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Design and Analysis of Modified Wind Turbine Blades

Article in Asian Journal of Research in Social Sciences and Humanities · January 2017
DOI: 10.5958/2249-7315.2017.00013.2

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 Asian Journal
Asian Research Consortium of Research in
Social Sciences
and
Asian Journal of Research in Social Sciences and Humanities
Vol. 7, No. 1, January 2017, pp. 166-177. Humanities
ISSN 2249-7315 www.aijsh.com
A Journal Indexed in Indian Citation Index
DOI NUMBER: 10.5958/2249-7315.2017.00013.2
Category:Science and Technology

Design and Analysis of Modified Wind Turbine Blades

P Sakthivel* and G.P. Rajamani**

*Associate Professor
Anna University

**Professor
Anna University

Abstract

Wind energy is the kind of renewable source of energy which is available in nature with pollution
free, hazard less and does not produce any waste during generation of electric power. The main aim
of this paper is to increase the wind power production. There are two electromagnetic induction
generators which are preferred to share the loads through single shaft over straight level gears. The
poles of these generators will be changed as alternate to parallel. The output electric current is
stored by series of battery to utilization through converter and step up transformer. Wind energy
conversion process is done by the control system to extract extreme energy from the incident wind
and the maximum power point tracker (MPPT) control schemes have been reported which is
operated by varying the speed of generator in order to optimize wind turbine aerodynamic
efficiency. However for the implementation, the measurement of accurate wind speed is required.
The optimum value depends upon the accuracy of the loss model parameters.

Keywords: Wind Turbine, Power, MPPT, HAWT, VAWT & MATLAB.

I. Introduction

Wind is a clean source of energy that does not pollute the air and it is a renewable energy which is
available at free of cost. The kinetic energy of the wind can be used to produce electrical energy by
wind turbine [1]. Wind Turbine is a type of power plant, the different configurations can be used
for wind turbines. Two different modes of operation can be used in the function of the wind turbine
as one is MPPT and another one is Fuzzy logic controller. These types of operation are used for
both fixed speed and variable speed wind turbine [2]. In the past years, fixed speed which can get
the maximum efficiency for one wind speed was used. But, the power conversion is not in efficient

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manner to avoid this reason nowadays variable speed wind turbines are used. Maximum efficiency
over a wide range of wind speed has been achieved by this design.

The output range of single windmill is small and it can't use for commercial purposes
therefore; a more number of windmills are erected over a large area which is called as wind energy
farm [3]. Wind farms are created with multiple number of windmills are placed in the same area for
the purpose is to generate of more amount of electric energy. Due to increasing the energy prices
and the result to search for some alternatives, nowadays there are thousands of wind farms are
available in many countries around the world. Each and every windmill is coupled together to get
the electricity for commercial applications. For production of electricity the rated wind speed
should be higher than 15 Km/hr. In recent years demand in increasing of power plants is observed
renewing the interest in Vertical Axis Wind Turbines (VAWT)[4]. The VAWT withstand high
wind speeds while compare with the Horizontal-Axis wind turbines (HAWT).

II. Literature Review

Deng, ZheChen [5], a multiple permanent magnet synchronous generators (MPMSGs) system is
engaged in the wind turbine. A multilevel converter interface is based on MPMSGs is established
to combine a desired high ac voltage output, which is directly connected to the grids. A phase angle
shift strategy is projected in this paper, which is effectively reducing the fluctuation of the
electromagnetic torque sum and results having a good performance for the MPMSGs structure.

The authors [6] analyzed the flow field of an array of 18 counter-rotating vertical-axis
wind turbines (VAWTs), with an importance on the fluxes of turbulence kinetic energy and mean.
The turbine wakes the recovery of the average wind speed between the turbines rows are derived by
the measurements of the velocity using a meteorological tower. Flow field in a wind farms are
highly complex due to the contact between the wind turbines and the atmospheric boundary layer.
The average horizontal wind speed during the measurement is 8.05 ms−1 at 10 m, which means
above the top of the wind turbine canopy, with a deviation of 2.1 m/s. The turbine is commercially
available with a lift-based rotor design consist of three airfoils and a 1200w generator is connected
to the base of the turbine shaft.

By means of placing seven sensors at different positions gives the average mean horizontal
flow velocity at the mid height of rotor at each location. This is done to averaging the velocities.
The experimental field study has analyzed the flow field along with the center line of an array of
nine pairs in full-scale counter-rotating VAWTs. From the velocity field result shows the blockage
effect of the wind turbineand individual turbine pairs within the array.

The authors [7] considered high torque which would be useful in self-starting and rotor
having a high tip speed ratio for electrical generation. Historically VAWTs has cost more to operate
and maintain than HAWTs. The wind turbine rotors and stator levitated correctly by using
permanent magnets which allows negligible friction with smooth rotation. At a reasonable wind
speeds the power output of the generator satisfies the specifications need to supply the LED load.
Finally the SEPIC circuit operated effectively and to the specifications that slated at the beginning
of the circuit design.

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B.O.Omijeh, C. S. Nmom, E. Nlewem [8] the performances of a VAWT (Vertical Axis

Wind Turbine)with PMSG is investigated and modeled in this paper. To implement a wind turbine,
careful and wide-ranging investigation is required since different environmental locations call for
different wind speed. For an example Nigeria is a country which has low and unsteady wind
speeds. The wind turbine system consists of three main part; wind speed, turbine and generator.

A three phase PMSG is chosen for the experimental work due to its higher efficiency and
less maintenance when compared to other generators. It does not require rotor windings which
involve a reduction of weight and cost. These elements and the entire idea of this work have been
modeled and simulated by using MATLAB/ SIMULINK. Results show that good system
performance. The wind turbine system designed for generates three phases current, the peak value
ranging from 2.27A to 7.35A for a comparatively low wind speed range of 3m/s to 6m/s. From
these values, the generated current is sufficient under low and unsteady wind speed. Voltages from
the steady state values generated ranges from 32.9Vrms/phase to 117.2Vrms/phase for the wind
speed range of 3m/s to 6m/s. The power generated ranges from 32.08w to 335.6w for a relatively
low wind speed range of 3m/s to 6m/s. if the methodology is implemented, the cost of design, cost
of maintenance is reduced, making economical and affordable.

Peter J. Schubel& Richard J. Crossley [9] the design of wind turbine blade is presented
which includes the value of maximum theoretical efficiency, propulsion and practical efficiency,
HAWT blade design and amount load acting on blade. A detailed review of design loads for wind
turbine blades is offered by relating aerodynamic, centrifugal, gravitational, gyroscopic and
different operational conditions. For efficiency reasons, control, noise and aesthetics look of
modern wind turbine market is dominated by horizontally mounted three blade design. By the use
of yaw and pitch is to operate under different wind speed conditions. Basic load analysis result
shows that the blade can be modeled as a simple beam with a inbuilt support at the hub ends. A
uniformly distributed load is used to represent aerodynamic lift during the blade operation.

III. Power Obtained from Wind Turbine

The simple model is based on a linear momentum theory. The analysis assumed by a control
volume, in which consist the surface of a stream tube and double cross-sections of the stream tube
(Fig. 1). The wind turbine model is represented through the actuator disk, which have a uniform
discontinuity of pressure in the stream tube of air flowing through. This analysis is not limited to
any particular type wind turbine.

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Fig.1. Actuator Disk of a Wind Turbine Fig.2 Power Vs Wind Speed of Wind Turbines

The total static pressure in upstream and downstream of the rotor system is equal to the
undisturbed ambient static pressure. By applying the conservation of the linear momentum to the
control volume enclosing the entire system, it is possible to find the force on the filling of the
control volume. The net force is equal and opposite to the thrust, which is the force of the wind on
the wind turbine. The momentum for a 1D incompressible, time-invariant flow is,T = V1 ρAV 1 −
V4 ρAV 4

ρ is the density of air, A is the value of cross sectional area, V is the velocity of air and the
subscripts indicate the values at numbered cross sections in the Figure 1. For steady state flow
(ρAV) 1 = (ρAV) 4 = m, T = m V1 − V4

The thrust value is positive so the velocity behind the rotor V4 is less than the velocity of
free stream V1. From the Bernoulli equation is used in the two control volumes on both side of the
1 1
actuator disk. The stream tube upstream of the disk,p1 + 2 pv12 = p2 + 2 pv22

1 1
The stream tube downstream of the disk,p3 + 2 pv32 = p4 + 2 pv42

The upstream and downstream pressures are equal (p1=p4) and the velocity across the disk
remains same (V2= V3).The thrust of actuator disc:T = A2 P2 − P3
1
Solving the equations it is possible to obtain:T = ρA2 V12 − V42
2

V1+ V4
Equating the thrust values and the mass flow rate is A2V2,V2 =
2

Wind velocity at the rotor plane is calculated by the average of the upstream and
downstream wind speeds. The axial induction factor “a”, then

V1 − V2
a= ; V2 = V1 1 − a ; V4 = V1 1 − 2a
V1
1
The axial thrust on the disk is:T = 2
ρAV12 4a 1 − a

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T Thrust Force
The non-dimensional thrust coefficient as:CT = 1 =
ρA V 2 Dynamic Force
2

IV. Materials and Methods

4.1 Windmill using Multi Generator

The two electromagnetic induction generators are connected to the end of the shaft by coupling.
The wind turbine rotor transmits the power to the two generators through the bevel gear. The
outputpower of multi-generator used wind turbine will be double times of single generator wind
turbine.

4.1.1 Principle of the methods

The wind turbine is works by the conversion of wind energy to electrical energy by using generator.
The blades of wind turbine are rotated due to the force of air strikes the blade. Due to the blade
rotation electricity is generated by means of shaft.

4.1.2 Construction of the Methods

Fig.3 Wind Turbine Configuration

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The main parts of the Horizontal blade wind turbine are follows: Blades and rotor,
Electromagnetic Induction Generator, Gear and Shaft. The blades are attached with rotor. The rotor
connected with gear through shaft and balanced by bearing mountings. The gear box consists of
driven gear and driver gear. The driven gear teeth are meshes with driver gear. One end of the low
speed shaft is connected by driver gear and other side is connected by turbine rotor of the wind
turbine. The high speed shaft is connected by the center of driven gear. The both end of the shaft is
connected with two same or different generators through coupling. For vertical blade wind turbine,
the main parts are follows: Blades and rotor, Electromagnetic Induction Generator, Gears and
Shaft.From these two types of generator, one is rotated at clockwise direction and other one is
rotated at anticlockwise. Due to the anticlockwise rotation of generator, it does not produce the
current.

4.2 Power and Torque Transmission in Bevel and Spur Gear

By using the spur gear, the power produced from the wind turbine rotor flows through driver gear
and it is divided into two ways: one part goes straight and another side goes to driven gear, then it is
divided into two sides, one is right side which is used by generator and other side is loss of power
and torque. So, the windmill carries with an efficiency of 50%.

Fig.4 Power and Torque Flow of Transmission in Spur & Bevel Gear

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In bevel gear system, the power and torque produced from the wind turbine flows to the
driver gear and again goes to driven gear then it is divided into two sides, one is right side
Generator G2 and opposite side by Generator G1. So, the windmill carries increased efficiency
while compare with spur gear arrangement.

4.3 Parts of Windmill

4.3.1 Blades: The blades are basically fly of the wind turbine. Blades are act as barriers to wind.
When the wind forces the blades to rotate, it transforms some amount of energy to the rotor. Blades
are generally available in two types as follows: Horizontal and Vertical blades.

4.3.2 Shaft: The wind-turbine shaft is connected to the rotor. And the rotor transfers its mechanical
energy to the shaft, which enters into the generator on the other end of the shaft. The shaft is a
machine member which has high strength to with stand the total weight of all the three blades.

4.3.3 Gear (bevel gear): Bevel gears are drive system which converts the direction of a shaft's
rotation exactly at perpendicular. It usually fixed on shafts that are 90 degrees angle, but it can be
designed to work at other angles as well.

4.3.4 Generator: Generator is a device that uses the electromagnetic properties to produce electrical
energy. A simple generator consists of conductor and magnets. The conductor is typically a coiled
wire. Generator shaft connects to an assembly of surrounded by permanent magnets that the coil of
wire.

4.3.5 Tower: The turbine is positioned usually upwind of its supporting tower. It supports the rotor,
drive train mechanism and other equipment’s including controls mechanism, ground support
equipment and interconnection devices.

4.4. MATERIAL SPECIFICATION: The Material is used to make of shaft, gear, bolt & nut is
Alloy steel: 40 Ni 2 Cr 1 Mo 28 [Case Hardened]

Table 1.Chemical Composition

Name of Material Composition Name of Material Composition

Carbon C 0.35 - 0.45 % Manganese Mn 0.45 - 0.70 %
Chromium Cr 1.0 - 1.40 % Molybdenum Mo 0.20 - 0.35 %
Nickel Ni 1.30 – 1.40 %

Table 2.Mechanical Properties

Tensile Strength (N/mm2) Yield Strength (N/mm2) Hardness ValueBHN

800 to 1300 600 to 1200 300 to 400 BHN

4.5. Schematic of Wind Hydro Hybrid System

Fig.5 shows that the schematic layout of a 3-phase 4-wired autonomous system. The two back-to-
back connected with insulated gate bipolar transistor system (IGBTs), pulse width modulation
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(PWM) and voltage source converters (VSCs) are connected among the stator windings of SCIG
and PMSG to facilitate bidirectional power flow.The tip speed ratio determines the SCIG rotor-
speed set point for a given wind speed, the mechanical energy is generated at this speed lies on the
maximum energy of the turbine. The load-side converter is controlled by the regulation of load-
voltage magnitude and frequency. For maintaining the load-frequency constant, it is also essential
that excess power in the system is sidetracked to the battery source.

Fig.5 Schematic Layout of Hybrid System

The BESS on the DC bus of PWM converter is to transfer the power from battery without
any converter. The role of transformer and converter is to recompense the unbalance condition by
the load currents.

Fig.6 Coefficient of Performance Vs Ratio of Tip Speed

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The new system consists of three different modes of operation. For the first mode the
necessary power of the load is less than the power produced by the synchronous generator.The
excess power generated by the PMSG is transformed to the BESS through the load-side converter.
In the second mode the power generated by SCIG is supplied through the converter of load-side
and remaining is stored in BESS. The third mode, the shortage power is supplied by the BESS, the
generated power by PMSG and the shortage by BESS is supplied to the load-side converter.

4.6 Wind Turbine Design

The hybrid system being considered has a wind turbine capacity of 55kW and a hydro turbine of 60
kW respectively. Voltage of the battery bank is considered as 700V. The maximum value of rms
line voltage at load terminals is 415 V. By considering the ability of the new system to provide
electricity to a load rate of 60 kW for 10 hrs, the storage capacity of the battery power bank is taken
as 600 kWh. The commercially available battery bank contains of cells of 12 V. The capacity of
each cell is taken as 150 Ah. To achieve a voltage range (700 V) through series linked cells of 12
V, the battery bank have 59 (700/12) number of cells in series. The storage capacity of this
combination is 150 Ah and the total ampere per hour required is (600 kWh/700 V) = 857 Ah and
the number of sets are required to be linked in parallel connection is (857 Ah /150 Ah) = 5.71 = 6.
The battery bank contains six parallel-connected sets and 59 series connected battery cells.

4.7 Gear Ratio of Wind Turbine

The wind turbine is to produce 55 kW at a rated wind speed of 1.2 m/s. For wind speeds below the
rated wind speed, mechanical power Pm taken by: wind speed Vw, turbine radius r w, density of air
ρ and coefficient of performance Cpis Pm = 0.5 Cp πr 2 ρV3 .The maximum coefficient of
performance is achieved at optimal tip ratio (λ∗w). The values of Cpmax and tip ratio are 0.4411
and 5.66. Consider the values of wind speed Vw = 11.2 m/s Pm = 55 kW, Cp= 0.4411, and density
of air ρ = 1.1544 kg/m3 for 4.1, the radius of the wind turbine r w is found as 7.5m. So the gear ratio
is 12 [(100*705) / (5.66*11.2)].

V. Simulation Results

A balanced load and secondary dynamic load at wind speed of 11m/s is connected to the network.
At this wind speed, the wind turbine produce 55 kW and hydro turbine produce 60 kW. So the total
power generation is 115 kW. The model is tested withhalf load of 57.5 kW, full load of 115 kW
and 10% of overload. The wave forms are purely sinusoidal as expected for the above conditions.
Also magnitude and frequency of the load voltage are maintained constant level.

5.1. Double Multiple Stream Tube Model

The Double Multiple Stream tube (DMST) models are found for the difference between the upwind
and downwind passes through each blade is by dividing stream tube into an upwind and downwind
half. The turbines interact with wind in upwind and downwind separately by passes through the
blades. The upstream wind induced velocity (Vau) will be the average of the air velocity at far
1
upstream (V∞) and the air velocity at downstream equilibrium (Ve) Vau = Vα + Ve or Ve =
2
2Vau − Vα

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The conventional airfoils used for Darrieus VAWTs were NACA0012, NACA0015 &
NACA0018. These blades are of symmetrical geometry with minimum or negative torque
generations at lower TSRs. Among these blades profile NACA0018 was selected for the analysis.
The airfoil selected is to vary the trailing edge which is from the original dimensions. For this
analysis, the conventional NACA0018 symmetrical airfoil was used for the analysis of double
multiple stream tube (DMST) model. The trailing edge axis inclination of the blade is set to 15˚.

Fig.7 Modified Airfoil of NACA0018

5.2 CFD Analysis

The VAWT analysis, modified airfoil limit is set to 0.2 m chord length with radius equal to 2 m.
The 2D model of the turbine is created by Gambit software, mesh of the model is generated and the
commercial CFD fluent is used for numerical solution. The RNG k-epsilon model was adapted for
the turbulence closure.

5.3 DMST Analysis

The VAWT analysis by using DMST, the normal NACA0018 airfoil is set to 0.2m chord length
and the radius of turbine radius is 2m. The wind velocity used for this analysis is 4 (m/s) and tip
speed ratios (λ) are 0.5, 1, 1.5, 2, 3, 4, 5, and 6. The number of stream tube used for the analysis is
12 with an angle of Δθ=15˚.

Table.3 Flow Conditions

TSR (λ) 0.25 0.5 0.75 1 1.5 2 3 3.5 4 5

Velocity m/s 4 4 4 4 4 4 4 4 4 4
Turbine angle Velocity (rad/s) 0.5 1 1.5 2 3 4 6 7 8 10

5.4 Results and Discussions

The coefficient of power for the modified airfoils is calculated by combining the performance of
turbine trailing edge angle of 15˚for TSR limit is 0.1 to 1 and without inclination of the trailing
edge for TSR value is greater than 1. The Cp was found from the ratio between the modeled turbine
power and the available wind power in the air. In DMST Cpvalue is less than about 2.6. From the
CFD analysis for the modified airfoil system indicates the positive torque occurs at low tip speed
ratios.

The Cm Values are obtained from the average moment of three airfoils which is modeled
and analyzed through the computational analysis. The modified airfoil tip speed ratio has the values
as 0.1, 0.25, 0.75 and 1. As can be seen, the value of Cm is higher and seems to reduce up to TSR =

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0.5 and then starts to rise. The torque values were calculated from the coefficient moment (Cm) by
using the value of modeled airfoil, turbine area, air density, free stream velocity and the radius of
the turbine. From the graph shows the average torque values at each of the TSR simulated values
are positive.

Fig.8 Simulation of Blade

Fig.9 Stress and Displacement Analysis of Blade

The analysis result shows that the minimum stressvalue is 7.63607X10 -7 N/mm2 (MPa) at
node no 16099and the maximum stress value is 0.304129 N/mm 2 (MPa) at node no11102. The
maximum displacement value is 0.101712 mm at node no 8538.

VI. Conclusion

Theoretical and experimental work is carried out to confirm validity of the analytical work. The
control system of the induction generator in combination with MPPT of the wind turbine has
developed with minimum resistive power loss, simulation is carried out by using MATLAB and the
results have been tabulated. From the simulated result the total ohmic loss has been reduced to
5.79% in the grid side inverter and the power output increases for 100w and the efficiency increases
11.5% hence it can be one of efficient wind energy conversion system. Among the renewable
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 (2017). Asian Journal of Research in Social Sciences and Humanities,
Vol. 7, No.1, pp. 166-177.

energy sources small hydro system and wind system have the ability to match each other. Further,
there are many isolated locations which cannot be linked to the grid, where the wind potential and
hydro potential are exist simultaneously. For such locations, a type of three-phase four wire
autonomous wind-hydro hybrid system is used with one cage generator driven by wind turbine and
another one synchronous generator is driven by hydro turbine which includes the BESS. The
system has been modeled and simulated in MATLAB and Sim Power System. The performance of
the hybrid system has been demonstratedby consumer load variation and mechanically by variation
of windspeed. The performance of the system is within the load range while maintaining constant
voltage and frequency ranges.

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