The objectives of our Experimental Setup are as follows: Design calculations of rotor axle, bearings and stator coil CAD design of various components of VAWT, like Hub, Axle, Blade Supports and Spoke Flange Analysis of Hub in NX-NASTRAN 9.0 Fabrication of individual components of the setup Assembly of VAWT Testing of Experimental Setup Results

1. Project II presentation
on
Power Generation using Neodymium Magnet in Vertical Axis Wind Turbine
By
Sumit Bhattacharya ME 851
Sharvil Dalvi ME 815
Vivek Padayattil ME 838
Abhas Raj ME 862
(B.E.Mech)
Guided By
Prof. G.V.Patil
Department Of Mechanical Engineering
April 26, 2016

2. Introduction
• Wind Turbines harness wind energy
and generates electricity
• Many different configurations of
wind machines, most of them can
be categorized into two classes
• VAWT has main rotor shaft set
perpendicular to the wind with
Higher efficiency, low
manufacturing cost, structural
stability, simplicity, omni-
directionality
Fig.1 Types of Wind turbines [1]

3. • Neodymium Magnets: permanent magnet
made from an alloy of neodymium, iron
and boron.
Using Neodymium along with VAWT:
• Power generation lies under the magnetic
effect
• It does not require continuous electric supply
• Integration of VAWT along with neodymium
magnets (permanent magnets) for power
generation
Fig-2 Neodymium Magnet
Fig-3 Magnets in Stator

4. Literature Review
• With ever increasing demands
there would be a great challenge
in fulfilling the demands
• Figure 4 shows the output from
the various sources.
• Figure 5 shows electricity
demands of different countries.
Fig-4 Outputs
Fig-5

5. • Energy demands of the modern
society and increasing pollution
has resulted in more investment
in renewable energies
• By end of 2009, the capacity of
wind energy power plants has
reached 158 giga watts
worldwide
Fig 6 - Annual Capital investment in renewable energies from 2004 to 2009.

6. • Development of practical
permanent magnet synchronous
AC electric motor technology
allows lower speed and higher
torque output compared to a
conventional AC induction motor
• Using this technology, the
number of mechanical drive
components required in a number
of machine applications can be
reduced
Fig 8-Axial flux permanent magnet machine with air gap windings

7. Problem Definition
• Fabrication and Testing of Vertical axis Wind turbine setup using Neodymium
Magnets
Initiates the
Rotor which
consists of
NEODYMIUM
as the
permanent
Magnet
Power
generation
with the help
of the rotor
assembly
Work Flow Diagram

8. Objectives
The objectives of our Experimental Setup are as follows:
• Design calculations of rotor axle, bearings and stator coil
• CAD design of various components of VAWT, like Hub, Axle, Blade
Supports and Spoke Flange
• Analysis of Hub in NX-NASTRAN 9.0
• Fabrication of individual components of the setup
• Assembly of VAWT
• Testing of Experimental Setup
• Results

9. Methodology
Methodology
Design Calculations
StatorBearingRotor axle
CAD Design
Hub Spoke
flange
Axle Blade
Support
Analysis
Experimental Setup
Fabrication
Assembly
Results
Hub
Blade
Support Magnetic
Disc
Stator Axle

10. Design Calculations of Rotor axle
Total weight(W)= 21 kg
Torque(T)= 245.25 Nm
Power(P)= 71.9 W
Compressive stress= 0.25*106 N/m2
Shear stress= 1.16*106 N/m2
SR Wind Speed (m/s) Speed (RPM)
1 2 8
2 5 14
3 7 25
4 10 34
5 15 49
6 20 70

11. Design of Bearing
• Radial load (Fr)= 245.5 N
• Dia of shaft (d)= 35mm
• Bearing selected= SKF NU 2307
• Life of bearing is calculated

12. CAD Design
Parts designed:
• Hub
• Spoke flange
• Axle
• Blade support

13. Neodymium Magnets(Nd2Fe14B)
• Rare earth permanent magnet
• Alloy of neodymium (Nd), iron (Fe) and boron (B).
• Dimension of Magnet: 40*25*10 mm
• Produced by-
1. Sintering magnets
2. Magnetic bonding

14. Analysis
• Element type: Tetra 4
• Material: CI (FG 240)
• Yield stress: 260 N/mm2
• Boundary conditions: Bottom
region is fixed and a torque of 10
Nm is applied.
• Observed stress: 13 N/mm2

15. Stator coil specifications
• Coil wire material – copper (Cu)
• Diameter of wire – 2mm i.e. ( 14 gauges)
• Total coils wound – 9 i.e. (3 coils per phase)
• Coil connection – 3 phase star connection

16. Fabrication of stator coil
The steps are as follows :-
• The wire is wound on the spool by
using a lathe machine.
• The wires are firmly secured with
insulation material all over the coils.
• All 9 coils are wound and arranged on
the stator disc mould.
• The coils are connected in 3 phase star
connection.
• Insulation (resin) is poured to make the
assembly waterproof and sturdy.

17. Fabrication of magnetic disc
The steps are as follows :-
• Position of magnets are marked on the
disc
• Determine the poles of each magnet
• Mark the point where the first magnet
is placed
• Place the magnets on the disc with
alternate poles facing upwards
• Secure the poles in place with an
adhesive (araldite)

18. Experimental setup of VAWT
• The two bearings were fitted on the hub along with circlip.
• Drills were made on the hub as well as on the blade support to properly
attach them using nuts and bolts.
• The stator along with the magnetic discs are attached to the support
using the tie rods.
• The hub is first inserted through the axle and is properly fix.

19. Diagram of Experimental setup of VAWT

20. Working
• The stator is subjected to a rotating magnetic field of the PM discs.
• This induces a voltage difference between the windings of the stator.
This produces the alternating current (AC) at the output.
• This current at the three phase windings which is then recorded with
the help of a multimeter.

21. Result
Analytical voltage was calculated using Erms equation.
The Experimental Results:
• For speed = 30 RPM, percentage error is 95.07%.
• For speed = 40 RPM, percentage error is 88.38%.
• For speed = 50 RPM, percentage error is 87.36%.

22. Discussions
The probable reasons for the deviation and errors are as follows
• Loose connections
• Thickness of resin
• Wire gauge thickness
• Uneven surface
• Uneven air gap

23. Conclusion
• Experimental setup was designed, analysed, fabricated, assembled and
successfully tested.
• Problems occurring can be eradicated by
1. Proper connections in the stator.
2. Reducing weight of the setup.
3. Proper amount of resin used in the stator.
4. Proper gauge selection of copper wire.

24. Future Scope
• VAWT is well suited for green buildings.
• Can be used in place of Horizontal axis wind turbine.
• Can be used in rural areas to produce electricity.
• It can also be used in areas where wind speed is as low as 4 mph

25. References
[1] Dr. Adapa Rama Rao, K Gopi Nata, K Pradeep, G Pradeep Kumar, M S Sanketh, “Magnetically
Levitated Vertical Axis Wind Turbine”.
[2] Anton Aleksashkin Aki Mikkola, 2008 “Literature Review On Permanaent Magnet
Generators Design And Dynamic”, ISBN 978-952-214-708-0 ISBN 978-952-214-709-7 (PDF) ISSN
1459-2932
[3] Mark Paluta, Dan Reitz, Ryan Snelling, Joe Gadient, 2013 “Design and Fabrication of a
Vertical Axis Wind Turbine”
[4] Mayank Grover, B. Lohith Kumar, Isaac Ramalla, December 2014 “The Free Energy
Generator” ISSN 2250-3153
[5] Johnson, Howard R: US patent # 4,151,431(April 24, 1979), “Permanent Magnet Motor”
[6] RAMU KRISHNAN, “PERMANENT MAGNET SYNCHRONOUS AND BRUSHLESS
DC MOTOR DRIVES”
[7] NIMA MADANI, 2011, “DESIGN OF A PERMANENT MAGNET SYNCHRONOUS
GENERATOR FOR A VERTICAL AXIS WIND TURBINE” XR-EE-EME 2011:013
[8] S. J. Chapman, “Appendix B-Coil Pitch and Distributed Windings,” in
[9] Electric Machinery Fundamentals, Fourth Edition, USA: McGraw-Hill, 2004.

26. Websites sited date (10/08/2015)
[1] http://www.freemagneticenergy.info/
[2] http://www.ndfeb-info.com/
[3]http://blog.hasslberger.com/2013/11/german_inventor_solves_perma
ne-print.html