Mechanical Engineering Project: Design of Portable Wind Turbine CE 2.1

This report details a student's project focused on the design and implementation of a portable wind turbine. The project aimed to create an efficient and easily transportable small-scale energy generation system. The student designed a 400W wind turbine prototype, including blade optimization, airfoil selection, and simulations using TurbSim Software. The report covers the project's objectives, the student's responsibilities, and the engineering knowledge applied, including gearbox design, blade geometry, and structural analysis. Issues encountered, such as bearing placement, and their solutions are also discussed. The project results demonstrate the turbine's output at various wind speeds and loading conditions, with a maximum efficiency of 21%. The report concludes with a review of the project's overview and the student's contributions, highlighting the successful implementation of the portable wind turbine design.

Career Episode 2
Competency
Demonstration Report

CE 2.1 Project Information
Name of the project : Design of portable wind turbine
Location of the project : [PLEASE FILL]
Project Duration : [PLEASE FILL]
Organization : [PLEASE FILL]
Role and Designation : Team Member
CE 2.2 Project Background
CE 2.2.1 Characteristics of the project
Through this project, I have focused on providing innovative solutions for the energy
cultivar ions and small scale energy generation processes. Therefore, in this project, I have
proposed an enhanced solution for the small size portable energy development system. During
this project, I have developed the design and prototype model for the 400W wind turbine. In
addition to that, I have provided the portable version of the wind turbine required for the
generating electrical energy using the flow of wind. In this project, I have developed the
prototype of the wind turbine with appropriate metals while conducted the testing of the wind
turbine using the wind tunnel. Through this project, I have aimed at providing efficient and
enhanced design for the wind turbine for increasing the performance and effectiveness of the
proposed model.
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CE 2.2.2 Objectives developed for the project
For developing the design of the wind turbine, I have developed the appropriate objective
for developing the portable prototype model for the implementation of the wind turbine. Through
the project I have focused on achieving considerable safety, and enhanced performance of the
wind turbine that can be easily portable by the users. Therefore, for the successful completion of
the undertaken project, I have developed the following objectives:
 To develop the prototype model for the wind turbine;
 To develop the appropriate design criteria for the portable wind turbine;
 To define the working principle for the wind turbine;
 To evaluate the performance of the proposed model of the wind turbine;
 To develop the required performance measurement of the wind turbine;
 To select the appropriate design of the airfoil;
 To simulate the airfoil of the wind turbine;
CE 2.2.3 My area of work
I have worked in this project as a team member for the design and implementation of the
portable wind turbine. I have evaluated the various characteristics of the wind turbine. In
addition to that I have evaluated the performance criteria for developing the accurate design and
dimension of the wind turbine. Apart from that I have simulated the loads and force acting on the
blades of the wind turbine. In addition to that, I have used TurbSim Software for simulating the
developed wind turbine model and the forces acting on it.
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CE 2.2.4 Project Group
Figure 2.1: Team Member Associated with the project
CE 2.2.5 My responsibilities throughout the project
In this project, I had the significant responsibility of developing the prototype model for
the portable wind turbine. Apart from that, I have determined the appropriate specification and
configuration of the features and size of the wind turbine. Apart from that, I have optimised
blade with various iteration process. Moreover, I have worked in this project for improving the
performance and optimisation of the wind turbine. In addition to that, I took more responsibility
in developing the prototype model and simulating the load analyses.
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CE 2.3 Distinctive Activity
CE 2.3.1 Comprehending the theory of the project
Figure 2: Block Diagram for the system
The portable wind turbine is powered with three bladed horizontal axis upwind turbine
(HAWT), variable speed , and regulated power supply. In this project, I have focused on
developing a small sized portable wind turbine having variable speed. I have chosen three bladed
rotor for minimizing the blade length and top oscillation. Apart from that, I have selected HAWT
configuration for providing better efficiency of the vertical axis of the turbine during the low
wind characteristics. Apart from that, in order to differentiate the proposed wind turbine in this
project, I have implemented a shrouded rotor. Through this, I was able to increase the safety of
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the turbine while increasing the performance efficiency. In addition to that, I have provided a
collapsible design of wind turbine for maximizing the portability of the wind turbine.
CE 2.3.2 Engineering knowledge and skills applied in the project
I have worked in this project for the development and implementation of the wind turbine
prototype model. I have tried to keep the configuration and electromechanical property of the
wind turbine that are available in the market. I have developed a custom build Gearbox having
the gear ration of 4.55:1 for this project. I have used blade optimisation for combining various
twists, chord, rotor during the design of the blade. From the blade combination, I have selected
the blade geometry having the highest performance. At the initial level, I have tested the selected
design for the structural and aerodynamic performance with the application of laser sintering. For
improving the tip deflection and the structural quality of the turbine, I have increased the chord
length along the root and span of the structural margin. Through these modifications, I was able
to increase the life cycle cost, durability, manufacturability and safety of the wind turbine.
In this project, I have determined the mechanical power of the proposed system with the
multiplication of the rpm and the mechanical power output at various wind speed. Ii have
observed that the mechanical power of the mill increases with the increase of the wind speed.
The proposed turbine provides 1.7 W of energy with the constant speed of 4 m/s. The increased
in the wind speed from 4m/s to 5m/s has resulted in the increase of mechanical power.
Furthermore, I have observed that the value of the mechanical power was kept at 65% with
variable wind speed for the maximum angular speed.
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CE 2.3.3 Accomplishment and task performed
I have carried out the detailed analysis and review of the past studies, books and journals
for determining the appropriate design for the wind turbine. I have determined and evaluated the
appropriate design for the airfoil while utilising the Reynolds number for the laminar separation
of the wind turbine blade. In addition to that, I have worked for improving the structural analysis
of the wind turbine. Apart from that, I have conducted the appropriate calculations required for
the handle lads and shafts used in the wind turbine.
CE 2.3.4 Identified issues and their solutions
Issue: While designing the drive train components of the wind turbine, I have used single
step parallel shaft gear drive for providing power to the wind turbine. In the design module of the
wind turbine blade, I have provided load on the axial thrust and bearing support of the wind
turbine. After the implementation of the turbine blade, I have faced significant issue in the design
of the wind turbine. I have observed that the placement of the bearings were not equal for all the
blades. This has negatively impacted the performance of the wind turbine.
Solution: In order to mitigate the solution, I have redesigned the blade of the wind
turbine. In the revised plan, I have employed 50 tooth spur gear and 11 tooth pinion and
equipped them with locking screw and bore hub. I have further housed these gears with 6061
aluminum plates and kept 0.75 inch space between them. Through this I was able to achieve the
appropriate design for the wind turbine.
CE 2.3.5 Plan to produce creative and innovative work
I have provided creativeness and innovation while developing the appropriate design for
the loads of the wind turbine. I have selected Nylon 12 Glass Fiber for developing the prototype
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of the blade design. I have selected Nylon 12 Glass Fiber due to its aerodynamic finish and high
value of Young’s Modulus. I have optimized the design of the blade in such a way that the
moments and forces along the flap and edge critically enact on the blade. Furthermore, I have
used FEM model for analyzing and verifying the deflection of the blade. In addition to that, I
have determined the distributed load over the cantilevered beam as 7.08 N/m. While developing
the appropriate design of the blade, I have considered 0.0025 m as average thickness, 0.02 m as
the average chord of the blade. Furthermore, during the analysis, I have considered that the
distributed load of has direct impact over the blade face used in the wind turbine. Apart from
that, for measuring the dynamic and static blade deflation, I have developed the PATRAN
model.
CE 2.3.6 Collaborative work
I was an integral part of the project team for the development and implementation of the
portable wind turbine. I have worked under the supervision of the project manager and
efficiently carried out the work provided and allocated to me. In addition to that, I have
efficiently participated in the group activities for the design of the wind turbine.
CE 2.4 Project Review
CE 2.4.1 Project Overview
Overview: In this project, I was successful in providing the appropriate design for the
prototype model of the portable wind turbine. The small prototype model has been successfully
tested and validated for efficient operation. In addition to that, I have developed the appropriate
design if the power controls system for tracking the performance of the wind turbine.
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Output: During the testing phase, I have conducted analysis for determining the output of
the wind turbine at various wind speeds and loading conditions. From the testing, I have
observed that 1 W was power was produced with the 40 Ω of load and 4 m.s of wind speed. In
addition to that, the output power of the wind turbine gradually increases with the increase speed
of the wind. In addition to that, the net maximum efficiency of the wind turbine was observed to
be 21% among the constant wind speed of 4 m/s. On the other hand, increasing the speed of the
wind above 4 m/s decreases the efficiency of the system.
CE 2.4.2 My contribution to work
With the application of my technical knowledge, I was able to provide multiple iteration
of the gearbox design and blade for supporting the wind tunnel testing and structural analysis of
the wind turbine. In addition to that I have developed the preliminary design of the wind turbine
for demonstrating the safety efficiency of the turbine design. Through this project, I was
successful in efficiently implementing the appropriate design of the portable wind turbine.
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