MATEC Web of Conferences 10 8 , 08010 (2017) DOI: 10.

1051/ matecconf/201710808010
ICMAA 2017

Wind Turbine design and fabrication to power street lights

Mohammad Khan , Mohammed Alavi, Nithin Mohan, AbidAzeez, Abdul Shanif and Bilal Javed
College of Engineering, Abu Dhabi University, Abu Dhabi, UAE

Abstract.The objective of this work was to design and build a wind turbine which can be used to power small street
lights. Considering the typical wind speeds in Abu Dhabi, UAE and ease of construction, the design of the wind
turbine was chosen to be Sea Hawk design from vertical axis wind turbine category. A three phase AC generator was
used for its availability over the DC motors within the region. A 12V battery was used for storage and a charge
controller was used for controlling the charge flow into the battery and for controlling the turbine rotation when the
battery is fully charged. The blades used in the turbine were made of foam board according to the NACA 0018 airfoil
shape with a chord length of 15cm. The connecting shaft was made of stainless steel. Structural analysis and CFD
analysis were performed along with other calculations. Testing was executed to calculate the voltage output from the
turbine at different wind speeds. The maximum voltage the turbine produced at 6.4 m/s wind speed was 2.4Vand the
rotational speed of the turbine was 60.3 rpm.

1 Introduction Savonius drag-based VAWT works similar to the

paddle propelling in a boat. The drag is the pressure or
Wind turbines typically are divided into two types based thrust developed when wind passes through the blade.
on their axis of rotation with respect to the wind flow The blade is S shaped cross section; this is to implement
direction; Horizontal Axis Wind Turbine (HAWT) and the drag technique and also to provide certain lift
Vertical Axis Wind Turbine (VAWT). HAWT has blades [4].UAE is currently in the process of determining the
that are similar to propellers that spin on horizontal axis. viability in wind farm projects within the country. UAE
The position of main rotor shaft and electrical generators Ministry of Energy is carrying out various research
in horizontal axis turbine is at the top of a tower provided projects for further understanding the variability of wind
that this must be pointed in the direction of wind. from year to year [6].
Typically, the gearbox combined with the high-speed
shaft increases the rotation of about 30-60 rpm to almost
1200-1500rpm. This is the typical rotation speed required
for generators used in HAWT [1]. The offshore wind
turbines have the advantage in case of noise pollution as
it is far from shore without affecting the people and are
less affected by turbulence whereas the onshore turbines
create noise pollution and are affected more by
turbulence [2]. In a VAWT, the main rotor shaft is fixed
vertically. Vertical axis wind turbines can be subdivided
into two kinds: Darrieus and Savonius [1]. Typical Figure2. Red is average daily minimum, Green is maximum,
Darrieus wind turbine (different types shown in Fig. 1) and black is average wind speed with percentile bands [7].
contains 2 or 3 blades [3].
Figure 2 shows the wind speed data over a year in
Abu Dhabi. Daily maximum wind speed ranges from
lowest 5m/s to highest 7m/s. The lowest daily wind speed
can go to a maximum of 2m/s. In an average curve, the
maximum wind speed is found to be 5m/s and minimum
is 3m/s. Hence the design constraint was selected to be a
wind speed of around 5m/s [7]. The average wind speed
in Abu Dhabi is less than 5m/s and VAWT can be
utilized at such wind speeds. The start-up wind speed
generally is 2m/s for the same. Sea hawk design as shown
Figure 1. Types of Darrieus VAWT [3].

© The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative Commons Attribution
License 4.0 (http://creativecommons.org/licenses/by/4.0/).
MATEC Web of Conferences 10 8 , 08010 (2017) DOI: 10.1051/ matecconf/201710808010
ICMAA 2017

in Fig. 3 satisfies the regional conditions and is

appropriate for Abu Dhabi weather conditions [5].

Figure3. Sea Hawk turbine [5]. Figure 4. Lift-drag ratio of symmetric airfoils at various
The objective of the present work is to design and relative thickness [9].
construct a wind turbine to power small street lights of Figure 4represents comparison between six different
typically 30 W lamps. The wind turbine is to be designed NACA airfoil thicknesses which include 8, 10, 12, 15, 18,
for wind conditions encountered in Abu Dhabi UAE. The and 24 percentages. The relative thickness ‘RT’
turbine should run effectively with an average wind speed represents thickness / chord ratio (t/c ratio) and is the
of 5-6 m/s. A battery will be used to store energy while maximum thickness of the airfoil expressed as a
the wind turbine is running during the day. The same can percentage of the chord.Considering symmetric airfoil
power the street light after sunset. In addition, the whole shapes, the airfoils with 15% thickness has the highest lift
turbine should be modular and easily manufactured with drag ratio. This means 15% thickness can provide the
inexpensive material requirements. Considering the use maximum lift and least drag. The second highest lift drag
for street lighting, the typical wind velocities available in ratio is for 18% thickness NACA airfoil. It is evident in
Abu Dhabi, and the ease of manufacturing Sea Hawk the graph that when angle of attack increases after a
VAWT was selected as a good candidate to serve the specific value, the drag element increases and the ratio
purpose. decreases. When thickness increases beyond a limit, the
drag also increases accordingly. Thus airfoil with
thickness 15% or 18% is preferred. It should also be
2 Design of the Wind Turbine considered that 18% is thicker than 15% and is more
robust than 15%. Another important finding is that
Swept area of the wind turbine is the area of the wind
thicker airfoil increases the startup torque. It was found
turbine which captures the wind. The power available
that 19% thickness showed good start-up and traverse
from the wind turbine increases with an increase in the
characteristics. Theoretically it is proven that 18% has
swept area. Another parameter that greatly affects the
better performance at low Reynolds number and highest
power available from the wind turbine is the wind speed
power coefficient was achieved at 18% [9]. Studies [8]
[8]. Kinetic energy can be calculated as:
prove that a larger leading edge radius is preferred to be
KE = 0.5mV∞ 2 ; where ∞ is the free stream velocity and less sensitive to roughness. Thick blunt trailing edge is
m is the mass of air trans versing such that m = ρAV∞ in preferred for increasing lift [9]. Choosing an appropriate
which A = swept area and ρ = density of air number of blades for the turbine is a balance between
Therefore,
KE = 0.5ρAV∞ 3 (1) blade stiffness and aerodynamic efficiency. Increasing the
blade number for a specific radius and thickness leads to
Including coefficient of performance in equation (1), the sacrificing blades stiffness for a very slight increase in
power output can be determined as: aerodynamic efficiency. Single bladed turbines suffer
1
Pw = Cp ρAV∞3 (2) from a parasitic drag. Two bladed rotors are more
2 sensitive towards mass imbalance vibrations and causes
Power density is the terminology used to define the higher operating cost and maintenance compared to three
available power per unit area swept by the blade/airfoil
blades. Minimum three blades are required to decrease
[9]. Power density can be calculated as:
vibrations due to mass imbalance issues [9].In the sea
1
p = Cp ρV∞ 3 (3) hawk type of vertical axis wind turbines, the blades are
2 not cambered and are symmetric. The diameter of the
Symmetrical shape is easier to manufacture than
turbine is 0.80m and 1.2m tall. All the blades positions
curved shapes. NACA 0018, 0012, 0015 are all
are distributed evenly. Blades can be made from light and
symmetric in shape. NACA four series is recommended
inexpensive materials. Sea Hawk design was chosen as
since symmetrical airfoils work better for higher
the prototype design. This decision was made after
Reynolds number; particularly NACA 0012, 0015, 0018.
comparing the score in efficiency, cost, ease of
These are more appropriate for smaller angle of attack [8].
manufacturing, and ease of maintenance. The blades in
this type of turbine can be designed in straight, symmetric,
and anti-symmetric airfoil shapes.
Initial optimized parameters have been chosen to set the
initial design of the turbine. Table 1 summarizes the

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MATEC Web of Conferences 10 8 , 08010 (2017) DOI: 10.1051/ matecconf/201710808010
ICMAA 2017

initial dimensions of the turbine which were obtained 3 Design Parameters

based on best dimensions of the airfoil.
The main design objective of the turbine is to produce an
Table 1. Starting parameters. output power of 30W or above to power LED street lights.
Symbol Parameter Value The design constraints of the turbine are the turbine
Vff Wind speed 5m/s diameter, airfoil type, chord length, number of blades,
and pitch angle. The input parameters of the design are
TSR Tip speed ratio 0.625
the rotor radius, blade length, blade chord length, and
R Rotor Radius 0.385m
number of blades. The input parameters of the wind are
C Blade Chord 0.07m
the free stream wind speed, and air density. The
L Blade length 1.22m
parameters such as swept area, power available from the
N Blade numbers 6, 8, 15, 16
wind, angular velocity, rated blade velocity, tip speed
ratio, lift force, drag force, tangential force, normal force,
Once the initial dimensions and TSR are specified the torque and expected power output is calculated.
next step is to find the solidity which is a dimensionless Using the equation for Swept Area,
parameter which will help to find the geometry of the Swept Area (A) = H × D (5)
VAWT. The blade solidity ‘’ can be calculated as: A = 0.832m2
BC
σ= (4) Using equation (2),
R Power available from wind (Pw ) = 63.7W
where ‘B’ is the number of blades; ‘R’ is the radius of the
From the literature review and based on the wind data,
rotor; ‘C’ is the chord length 
An increase in solidity increases the production of the the cut in speed (Vd) was assumed to be 3.13
higher torque at the low tip speed ratios. Table 2 shows To find the Angular velocity(ω),
properties of different materials considered for the blade. Vd
ω= R
= 7.825 
(6)
The wind turbine structure is the main source of the
Using the equation for Blade velocity,
stresses as well as the change of input forces [11]. m
Blade velocity (Vb ) = R × ω =3.13 (7)
s
Table 2. Material properties. Using equation, the magnitude of relative velocity is
Material Stiff Tensile Density Elonga Max 2
ness Streng (g/cm3) tion at temp ⃗ = V∞ ωR + cosθ + (sinθ)2 (8)
W
(GP th break (°) V∞
a) (MPa) (%) Finding the relative velocity, lift force, drag force,
Steel 30 190 7.5 15 550 tangential force, torque, expected power output and
Alumi 10 90 2.7 12 400 coefficient of performance when the blade position is at
num 30 degrees and the pitch angle is at 10 degrees. Fig. 5
Glass- 73 3500 2.54 3 350 shows the velocity vector when the blade is at positioned
E at 30 degrees.
Carbo 350 4000 1.75 1.8 500
n
Arami 120 3600 1.45 11 250
d
Foam 0.5 1.5 0.065 0.2 70
T90

The shaft of the turbine (1.05m long) is made up of

stainless steel for its advantages such as durability and
resistance to corrosion and rust. At some point the flow Figure 5. Velocity vector when blade is positioned at 30 Degree
of charge from the generator to the battery should be When the blade is in position which is the azimuth angle
regulated. According to the generator rated power output ⃗ = 6.29 m
(θ) is at an angle of 30° , W
s
of 30W and voltage of 12V FW03-12A waterproof The angle of relative velocity can be found using
charge controller was chosen. The specifications of the equation,
controller are mentioned in Table 3.
sin θ ωx 0 C ωC
Table 3. Controller specifications. φ = tan−1 ω R − W
− 4W (9)
+cos θ
Specifications Vd
Where x0 is the blade attachment at the middle of chord
Rated power 300W
length, thus x0 = 0. Therefore, φ = 12.36°
Battery Voltage 12V
Using the equation for tip speed ratio,
Brake voltage 13.5V Rω
Level of protection IP67 λ = V = 0.624(10)
∞
Angle of attack and pitching angle is related to each other
and this can be mathematically modeled. By fixing the
azimuth angle as 30 o and varying the pitch angle -10o to
60o Fig. 6 was generated.

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MATEC Web of Conferences 10 8 , 08010 (2017) DOI: 10.1051/ matecconf/201710808010
ICMAA 2017

the only variation used was the blade number. This was
performed in order to choose the best number of blades
30
for the turbine. However, 16 blades were rejected as it
20
had almost same value of Cp as 15 blades and also to
10
Angle of attack

0
reduce the added weight on the turbine.
-12-10 8 28 48 0.105
-20 0.085
-30 0.065

Coefficient of
Performance
-40 0.045
Pitch angle
-50 0.025
Figure 6. Angle of attack vs Pitch angle. 5 10 15 20
For the calculation, the pitch angle was assumed to be 10o.
From the graph plotted in Fig. 6, the angle attack was
found to be 5.025o. No. of Blades
RPM of the turbine Figure 7. Graph of Coefficient of performance vs No. of blades.
60
 = 7.825 × = 74.72 RPM (11) The torque of the turbine was found using the equation
2
for torque
Using equation for Reynolds number,
ρWC Q = B × FT × R = 15 × 0.64 × 0.4 = 3.84Nm
Re = μ
= 58284.79 (12) (18)
The values for CL and CD are found to be 0.7352 and Using the equation for the power output,
0.03446 from the table for NACA 0018. Using the angle P = Torque × Angular Velocity = Q × ω = 30W (19)
of attack (α) which is equal to 5.025° . Using the equation for power,
Using the equation for lift force, Expected power output P
1
Cp = Power available from the wind
=P (20)
w
Lift Force (FL ) = × CL × ρ × W 2 × AP =2.779N (13)
2 Cp = 0.474
Using the equation for Drag Force, The above calculations for torque, expected power output,
1
Drag Force (FD ) = × CD × ρ × W 2 × AP = 0.13 and power coefficient were calculated by assuming the
2
(14) blade position at 30 degrees from the reference and the
Using the equation for Tangential Force, pitch angle at 10 degrees.
FT = FL sinφ − FD cosφ= 0.64 N (15)
Chord length for the turbine blade was determined after
comparing and analyzing existing VAWT turbine designs.
4 Structural Analysis of the Turbine
It was found that most of the turbine blade chord length Structural analysis of the turbine is one of the important
1 th 1 th
was somewhere between to of the turbine parameters that need to be considered in terms of design.
15 10
The factors considered in the structural analysis are
diameter. But based on the preliminary design and
sketches performed it was found that the gap between the maximum bending moment, normal and shear loads on
turbine blades was huge so the chord length was the blades, allowable stresses, and moment of inertia on
increased to 15cm from 7cm.According to the chosen the blades.
The normal stress is calculated using equation
NACA0018 blade, the thickness should be 18% of the
chord length. The thickness of the blade was computed σN =
Normal force
using equation (16) to be, (21)
Area perpendicular to force
T = C × 0.18 = 15 × 0.18 = 3cm (16)
Normal force ( ) is calculated using equation
The effect of coefficient of lift as well as coefficient of 1
drag will affect the overall performance of the turbine. CL F N = × ρ × C × L × W 2 × CN (22)
2
and CD are functions of Re and the particular airfoil Where  the coefficient of normal force, C is the chord
section. The values of coefficient of lift and drag for the length, ! is the density of air, and W is the relative
prototype blade with 15cm chord length was taken from velocity of the blade.
the table for NACA 0018. Using the equation for the The coefficient of normal force is calculated to be
coefficient of performance, CN = CL sinα + CD cosα = 0.09844 (23)
Expected power output P Therefore, the normal force from (22) is 0.372N
Cp = = (17) The perpendicular area is found by assuming the blade as
Power available from the wind Pw
CT × C × W 2 × B × λ cuboid. Thus, the perpendicular area is found using
Cp = equation
D × V∞2
CT = CL sinα − CD cosα = 0.03 Ad = thickness of blade × length of blade (24)
0.03 × 0.15 × 6.292 × 0.624 " = 0.03122
Cp = ×B Therefore, from (21),σN = 11.923Pa
0.8 × 52 Shear stress occurs due to tangential force. The tangential
The graph shown in Fig. 7 was generated by fixing the force was found to be, FT = 0.64 N which is same as the
wind speed, diameter of the turbine, tip speed ratio, and shear force Fs . The shear stress is calculated using
equation (25) as

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MATEC Web of Conferences 10 8 , 08010 (2017) DOI: 10.1051/ matecconf/201710808010
ICMAA 2017

F lift force, drag force, and expected power out depends on

τ = Blade sarea = 4.1 $ (25)
angle of attack. To achieve a constant torque and power
The bending moment is proportional to the centripetal output angle of attack has to be fixed.
acceleration. The centripetal acceleration is given by Total moment of inertia (30)
equation (26) = moment of inertia of one blade
%& 2
an = R
= 24.5m/s2(26) × number of blades = 0.405,-2
Where, ' is the centripetal acceleration, %& is the blade Therefore, the angular acceleration is given by:
velocity and R is the radius of the turbine. Q 3.84 Nm kg m<s 2 × m
Aa = = ×
Bending moment = FN × Distance = 0.558Nm (27) I 0.405 kgm2 kg m2
rad
= 9.5 2 (31)
s
5 Structural Design of the Rotor Load analysis for the blade dimensions can be divided
into centrifugal and aerodynamic loads.
The material selection was done comparing stiffness,
Centrifugal force is calculated by:
tensile strength, density, elongation at break, temperature
up to which it can hold, cost and ease of manufacturing.  =  >2 = 4.1128 (32)
The aerodynamic load is normal force (  ) and using
Table 4. Material Comparison [13]. equation (22)  was found to be 0.372N.
Material Stiff- Tensile Density Elongation Max The resultant force for one blade in rotation can be
ness Strength (g/cm3) at break temp calculated. The assumption made for this is that both
(GPa) (MPa) (%) (℃) centrifugal and normal force are in the same direction.
Steel 30 190 7.5 15 550 ? =  +  = 4 (33)
Al 10 90 2.7 12 400 Yield Strength
Glass-E 73 3500 2.54 3 350 Allowable stress = (34)
Tensile strength ×FS
Carbon 350 4000 1.75 1.8 500
Aramid 120 3600 1.45 11 250 Assuming factor of safety as 3, the allowable strength of
FoamT90 0.5 1.5 0.24 0.2 70 the Styrofoam board was found to be 0.5MPa.
For 74.72 rpm, the angular velocity on the shaft can be
Foam board was selected as the material for the blades. calculated by:
Figure 8shows the schematic of NACA 0018 with 15cm 2 2××74.72
> = 60 = 60
=7.8 / (35)
chord length.
Torque on the shaft is based on the generator output
power.
Power output from the generator
Torque =
>
= 3.8Nm(36)

6 Prototype and its testing

A foundation is required to hold all the blades in place in
a robust and straight manner. Two sheets 80cm diameter
Figure 8. Schematic of NACA 0018 with 15cm chord length and 2cm thick was used on top and bottom made from
The mass of the manufactured blade was found to be Styrofoam sheets to satisfy these criteria. This adds
0.169 kg.Acceleration analysis is done to determine strength to the shape and reduces the slanting of the blade
theoretically that the turbine can achieve the desired RPM while operating.The prototype has 15 blades with
[14]. The inertial moments by approximating the blade thickness of 3cm, height of 1m, and the material used was
shape as a cuboid; using Steiner theorem, is given using Styrofoam. The 3 phase AC PMA generator can produce
equation 30watt. It is 20cm in diameter. The steel shaft was 1
1 meter long and with a diameter 1.2cm. The shaft goes
Iblade = mblade [C 2 + (0.21C)2 ] + mblade R2 (28)
12 through the Styrofoam sheets and covers almost all of the
2
Iblade = 0.273 ,- turbine height.The generator is fixed to the flange which
Where &/  is the mass of the blade, C blade chord is, is then fixed to the base. Flange acts as a mediator to the
R is rotor radius. To get an approximate value of total generator and base. The diameter of the flange is 9cm and
momentum, inertial momentum is multiplied by the height is 25cm.Turbine base helps to avoid turbine from
number of blades. The angular acceleration (rad/s) can be tipping due to the force from the wind. The base was
calculated using equation made from marine plywood. The dimensions of base
Q
A a = I (29) were 60cm long, 54cm wide and 14cm. The turbine is
bolted to base to ensure stability.Table 5 shows the
Where Q is the torque and I is the rotor inertial moment.
specification of the generator.
Relative velocity, torque, tangential, normal, lift, drag
Table 5. Generator Specification
force, and expected power output were calculated for one
Generator type 3 phase AC PMG
blade positioned at : = 30° and ; = 10°. For VAWT the
Rated voltage DC 12V
torque varies according to position of the blade and angle
Rated speed 300 rpm
of attack, unlike HAWT were torque remains constant.
Power output 30 W @10 m/s
Relative velocity, torque, tangential force, normal force,
Weight 4.5 kg

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MATEC Web of Conferences 10 8 , 08010 (2017) DOI: 10.1051/ matecconf/201710808010
ICMAA 2017

Start-up wind speed 2 m/s 7 Conclusion

Torque 9.74 Nm
In conclusion, the project’s initial intention was to design,
Figure 9shows a 3D isometric view of the turbine create, and simulate a wind turbine which can be used to
respectively. A 15 blade model shown below was power LED street lights. The necessary approaches
developed using Solid works. This model was later used starting from literature review to find all the necessary
to perform structural analysis. background details required, collecting the wind data,
selecting the appropriate turbine, blade type, determining
the components required, calculating the power density,
structural analysis, CFD analysis, building the prototype,
till the testing of the turbine were performed. From the
literature review it was found that VAWT works better
due to the facts that the efficiency is better, works with
lower wind speeds, cheaper, smaller, cheaper, and easier
to manufacture. Operational parameters such as cut-in,
cut-out speed, rated wind speed, rated power output,
power coefficient, rpm and pitching of blade were
analyzed for performing calculations. From wind data it
was established that the average wind speed is 5m/s and
relative humidity typically varies from the lowest value
Figure 9. Engineering 3D isometric drawing of the turbine. of 16% to the highest 85%. From detailed design, it was
Wind turbine testing was done to ensure that it found that the power density increases as wind velocity
performs well at different wind speeds. Subjecting to increases. All the required design parameters such as the
various wind speeds the turbine voltage outputs were swept area, expected power output, turbine diameter,
recorded and analyzed.Bending test was carried out in the airfoil type, chord length, number of blades, angular
lab using the method of three-point bending experiment. velocity, rated blade velocity, tip speed ratio, lift force,
The strength and deformation capability of the blade was drag force, tangential force, normal force, torque and
found out using this. Before performing the test, the blade expected power output were calculated by using the input
was weighed and was found to be 0.169 kilogram The parameters of the design such as the rotor radius, pitch
stress loaded on the blade was determined using the angle, blade length, blade chord length and number of
equation (37) blades. In the structural analysis of the turbine normal
3F Load ed S stress, normal force, coefficient of normal force,
σb = 2CT 2
(37)where perpendicular area, shear stress, and bending moment
σb stands for the stress on the blade FLoaded is force were determined. The maximum voltage the turbine
loaded on blade, S means span, b is the width of the blade achieved at 6.4 m/s wind speed was 2.4 volts and the
and T is the thickness of the blade.The blade broke at a rotational speed of the turbine was 60.3 RPM. Future
load of 89.76N. Span was taken to 50 cm and ‘C’ the development would be to build a mechanism to prevent
chord length was 15cm and thickness of the blade was the wind turbine from rotating at high wind speeds that
3cm. Therefore, the stress load came out to be 49.8 Pa. may damage the blades.
The turbine was subjected to different wind speeds by the
help of wind tunnel facility. Fig.10compares the different
wind speeds and voltages as output while the turbine
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