuit designing helped me in designing the design of the
smaller wind turbine in the exhaust fan. Moreover, I had immense knowledge of motor
related application. Since, DC generator was applied here, motor related knowledge was
highly required and hence I was successful in fitting the DC generator perfectly. The next
knowledge required in this project was about the power consumption guidelines and even
regarding EMF regulation. This knowledge was needed for understanding the amount of

power to be generated from the wind turbine. I have undertaken the maximum power of about
300 kW in this project. Next, I have applied the skill of digital analog PLC design and
transformer related core mechanism and application.
CE 2.3.3 Accomplishment and Task Performed
The power that our rotor could extract was less than the actual available. The rotor
sheet area was calculated by
The total power available at 4m/s was
With the help of spiral involute blade, around 30% power output was being improved
and hence I considered structural as well as electrical variables.
CE 2.3.4 Identified issues and their solutions
2.3.4.1 Issues
There were a couple of issues that I have faced in this specific project. The first and
the most important and significant issue faced here was while selecting the blade shape of the
wind turbine. Since this was a vertical axis turbine, the blade should have been selected
properly. In the beginning, we have selected the shape of sheepsfoot. However, due to the
straight front edge as well as the dull black spine, the curves were completely down to meet

the straight edge and making the false point. Thus, our wind turbine was not successful in
generating power properly. The second issue that I have faced in this project was while
connecting the three involute spiral wind turbine blades with the respective turbine shaft. We
had taken 360 degree dividing gaps in the beginning of the project and hence our project was
giving proper results.
2.3.4.2 Solutions
I suggested for the first issue to use spiral involute blade shape in our small wind
turbine. The involute blade consists of the feature where the centre distance between two
gears is extremely little and this helps to change the center distance of the gear torque
transmission without even affecting the turbine. For the next issue, I suggested to use 120
degree dividing gaps. This would be helpful in connecting the blade attachment with the top
of the centralized mast bearing. Moreover, this dividing gap helped us in connecting to the
driving rim.
CE 2.3.5 Plan to produce creative and innovative work
While reviewing as well as analyzing the previous researches on the self compacting
concrete, I have made the significant plan to produce the most creative as well as innovative
work. Being a responsible team member of the project, I made sure that I have a complete
idea regarding the previous experiments and their results.
CE 2.3.6 Collaborative Work
I have successfully worked with all of my team members and project supervisor to
efficiently and effectively completing the designing and fabrication of small wind turbine for
generating power. For the issues faced in this project during the process of fabrication, I have
even discussed the same with my project team for solving these issues with higher
efficiencies.

CE 2.4 Project Review
CE 2.4.1 Project Overview
I have successfully designed and fabricated the smaller wind turbine. This turbine had
the capability to generate proper power and even fitting a supporting DC generator for the
project. I made the design with such an efficiency that it can generate maximum range of
300kW power. I have designed a savonious wind turbine in this project.
CE 2.4.2 My Contribution to work
My main contribution to the work was to design the smaller power turbine for proper
generation of power. Before successfully completing this project, I have used my core
knowledge and skills of electrical engineering to bring out perfect and error free results. I
even helped my team members in this project to clear their doubts.