ME F315 ADVANCED MANUFACTURING PROCESS FABRICATION PROJECT

GROUP NO 16

Topic - Wind mill water pump project

Members:
1. Amartya Ayushi 2019B2A41467H
2. Vrishan Ananth 2019B3A40595H
3. Krovi Abhinav 2019B4A40914H
4. Rajnish Kumar 2020A4PS2172H
5. Apoorv Awasthi 2019B2A41532H
6. Krish Garg 2019B2A41462H
7. Vaibhav shukla 2019B2A41549H
8. Siddharth Suri 2020A4PS1504H
9. Rohit R Kore 2020A4PS2229H
10. C Manikanth Reddy 2019B3A40739H
11. Rahul Mathew 2019B5A41398H
12. Kshiteej Jaiswal 2019B1A41546H

Introduction
Fossil fuels like coal, oil, natural gas, nuclear energy and wood have always been the primary
sources of energy. The fact that all these sources are constrained and are the primary source of
pollution has prompted development and increased attention to sustainable energy sources with
little to no impact on the environment. Because they are environmentally beneficial and
abundant in nature, wind energy, solar energy, and biomass are the most popular solutions to
the aforementioned issues, according to study and analysis. Wind energy can be produced by
either wind turbines, which provide electrical energy, or windmills, which produce mechanical
energy that is utilised directly on machinery, such as a water pump and a grinder. Our project's
primary goal is to create a windmill, so we will keep our focus on windmills that can pump water.
Based on the axis around which they rotate, windmills can be divided into two basic categories.
When using a horizontal axis, the primary rotor shaft runs horizontally. If the rotor has to face
the wind, a wind vane and servomotor are attached. The primary rotor shaft of a vertical axis
motor runs vertically. Depending on the desired firmness, the rotor assembly may include two or
more blades.
Literature Review
The rise in the price of fossil fuels has substantially influenced the development of more
affordable, environmentally friendly green energy sources. Wind energy is the main resource in
this category.
Wind energy can be produced by either wind turbines, which provide electrical energy, or
windmills, which produce mechanical energy that is utilised directly on machinery, such as a
water pump and a grinder.

Future projections of the contribution of renewable energy stand at With a 17% share of the
world's consumption of renewable energy, hydroelectric power leads the pack. Wind power isn't
far behind with a 14% share. Horizontal axis wind turbines, of which the 3-blade form is most
usually employed, are the main source of wind energy. Numerous studies have shown that
stronger wind speeds exist at elevations outside the range of the present wind turbines, despite
the wind turbine holding the title of the most widely used approach.

The placement of a windmill has a significant impact on its viability. The location must have
enough wind to propel the windmill and be clear of any obstacles that can stir up turbulence.
The wind speed for a certain place is not constant, so it is important to investigate the site's
climate for at least a year and record it on a wind map before determining whether it is suitable.

Compared to its predecessor, offshore wind energy is more advanced and able to generate
more power. Today, wind energy is a more dependable source of electricity. It is one of the
sources of electricity that is expanding the quickest and is thought to have the capacity to supply
all of the world's electricity needs.

Despite the fact that wind power production systems have significantly improved in size,
capacity, and design, it has been impossible to create a perfect system due to the wind's
unpredictable behaviour, which depends on its direction and reduces a system's efficiency.

Regarding the connection between documented health impacts and wind turbines, particularly in
terms of audible and inaudible noise, debate is still ongoing. In order to limit or avoid complaints
from or potential affects on persons living close to wind turbines, minimum setback distances
have been developed everywhere. To inform their decisions, those interested in this topic use
two different informational sources: popular literature and the internet as well as scientific peer-
reviewed studies published in scholarly journals.
Objective
The main goal of this project is to calculate the power from wind, a sustainable energy
source. A windmill should also be designed with its essential traits in mind. A further
goal of this research is to put into practise and use the principles of engineering.
However, there are other goals, which are:-

● Create a windmill using sustainable materials to generate electricity that will

reduce pollution.
● Reduce the price and energy required to pump water.
● Discover the benefits and drawbacks of windmills.
● Compare the power generated by a windmill in theory and in practise.

Theory

Definitions

● Power Coefficient -
Ratio of actual power generated to theoretical power is called Power coefficient.

Momentum is Mass * Velocity

So a change in mass or velocity will affect power generation
● Swept Area
This area of air surrounds the wind turbine or windmill while it is in motion and works
with the rotors to create the rotational motion. The swept area of a horizontal axis wind
turbine (HAWT) is circular. The swept area, on the other hand, is rectangular for a
Vertical Axis Wind Turbine (VAWT) with straight blades.
It is Calculated by

As =Swept Area in m^2

D = Root Diameter in m

● Tip Speed Ratio, λ

The Tip Speed Ratio (TSR) is a crucial element in the design of wind turbines. TSR
stands for the ratio of wind speed to the speed of the blade tips on wind turbines. The
blades spin more quickly the farther they are from the center.

The tip speed ratio is zero when the windmill is stationary. This suggests a stuck rotor.
This occurs when the torque generated by the wind is insufficient to overcome the load's
resistance. The wind angle that the blades "see" will be 450 when the tip-speed ratio is
1, which denotes that the blade tips are travelling at the same speed as the wind. The
tips are moving twice as fast as the wind at a tip speed ratio of 2, and so on.
 Based on empirical findings, the ideal tip speed ratio for a windmill with N blades to
produce maximum power extraction is given by

● Cut In Speed
The wind speed at which windmill turbine's blades begin to spin and produce power is
known as the cut-in speed.

● Rated Power
Up until a limit known as the rated speed, which is reached as wind speeds rise, more
electricity is produced. The turbine's maximum, or rated, power is produced at this time.

● Cut Out Speed

The wind speed at which the turbine must be turned off in order to protect the machinery
is known as the cut-out speed.

● Torque Coefficient, Ct
The torque produced by a particular size of rotor in a given wind speed is measured non-
dimensionally by the torque coefficient. This is stated as the ratio of the torque that is
actually produced to the torque caused by the wind's force on the rotors.

Here,
T = The actual torque produced (Nm)
Uo = Wind speed (m/s)
As = Swept Area (m2 )
R – Radius (m)

● Rotor Solidity
The percentage of a windmill's swept area that is made up of solid blades is referred to
as the solidity of a windmill. This is the proportion between the circumference of the rotor
and the total width, or "Chords," of all the blades.

Here,
σ = Rotor Solidity
 N = Number of Blades
AB = Area of one blade (𝑚2)
A𝑠 = Swept Area (𝑚2)

● Thrust Coefficient
The force acting on the windmill is measured non-dimensionally in this way. It is stated
as the proportion between the actual thrust force on the windmill and the average wind
force.

Thrust Force being applied n the wind mill is given by

Here,

TYPES OF WINDMILLS
In general, there are two main types of windmills, and they are categorised according to how the
rotor's axis is oriented. Below is a discussion of the major classifications below:

Vertical Axis Wind Turbine (VAWT)

This can capture wind from any direction since it includes blades that are positioned on a
vertical axis and spin as a result of wind, eliminating the need for a yaw mechanism. Unlike the
horizontal axis, it does not rely on the wind's direction to produce power. They have the benefit
of permitting the deployment or replacement of large equipment since they often work closer to
the ground. However, this has a drawback since less power is produced because winds are
weaker close to the ground. There are two primary VAWT kinds, namely:
Savonius
It utilises drag forces to function like a water wheel. Its straightforward design makes
construction reasonably straightforward and less expensive. It is typically employed in
circumstances where less power is needed. Although it has a greater power to weight ratio and
employs drag to spin itself, it is less strong than other HAWT. The drag force on each blade
determines the mechanism's overall turning torque.

Darrieus
It makes use of blades resembling those seen in horizontal axis wind turbines (HAWT). It
contains two or more curved blades that spin around a central column with the aid of the wind. It
works by producing a lift with the blades' spinning action. The blade is propelled in the direction
of rotation by a change in momentum caused by the wind acting on it. Since this cannot happen
until the blades are already rotating, they need a different method of beginning and are not self-
starting.

Fig 2.1: Darrieus Wind Turbine (Source: Green energy technology, Wortman, 1983)

Horizontal Axis Wind Turbine (HAWT)

It features blades that resemble aeroplane propellers in that they are formed like airfoils, and
airflow across them causes a lifting force that rotates the rotor. To make the best advantage of
the winds at higher heights, they ought to be mounted atop towers.

Large size models have an active yaw system that rotates the nacelle using motors and wind
direction sensors. Only 21% of the wind energy will be gathered if the rotor is retained in a
constant position in both upwind and downwind conditions. Rotors should be perpendicular to
the direction of the wind (Wortman, 1983). For upwind types, the rotor rotates by measuring the
wind's direction via a vane, which then transmits the information to the yaw drive. The rotor is
then propelled by the yaw drive so that the turbine faces the wind direction for maximum
harness. They are not affected by the wind shadow phenomena because the wind is tapped
before the tower blocks it.

They don't utilise a yaw drive for downwind kinds since the wind naturally orients the turbine.
Due to their location on the downwind side, the blades are able to catch the wind and rotate in
the same direction as it. These designs are vulnerable to "wind shading," a process where the
wind flow is blocked by an object, such as the tower, resulting in a reduction in wind volume
and, consequently, a drop in power production.

Fig 2.2: Horizontal Axis Wind Turbine (Source: Wind power Workshop, Hugh Piggott, 1982)
 Design specifications(Tentative):
The blade is to be designed in a way that the base is narrower than the top.

The projected area of the blade is a trapezium as it is shown below

Materials and Components Selection

1. Base : The will be a hallowed stand in order to hold the wind mill, the material will be
steel or wood depdending on the availability, but the components must be strong enough
to sustain the weight of the entire system.
2. Pole for the Wind Mill : The pole or the stand of the wind will made up of wood cut out in
order to stand the mill and install a generator.
3. Blade : Blades are one of the most important component of a windmill and blades arethe
one that basically convert wind energy into kinetic energy whic is further converted in to
electricity or other energies depending on the need of the installation. The baldes are
generally made up of fibreglass-reinforced polyester or epoxy or aluminium or carbon
fiber. Carbon fiber would be our choice of material since it's light weight and strong
material. The blade design has an impact on the rotor's overall design. Rotor blades
capture wind energy and use its kinetic energy to drive the hub's rotation. The difficulty is
that having more blades will cause the vibration to increase and the torque to decrease.

The group opted to utilise five blades for this project because five blades will revolve
more easily than three because three blade setup doent work great in low wind
condition.
4. Generator : Generator is used in order to convert the wind energy into electric energy.
The generator used will depend the amount of power generated by the wind mill.
Because we dont have data on the wind speeds inside our campus or around area of
campus.