Highway wind turbine report

Designing, Analysis & Fabrication for
Prototype of
Highway Wind Turbine
Authors
Ali Rehman 14001134009
Ammar Aftab 14001134036
Fahad Bin Qamar 14001134004
Muazam Iqbal 14001134027
Supervisor
Mr. Mustafa Shahid
Assistant Professor, Department of Mechanical Engineering
DEPARTMENT OF MECHANICAL ENGINEERING
UNIVERSITY OF MANAGEMENT AND TECHNOLOGY
LAHORE
June 2018

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Designing, Analysis & Fabrication for Prototype of
Authors
A Project submitted in partial fulfillment of the requirements for the degree of
B.Sc. Mechanical Engineering
Project Supervisor: Co-Advisor:
Mr. Mustafa Shahid Mr. Rizwan Younis
Assistant Professor Lecturer
External Examiner Signature:________________________________________
Project Supervisor Signature: ________________________________________
DEPARTMENT OF MECHANICAL ENGINEERING
UNIVERSITY OF MANAGEMENT AND TECHNOLOGY
LAHORE
June 2018

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Abstract
Designing, Analysis & Fabrication for Prototype of
Project Supervisor: Co-Advisor:
Mr. Mustafa Shahid Mr. Rizwan Younis
Assistant Professor Lecturer
Worldwide dependence on “GREEN ENERGY” can comprehensively be impacted by Vertical Axis
Wind Turbines (VAWTs) as they possess huge prospective to contribute towards ever growing demand
of green energy. For sustainable contribution of VAWTs, these turbines should be made utilizable
outside their conventional farmland environments. This project features goal to utilize the power of
urban environment to produce energy using VAWTs effectively and efficiently. The main purpose of
this project is to design a wind turbine to utilize wind energy from atmosphere and vehicles on the
highway.
The turbine will be placed along medians of highways and sides of highways and effective
circumstances will be considered in this report. The turbine will be designed under modern engineering
standards and is given modern and effectively smart design. They also can be installed on parks, roads,
public facilities or other amenities. The proposed Helix wind turbine for highways are designed to
produce power up to 100 watts depending upon conditions. The power generated through turbine can
be used to provide electricity to streetlights along the highways and for miscellaneous use.
Keywords: Green Energy, Vertical Axis Wind Turbine, Helix Wind Turbine

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UNDERTAKING
Use the following undertaking as it is.
I certify that research work titled “Design, Analysis and Fabrication of Highway Wind
Turbine” is my own work. The work has not been presented elsewhere for assessment. Where
material has been used from other sources it has been properly acknowledged / referred.
ALI REHMAN
14001134009
AMMAR AFTAB
14001134036
FAHAD BIN QAMAR
14001134004
MUAZAM IQBAL
14001134027

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ACKNOWLEDGEMENTS
Final Year Project is a valued chance during which we apply most of the skills and engineering
education and knowledge that we acquired through the tenure of BS Mechanical Engineering.
This is a complicated phase in our education as we approach towards the conclusion of BS-
Mechanical Engineering Program at University of Management and Technology (UMT).
The Highway Wind Turbine project team would like to extend their thanks, admiration, and
appreciation toteam advisor SIR MUSTAFASHAHID and project Co-advisor SIR RIZWAN
YOUNAS for their administration and effective instruction and training throughout the
project. We would like to thank Dr. TIPU SULTAN for his headship, support, devotion and
supervision towards the senior year project as senior year projects supervisor.
The project team would also like thank UMT faculty, facility and staff for providing us the
education and skills that made all of this possible and for transforming us to reach at
respectable level

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TABLE OF CONTENTS
Abstract ............................................................................................………...3
Acknowledgement............................................................................................6
List of Figures ................................................................................................10
List of Tables..................................................................................................12
Chapter I: Introduction...................................................................................14
1.1 Global and Native Utilization.............................................................14
1.2 Problem Statement..............................................................................17
1.3 Motivation..........................................................................................18
Chapter II: Project Formulation……………………………………..............20
2.1 Overview............................................................................................20
2.2 Project Objectives...............................................................................20
2.3 Applications and Discussion...............................................................21
Chapter III: Literature Review……………………………………................22
3.1 Project Background ............................................................................22
3.2 Comparative Study.............................................................................26
3.3 Prior Work..........................................................................................30
Chapter IV : Project Management
4.1 Overview…………………………………………………………….38
4.2 Gantt Chart and Timeline……………………………………………39
4.3 Breakdown of work………………………………………………….40
Chapter V : System design
5.1 Requirements, constraints and specifications………………………...42
5.2 Design Methodology…………………………………………………44

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5.3 Product Subsystems and components………………………………..46
Chapter VI : Engineering Design and Analysis
6.1 Theoretical gained power calculations……………………………….51
6.2 Study of blade arc angle and effect on Cp…………………………....55
6.3 Aspect ratio and Overlap ratio of wind turbine……………………....58
6.4 Design and Simulation (Solid Works)………………………………..59
6.5 Design and Simulation (Ansys)………………………………………66
Chapter VII : Fabrication of Highway wind Turbine
7.1 Overview……………………………………………………………. 71
7.2 Material Selection……………………………………………………71
7.3 Description of Turbine……………………………………………….72
7.4 Discussion……………………………………………………………75
Chapter VIII : Testing and Evaluation of Highway wind turbine
8.1 Overview……………………………………………………………76
Chapter IX : Design Consideration
9.1 Health and Safety……………………………………………………78
9.2 Assembly and Disassembly…………………………………………79
9.3 Maintenance of the system………………………………………….79
9.4 Environmental impact and sustainability……………………………82
9.5 Economic Impact……………………………………………………82
Chapter X : Design Experience
10.1 Overview…………………………………………………………….83
10.2 Standards used in the projects………………………………………83
10.3 Contemporary Issues ……………………………………………….83

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10.4 Life-Long Learning Experience……………………………………..84
Chapter XI : Conclusion and Future Recommendations
11.1 Conclusion…………………………………………………………..85
11.2 Specifications………………………………………………………..86
11.3 Future Recommendations……………………………………………86
References……………………………………………………………………89

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LIST OF FIGURES
Figure 1.1: Energy access percentage in developing countries [1]………………………14
Figure 1.2: Installed capacity of wind power worldwide [2]………………………….....15
Figure 1.3: Annual Installed Capacity [3]………………………………………………..15
Figure 1.4: Total installed capacity of wind power (GW) by country [2]………………..16
Figure 1.5:Wind Map of Pakistan [4]…………………………………………………….17
Figure 3.1: Horizontal Axis Wind Turbine [8]…………………………………………...21
Figure 3.2: Vertical Axis Wind Turbine [10]…………………………………………….22
Figure 3.3: Horizontal and Vertical Axis Turbines [12]………………………………….23
Figure 3.4: World’s Biggest VAWT Quebec, Canada [13]………………………………24
Figure 3.5: Helix Wind Turbine [14]……………………………………………………...27
Figure 3.6 Betz’ Limit [27]………………………………………………………………..36
Figure 3.7: Actual power according to Wind Speed © Democritus University…………..37
Figure 3.8: Rotational speed as per Wind Velocity © Democritus University…………...37
Figure 4.1: Gantt chart for organization of work………………………………………….39
Figure 5.1: Applied phases of methodology……………………………………………….44
Figure 5.2: Main components of VAWT…………………………………………………..45
Figure 5.3: Rotor Blades of VAWT………………………………………………………..46
Figure 5.4: Shaft of turbine………………………………………………………………...46
Figure 5.5: Bridge Rectifier…………..……………………………………………………49
Figure 6.1: Graph V vs P th………………………………………………………………..52
Figure 6.2: Graph V vs P real……………………………………………………………...52
Figure 6.3: Graph Cp vs TSR……………………………………………………………...53
Figure 6.4: Two-dimensional schematic diagram of Helix turbine………………………..55

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Figure 6.5: Computing domains and boundary conditions……………………………….56
Figure 6.6: Wind turbine design SOLIDWORKS.......................................................…...58
Figure 6.7: Design report of helix wind turbine…………………………………………..60
Figure 6.8: Velocity profile SOILDWORKS……………………………………………..61
Figure 6.1: Design Modular Ansys………………………………………………………..65
Figure 7.1: Helix wind turbine…………………………………………………………….71
Figure 7.2: Main shaft of turbine…………………………………………………………..72
Figure 7.3: Flanges of Turbine…………………………………………………………….72
Figure 7.4: Complete assembly of turbine………………………………………………...73
Figure 8.1: Graph between wind speed v/s time…………………………………………..75
Figure 8.2: Theoretical vs Experimental Calculations of Gained power…………………78
Figure 11.1: Future applications of highway wind turbine………………………………..86
Figure 11.2: Design concept of modern wind turbines……………………………………87
Figure 11.3: Application of highway wind turbine………………………………………..87

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LIST OF TABLES
Table 3.3.1: Wind speed calibration Data. © Memorial University………………………36
Table 3.3.2: RPM vs Velocity © Democritus University…………………………………37
Table 4.1: Work breakdown structure…………………………………………………….40
Table 5.1: Electrical Parts…………………………………………………………………48
Table 5.2: Battery Specifications………………………………………………………….50
Table 6.1: Theoretical Gained power calculations………………………………………...51
Table 6.2: Theoretical efficiencies for TSR……………………………………………….54
Table 6.3: Dimensional Parameters……………………………………………………….55
Table 6.4: Maximum coefficient of power for each case………………………………….57
Table 6.5: Goal plotting in solid works……………………………………………………59
Table 7.1: Strength Parameters of fibreglass………………………………………………71
Table 8.1: Experimental Readings (Normal winds)………………………………………..76
Table 8.2: Projected Readings (Windy day)……..………………………………………...77
Table 8.3: Theoretical vs Experimental gained power……………………………………..78

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CHAPTER 1
Introduction
Vertical axis wind turbines are distinguished for their capability to catch the maximum of wind
from all the directions thus neglecting the need of yawing mechanism and rudders. There are
two types of Vertical Axis Wind Turbines: The Darrieus and The Savonius type. Research and
development on Darrieus Wind Turbine continued from 1980’s in USA pioneering this
development was Sandia National Laboratories USA.
From then, new and revolutionary concepts had made impacts on wind energy production. One
of the revolutionary concepts that can be of substantial importance is Helical or Helix Vertical
Wind Turbine for their application in urban or city environment. Due to their safer use,
minimum risk of blade ejection and capturing power in all directions of wind makes this type
a perfect ingredient to perfect recipe.
On the other hand, horizontal axis turbines being more efficient at converting power of wind
to electricity is still the best fit for commercial market or utility scale power generation.
However, small vertical axis wind turbines are more suited to onshore wind generation and to
urban areas as they low or no noise levels and their reduced risk rate.
Energy extraction from wind sources flourished in 1970’s after the global oil crisis. During that
era USA, GERMANY and DENMARK imbued huge amount of money to carry out research
in alternative sources of energy. Europe continued its commitment of renewable energy sources
and still tops in term of technology and wind capacity installations.
With petroleum utilization as its peak globally making them crucial for wellbeing of humans,
one can optimise the future where each human community in the world will fortified with wind

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generators and solar collectors. Efforts made in green energy generation will contribute great
towards the noble cause of transforming human lives and whole community on earth.
The financial and social expansion of horizontal axis turbine may suffers limitation in near
future particularly due to high amount of stress being produced in larger turbine blades. It is
also recognized that rather less effective vertical axis wind turbine will not have to face such
problems and they will be made to pioneer the green energy production from wind sources.
1.1) GLOBAL AND LOCAL UTILIZATION OF WIND ENERGY
Vertical helix wind turbine with its extensive and adequate features can be made utilizable in
cities, highways around the globe. Vertical helix wind turbine can be the optimum choice for
developing countries as they have variable amount of access to electricity and the efforts in
renewable sources of energy can aid these countries to count less on conventional sources of
energy generation.
The following figure shows the geographical distribution of the areas with percentage access
in developing countries.
Figure 1.1: Energy access percentage in developing countries [1]

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Global use of wind energy increased immensely from 2001 to 2010. Figure 1.2 indicated newly
installed capacity installed yearly. The rate of wind energy growth took leaps and bounds by
growing 21.3% in 2004 and up to 31.7% in 2009. The World Wind Energy Association extracts
the shown in this section from World Wind Energy Report 2009 [2].
Figure 1.2: New installed capacity of wind power worldwide [2]. 2010 data is prediction.
In the past few years’ annual installed capacity for different regions have witnessed many
variations. With Europe now struggling with regard to growing wind power capacity due to
early exploitation, Asian region particularly China and India show significant growth [3].
Figure 1.3: Annual Installed Capacity [3].

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Total installed capacity of wind energy generation, country wise represents the devotion and
commitment of countries contributing in renewable energy resources. Figure 1.3 exemplifies
the capacity by country, which shows USA leading in installations of 35.1 GW followed by
CHINA and GERMANY at 26 and 25.7 GW. Apart from them Denmark, Portugal and Spain
are also major contributors in wind energy production [2].
Helix Wind Turbine Application along highways of PAKISTAN:
Pakistan has one of the biggest highway networks in south Asia as it has two motorways M-1
and M-2 along with national highways. Based upon wind map of Pakistan highways along
Makran coastal Highway, Motorway from Lahore to Islamabad and national highway in KPK
and AJK has great potential for wind power generation.
In addition to natural wind prospective, vehicles along the highways induces wind turbulences
and this phenomenon can enhance the wind speed. Average vehicle passing rate at M-1 and M-
2 are 16 and 22 respectively with heavy traffic using left most lanes. The effect of wind
turbulence created by passing of vehicles measured to be 0.6 – 0.9 m/s and 0.8 – 1.1 m/s for
Figure 1.4: Total installed capacity of wind power (GW) by country for top ten countries [2].

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low and heavy traffic respectively. Therefore, Pakistan has a good potential of producing
electricity from wind power it appropriate efforts are progressed effectively.
[4]
1.2) Problem Statement
Challenges that wind power generation technology faces are:
 Devoted area for installation of turbines
 Fluctuations in the sources of wind
 Safety and aesthetic look
 Efficiency
Figure 1.5: Wind map of Pakistan

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 Design of blades to capture maximum of wind power
 Optimum use of inverter and other electrical equipment.
 Cost / Capital Investment
Helix wind turbines will eliminate the criteria for dedicated use of land, as the turbine will be
mounted on small utility poles between medians of highways. An in depth analysis will be
conducted on fluid flow to attain boundary limitations for wind turbine. The turbine will be
designed to generate power at rather less wind speed for this turbine design will have to go
some reconsiderations and changes.
Helix wind turbine will be given an aesthetic look so it does no harm to beauty of environment
and adjust herself to surrounding conditions quickly. Safety issues factor as of prime
importance will be addresses thoroughly throughout this project design and fabrication
processes. In order to increase the efficiency of turbine, efforts will be part of project to reduce
the level of losses at any stage.
In Helix wind turbine, some design changes will be undertaken and experimental results will
conclude the optimum considerations for design alternations to obtain maximum of wind
power. Apart from changes in design, optimum use of electrical and controlling parts will be
of vital importance to enhance the gaining benefits from this project.
Cost analysis will also be an important and integral part of project, as cost-benefit analysis will
lead the productive and feasible outcome of the project.
1.3) Motivation
The world is confronting a massive challenge of accomplishing its energy needs from
renewable and supportable sources. Conventional ways of producing electricity is being
discouraged globally, wind and solar are well-established and appreciated “GREEN” energies
in the world. Both have extensive amount of prospective for energy generation around the

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globe. More expedient and inexpensive ways for energy generation from renewable sources
should be introduced to the world, so that population could get their priorities change from
fossil fuels to renewable energy sources.
Today, renewable energy systems still face massive hurdles in developing nations as they
have high investment and are generally unsightly. As wind turbines are expensive, it is very
difficult to many developing countries to rationalize capitalising in renewable energy
technologies. Globally governments and local populations always choose cheap and suitable
ways of generating electricity. Regrettably, it is evident that renewable energy resources are
extremely expensive which created many spaces for conventional sources to fill that gap.
The basic inspiration and motivation for opting the project of HIGHWAY WIND TURBINE is
to positively contribute toward the globally progress of renewable energy resources in
practicable way, making it preferred choice for developing countries. Wind turbine are often
used in rural topography while the aim of this project is to promote onshore wind energy
generation by utilizing turbines in cities.

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CHAPTER 2
Project Formulation
2.1) Overview
Immense prospects can be practised to improve and enhance the performance the vertical axis
helix wind turbine in upward as well as downward manner. Many design considerations will
arise in this project from selection of turbine blades, materials and components. Efficiency of
blades and backing configurations will be tested.
As helix wind turbine will be deployed at outdoor environment, it’s all components will be
made to endure severe climatic circumstances. Low maintenance and low cost for material will
be effective subsets of the project. Turbine lifetime and cost-benefit analysis will be integral
constitute of Highway wind turbine project.
Wind energy systems should employ to work to cater the needs just because of its extensive
potential of participating in global clean energy technologies in the near future.
2.2) Project Objectives
Helix Wind Turbine for Highways will be designed with following aims and objectives:
 To design wind turbine-taking account of Pakistani wind potential.
 To analyse the increase in efficiency of Helix Wind Turbine.
 To determine the optimum value of Cₚ and study the effects of blade arc angle on Cₚ
for enhanced efficiency of turbine.
 To offset the quantity of pollution generated by combustion of fossil fuels by
introducing a feasible and potential source of clean and green energy.
 To learn and gain exposure on Computational fluid Dynamics (CFD) using Ansys.

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2.3) Applications of Helix Wind Turbine for Highways and Discussion
2.3.1) Application:
Application of this project is quite clear and vibrant, as it emphasis on consuming energy
provided by wind by designing and fabricating a Vertical Axis Helix Wind Turbine for
highways. Highways will be optimum place for installations so extract maximum power of
wind.
Apart from highways, public facilities such as parks, stadium tops and communication towers
can be operating places for installation of helix wind turbine because wind speed varies
significantly around stadiums, high service buildings and surroundings of the motorways and
highways.
Electricity generated from wind turbine will be utilized to charge the batteries and will lighten
up the streetlights at night. Reducing pollution whether emissions and noise are important
applications of wind turbine.
2.3.2) Discussion:
The project will commence with prodigious sanguinity and high prospects for the final product
to be installed and tested in reality on motorways and highways scenario. However, issues
regarding installation of wind turbines along motorways and highways can face hurdles in near
future and if not solved appropriately then it would be very difficult for the project team to
conduct experiments along highways and motorways. Because, there are many bureaucracy
related problems that will occur while gaining permission for the experimentations.
Development of prototype rather than full-scale turbine can be a major possibility if
manufacturing of full-scale turbine will cost too much in terms of money. The major portion

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of testing will be relied on theoretical model, which will allow the project team to make any
changes before initiating the manufacturing phase of project, to avoid ever-increasing cost of
the project.
CHAPTER 3
Literature Review
3.1) ProjectBackground
Since, energy sector constitutes the chief and vital part of any country economy and it is not
easy to possess all or most the types of energy resources by a country. However, retaining
multiple sources of energy generation is tremendously imperative to secure and amplify the
basic needs of people in any country. Since, conventional or old generation methods of energy
production cost too much and is dangerous to environment, so in this critical moment nature
can help us by allowing us to utilize the energy present in the natural phenomenon such as
solar, wind, sea and geothermal energies.
Renewable energy is defined exquisitely by Science Research Newspaper as: “Energy from an
energy resource that is replaced rapidly by a natural process such as power generated from
sun or from or from wind ” [5].
Recently, rise in the demand of renewable energies have perceived a huge increment.
According to a report published by International Energy Agency, the growth in amount of
electricity generated from renewable resources have increased from 13% in 2012 to 22% in
2013. It is also believe that by 2020 the energy generation from renewable resources would hit
26% [6].

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Looking in Pakistan, we notice that primary sources of energy generation is power plants that
utilize either furnace oil, gas and coal which extremely anti-environment. Oil utilizing power
plants were declared the chief contributors in polluting the earth environment by EcoSpark
Environment Charity [7] . Following are some of environmental suffering from usage of oil or
coal power plants.
 Greenhouse emissions and increased air pollution
 Perilous solid waste and slurry
 Non-renewable energy resource
 Destruction of environment as result of extraction and refining
 High usage of water thus crafting water pollution and high thermal discharge
Some of these devastating effects force us to think of clean, cheap and renewable sources of
generating electricity, which will ad in reducing global warming and helps us in enhancing life
style of people around the globe.
With the word renewable energy, people instantly thinks of Wind power generation. The idea
of wind energy is to extract the kinetic energy stored in wind as to convert and enhance it to
useful mechanical work. Our plan ties the knot with wind energy source. The idea of this project
is to convert wind energy into electricity by using Vertical Axis Wind Turbine (VAWT).
There exists two main types of wind turbines, Horizontal Axis Wind Turbines, as shown in
figure 3.1 are more commonly utilized around the globe and majority of them are used in form
of power plants.

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In research studies comparing the performance analysis of wind turbines, Horizontal wind
turbine came out to be more efficient than Vertical axis wind turbine. However, large
devoted area or large blade diameter of horizontal wind turbine which is quite large than
vertical turbine limits its utilization to restricted locations. Many believe globally, that
blade area of horizontal axis turbine makes that machine distasteful [8].
The further category of wind turbine is the Vertical Axis Wind Turbine (VAWT), which
shown in figure 3.2. Utilization of VAWTs on small scale allows everyone to convert
his/her home into source of green energy generation.
Figure 3.1: Horizontal Axis Wind Turbine [8]

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VAWT lags behind HAWT in terms of usage as power plant generators because of their
low yielding power or efficiency. Nevertheless, VAWT results good efficiency when
utilized in homes, parks offices are alongside highways and motorways. VAWTs are very
adaptable as they can powered by wind coming from all 360 degrees. Because of its diverse
applications, VAWTs are considered appropriate solution in the conditions, which does not
cater consistent wind speeds [9].
Figure 3.2: Vertical Axis Wind Turbine [10]

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3.2) Comparative Study
Different types of Wind turbines exist in modern day world. Horizontal and vertical axis wind
turbines are two main types of turbines. Both have certain advantages and disadvantages over
each other regarding different aspects. Explanations and brief description of sub types of the
categories constitute the comparative study section.
Horizontal AxisWind Turbine
Horizontal axis wind turbine (HAWT) establish the most communal type of wind turbine in
use today. In fact, all the grid connected commercial utility turbines are now days horizontally
designed with propeller type rotor mounted on top of vertical tower. Horizontal axis turbines
needed to be aligned with direction of wind thereby consenting the wind to flow parallel to axis
of rotation.
[10]
Distinctions have been made in horizontal wind turbine as the UPWARD and DOWNWARD
rotor turbines. In upward turbines, rotor stands facing the wind in front of the vertical tower
thus avoiding the wind shade effect from the presence of the tower but they need yaw
Figure 3.3: Horizontal and Vertical Axis Turbines

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mechanism to keep rotor axis aligned with wind direction. Downward wind turbines are placed
on lee side of the tower allowing fluctuations in wind power needing yaw mechanism. The
enormous majority of wind turbines in operating conditions today have upwind rotors.
Vertical AxisWind Turbine
Vertical axis wind turbine or (VAWT) are among types of turbine that witnessed the light of
day from the past century. VAWTs are designed to correspond to wind quickly. Requiring
complex designing, it hardly meets the efficiency of HAWT. However, its localized or
domestic utilization makes it extremely important in small-scale onshore wind power
generation. The figure 3.4 shows the biggest prototype of vertical axis turbine (100 m rotor)
with capacity of 4.2 MW. Operational from 1983-1992, it was the only vertical axis turbine to
have been manufactured commercially.
Figure 3.4: World’s Biggest VAWT Quebec, Canada [13]

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Advantages of HAWT:
 Access to stronger wind area in sites courtesy of tall base tower increase the wind speed
up to 20% and enhancing power output to approximately 34%.
 HAWT yields high efficiency as the blades continuously move perpendicularly to the
wind thus getting power through entire revolution.
Disadvantages of HAWT:
 Immense construction is required for tower construction to support the heavy blades,
gearbox and housing for generator.
 Difficulty in transportation of rotor blades, shaft and other components. Components
of HAWT is usually lifted into position such as gearbox, rotor shaft and brake assembly.
 HAWT generally requires a yaw mechanism to turn the blade towards wind.
 HAWT involves braking system in high winds to brake the turbine from spinning,
abolishing and injuring itself.
 Induction of cyclic stresses and vibrations in blades of HAWT. This cyclic winding can
rapidly fatigue and destroy the blade, hub and axle of turbine.
Advantages of VAWT:
 VAWT accommodates generation of electricity from wind flowing in all directions.
 VAWT has generator, gearbox and other components placed on ground, strong support
or tower in not usually required.
 VAWT does not require yaw mechanism and pitch mechanism to point turbine in wind
direction.
 Easy installation and Maintenance as compared to other turbines.
 Transportation of VAWT is quite tranquil.

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 High utilization of VAWT in urban environment.
 Low risk rate for humans and flora as VAWT operated on low speed.
 Adoptable for many climatic circumstances such as mountains, deserts, cities etc.
Disadvantages of VAWT:
 VAWT generally harvests low efficiency because additional drag created when blades
rotate.
 VAWT faces turbulent flow, which can result in vibration.
 Small-scale utilization of VAWT making it inappropriate for commercial usage.
Helix Wind Turbine:
The unique vertical axis, double helix blade design makes this turbine adaptable, reliable and
efficient way of generating renewable, pollution free power day and night. Helix wind turbine
possess the property of access the wind flowing from all directions without requiring yaw
mechanism. Helix wind turbines produces output even at low wind speed of 2.8 m/s. Helix
wind turbine exhibits robust as little shear. Helix wind turbine has low or no maintenance, low
operating costs and non-complex structure.
Helix wind turbine can withstand extreme weather such as frost, ice, humidity and wind speed
up to 45 m/s depending upon models. Helix wind turbines are practically silent and eliminated
the strobing effects with its non-reflecting surfaces. Helix wind turbines have pleasant and
aesthetic look with effective smart design. Helix wind turbines have the performance
optimization using the latest power electronics.

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3.3) Previous Work
Preliminary research has been done on “Vertical Axis Wind Turbine” on large scale. Different
organizations and research institutions in Europe and USA have been developing VAWTs for
integration into their national supply. These advancements have led admired institutions i.e.:
MIT and Caltech to accomplish their own research and simulations of these revolutionary
machines.
There are two main styles of VAWT i.e.: Savonius and Darrieus. Our project is based mainly
on Savonius style VAWT. Most of the wind turbine today in small-scale utility are the Savonius
model turbines.
Sigurd Johannes Savonius from Finland invented Savonius wind turbine in 1922. Although
various attempts had been made to design this turbine from the past centuries [11].
International Research Journal of Engineering and Technology in June 02, 2015 has published
research titled “DESIGN, ANALYSIS AND FABRICATION OF SAVONIUS VERTICAL
AXIS WIND TURBINE ” [12].
Figure 3.5: Helix Wind Turbine [14]

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The research accomplished the showcase of efficiency of Savonius model as per varying wind
conditions. It also shows that Savonius rotor is not solely drag driven but is a combination of
drag driven and lift-driven device. Therefore, it can surpass the maximum Power Coefficient
Cp established for purely drag driven machine.
The research article “Construction of helical vertical axis wind turbine for electricity supply”
published by Taylor and Francis ISSN: 1686-4360 [13] shows the effective constructional
methodology for Helix wind turbine.
International Journal of Energy and Environmental Engineering in 2013 published research,
which titled “Wind tunnel testing and numerical simulation on aerodynamic performance of a
three bladed Savonius wind turbine” reflects the efficiency of three bladed Savonius rotor in
comparison with two-bladed rotor Savonius model [14].
Journal of Physics published research paper “ANALYSIS OF DIFFERENT BLADE
ARCHITECTURES ON SMALL VAWT PERFORMANCE” highlight the effect of blade
design on small-scale utility and concludes the comparison of different VAWT structures [15].
International Journal of Innovative Research in Science. Engineering and Technology
published paper “Design and analysis of helical blade wind turbine” describes about the wind
power and its potential that can be harnessed in future using smart design of Helix wind turbine
[16].
Technical journal, University of Engineering and Technology Taxila, Pakistan issued a
research article on “Common vertical axis Savonius –Darrieus Wind turbines for low wind
speed highway applications” in 2016, which discussed the hybrid mechanism of both turbines
for applications in low speed conditions [17].
Books on wind energy and Wind power generation technologies i.e.:

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 Introduction to Wind Energy Systems
 Wind Energy Engineering
 Guidelines for design of Vertical Turbines
 Wind Energy Design
Were supportive for gaining exposure of wind energy technology.
The generating capacity of power generation system is calculated by equation listed below:
In this equation, ρ is air density, A is blade swept area, V is relative wind velocity, Cₚ is power
conversion coefficient and ƞₚ, ƞg, ƞₑ are coefficient of mechanical transmission, generator
efficiency and power conversion efficiency respectively [18]. The basic purpose of this project
to maximise P by playing with factors the effect P. Density of natural air cannot be altered [19].
Velocity of wind can be enhanced by locating the place of turbine where there will be high
exposure of wind gusts along highways and motorways created by traffic passing by.
For vertical axis turbine, there are many factors, which must be put under consideration in
calculations of capability of Wind turbine. The density of wind and wind speed are important
two factors that enhance the power generated.
For calculations of blade swept area, distance between blades and rotor have to be multiplied
with length of turbine’s blade to find out the area. The equation is defined as [20]:
D = diameter of turbine’s rotor
l = length of turbine’s blades

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Betz Limit:
Wind turbine when converts the energy from flow of wind to mechanical energy, there exists
a limitation in doing so. This limitation is mathematically proven using Betz’ Law. The law
shows that there is a limit by utilizing following equation [21]:
The maximum value for Cₚ is found out to be 59.9% for HAWT and can be enhanced to 63%
for VAWT.
Tip Speed Ratio (TSR):
Tip speed ratio is vital when designing a wind turbine. It is usually defined as wind speed at
blade tip divided by wind speed. For instance, if wind is flowing at 6 m/s and tip of blade is
travelling at 24 m/s then TSR will be 4, so the blade will be traveling 4 time faster than wind
driving it.
TSR is extremely important in determining the number of blades in a turbine. This phenomenon
is vital because wind flowing off one blade affects the flow of wind on following blade. For
example, if blades moves too slowly the wind will pass through rotating blades, wind energy
will not be utilized appropriately, and in the same way in case of strong wind situation, the
wind will break over the turbine just like over buildings.
With some known values, it is possible to estimate the rotational speed of turbine’s rotor. Using
the equation:

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ω = Rotational speed of turbine rotor (RPM).
λ = Tip speed ratio.
r = Radius of turbine rotor (m)
V = Speed of wind (m/min) [22].
In order to select a power coefficient Cp, we should stick to TSR value for blades being used
in turbine from figure 3.3.1 [23].
In order to calculate the power produced by the turbine, Pt,the maximum power coefficient Cp,
will be multiplied with value of power produced by wind by utilizing the following equation
[21]:
Reynold’s Number:
The project lost its credibility if fluid flow is not under consideration i.e.: negligence to mention
Reynold’s Number. Reynold’s Number is the ratio of inertial forces to viscous forces.
Figure 3.6 Betz’ Limit [27]

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Reynold’s number usually determines the category of flow as laminar, turbulent or mixed flow.
Considering, laminar flows in which viscous forces stands dominant, fluid motion is smooth
and constant, which is ideal and appropriate for wind turbines. On the opposite side, inertial
forces controls the phenomenon in turbulent flow, which can result in vortices and uncertainties
that can damage the effectiveness of turbine. To calculate the Reynold’s number (Re) following
equation is utilised [21]:
V= Wind Speed.
TSR = Tip speed ratio.
ρ air = Density of air.
Lc = Length of aerofoil chord.
μ air = Dynamic viscosity of air.
It should be noticed that as the wind speed increases and the TSR increases the flow of the
wind would become turbulent thus decreasing the efficiency of turbines and inducing
dangerous problems. This turns out to be an important factor too when considering the
maximum speed turbine can withstand before it is forced to shut down for betterment of
turbine’s life and safety purposes.
Apart from that some of the important factors to be considered are:
Wind Shear: Wind shear describes the change in wind speed as function of height. Open
agricultural and lands surrounding motorways and highways have wind shear ranging from
0.15 – 0.17.

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Cut – In Speed: Speed at which turbine starts producing power. Range for helix turbines is 2.5
– 5 m/s.
Rated Speed: Speed at which rated power is produced by turbine.
Cut – Out Speed: Speed at which turbine stops operation under safety concerns. Its typical
range is 25 – 50 m/s for helix wind turbines.
A student project from MEMORIAL UNIVERSITY [24] devoted to designing and evaluating
of twisted Savonius wind turbine aimed testing self-starting of turbine. Developing a design,
which can withstand harsh climatic circumstances for longer-term reliability, was also main
objective of that project. The table 3.3.2 exhibits the conclusion of the wind turbine that proved
to be self-starting at low speed.
One more student project that was considered during data searching was “Designing a Savonius
Wind Turbine” from Democritus University of Thrace [25] with objective to study and
Table 3.3.1: Wind speed calibration Data.

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manufacture a vertical wind turbine. Important considerations in that project was geometrical
design off blades, efficiency, and account of cost, sophistication and feasibility along with
robustness of turbine.
After experiments, relation between wind velocity and actual power produced was deduced.
They drew that if wind speed in doubled than actual power will witness the increment 8 times
more than previous power, as shown in figure 3.7:
An important result exhibits the rotational speed of turbine varying with wind velocity as
shown in figure 3.8 and table 3.3.2:
Figure 3.7: Actual power according to Wind Speed
Table 3.3.2: RPM vs Velocity
Figure 3.8: Rotational speed as per Wind Velocity

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CHAPTER 4
Project Management
4.1)Overview
Project management is the process and activity of planning, organizing, motivating, and
controlling resources, procedures and protocols to achieve our goals. A project is a temporary
endeavour designed to produce a unique product, service or result with a defined beginning
and end (usually time-constrained, and often constrained by funding or deliverables),
undertaken to meet unique goals and objectives, typically to bring about beneficial change or
added value.
Like any other project, the senior student project described in this report needed attention in
terms of project management. Achieving minimum goals set by the university (client in project
management terminology) regarding the senior projects was a challenge in presence of certain
constraints such as time, scope and budget. Furthermore, achieving the best quality was simply
not possible in the absence of a proper equipment and the required laboratories and tolls that
needed for such projects.
The team began this project with very large and optimistic expectations. Originally, multiple
full-scale turbines were planned for construction. This was soon seen to be unrealistic. The
construction of even one full scale exact turbine made with design specifications was out of
reach due to time and manufacturing constraints. The most value was determined to be in the
creation of to scale models which would allow for the most productive analysis to be
performed. With many tasks to complete and a tight timeline to follow, proper project
management was imperative to the success of this project. The project began in a very broad
fashion. The project planning has started when the projects were assigned to the groups. Team

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leader also nominated and assigned by the group members. We start planning for work
distribution to meet the millstones that been given by the instructor.
The design of turbine and supports themselves was conducted completely on University
grounds. Three-dimensional drawings of turbine and supports were made in SolidWorks, Creo
and AutoCAD along with simulation and analysis in Solid works and Ansys. Each of these
configurations was also designed and drawn in SolidWorks. These CAD models allowed for
mock-ups to be created before the physical models were assembled. All of the team members
were expected to research the pros and cons of the different design options to ensure the most
efficient design. The preliminary Solid works design of the highway wind turbine was updated
with new information.
4.2) Gantt Chat for the Organization of Work and Timeline
The below figure shows a timeline that the team developed to plan carefully for the required
tasks and meet the deadlines.
Figure 4.1: Gantt chart for organization of work

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4.3) Breakdown of work into tasks:
Contribution of the team members of this project was proactive the team work was going
smoothly over the semester achieving the milestone one by one. All the group members
were participating in all of this project steps:
This project steps are:
 Planning
 Research and Analysis
 Designing and Manufacturing
 Bi-weekly reports
 Weekly meetings
 Final report writing
 Mid and Final presentation
 Final demonstration
All team members were expected to participate in the research and design of the highway wind
turbine. Team meetings were frequently held at least once a week. ALI REHMAN had the most
influence in collecting and analysing relevant data relating to the turbine design and was
charged primarily with the solid works rendering of the turbine. AMMAR AFTAB was in
charge of experimentation the completed model on before production of the prototype. FAHAD
BIN QAMAR was in charge of all the simulation and media works. MUAZAM IQBAL was
in charge of plotting the results and graphical sections. Much of the work was performed as a
team but these were the areas where each individual made the most impact.

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Table 4.1: Work Breakdown structure
Task Members Hours
Project Overview All Members 6
Proposed Design All Members 12
Design Survey Ammar Aftab 15
Preliminary Sketches Fahad Bin Qamar 12
Solid Works Design Ali Rehman 50
Researchand Data
Analysis
Ali Rehman 40
Cost Analysis Muazam Iqbal 10
Material Selection Ammar, Fahad, Muazam 8
Ansys and Solid Works
Simulation
Ali Rehman 80
Design Prototype Ali Rehman 48
Testing Prototype All Members 30
Optimize Prototype All Members 20

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CHAPTER 05
SYSTEM DESIGN
5.1 REQUIREMENTS, CONSTRAINTS AND SPECIFICATION
5.1.1 General specifications
Helix wind turbine is new way of producing energy form Vertical-axis method. This new
energy source is useful in the modern cities because of it is nice design and free noise. Helix
wind turbines, which are small and can produce up to 100 watts.
The positive point of wind energy is that unlike solar energy that only can be used with
Sunlight only. Wind energy can be useful all the 24 hours all the year. This project is green
source of energy and has no effect on the life of earth.
There are no effects on the environment at all. Moreover, it is reduce the CO2 and CO gases
that effect the environment in the earth. One of the biggest challenges is the social accept of
Helix Wind turbine.
5.1.2 Constraints and requirements
One of the most difficultly problem is the lack of necessary equipment needed for the
analysis and selection of materials accurately in the university. In addition, in the market, it
was really difficult to find some of the needed materials.
These problems make the function of this project relying for some parts in design of
previous studies by doing the reverse engineering.
Getting a sufficient wind, to analyse and test work. It was also the one of the berries that
we have encountered, because of the lack of wind in the area at that time, and the lack of
experience in aerodynamic science.
Beside the Lack of important resources, the lack of financial support was a major obstacle

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in our way even though the budget was estimated. Although the existence of moral support
from our professors, Lack of sufficient time was a real challenge to show up the work as long
as there was only two semester to complete the senior project.
5.2 DESIGN METHODOLOGY
The methodology applied to this project can be divided into six phases. These phases are
information gathering, concept generation, model generation, model analysis and
refinement, concept selection, and verification, these phases are shown in figure
Figure 5.1: Applied phases of methodology
Prior any appropriate solution can be developed, a thorough investigation has to be
conducted in order to find out what solutions have already been proposed (information
gathering).
Once these solutions have been analysed and the team has an understanding of why the
respective solutions are not currently being implemented, a solution generation phase is
taking place. Here various solutions are presented and evaluated against criteria and
constraints (concept generation).

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The results of the models are then analysed and the model, as well as solution parameters,
may be tweaked (model analysis and refinement). Once the team has satisfactorily modelled
all solution concepts of interest, the concept that performs best analytically, in addition to
meeting all criteria and constraints, is selected (concept selection). The analytical model may
then be verified experimentally, using a small scale modelling scheme or through a full-scale
experimental model.
The objective of this project is to design a vertical axis wind turbine (VAWT) that could
generate power under relatively low wind velocities. To accomplish this goal, the objectives
are to:
 Analyse how different geometry of the wind turbines would affect the output power
of the wind turbine.
 Compare the operation of turbines with respect to the numbers of attached blades.
To meet the above objectives, the tasks were to:
 Conduct background research and analysis on wind turbine technology
 Design initially turbine blade for testing.
 Looking for power generator that has good efficiency with low start up speed.
 Create experimental set up.
 Develop future design recommendations.

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5.3 Product Subsystems & Components
Vertical axis wind turbine VAWT are one whose axis of rotation is vertical with respect
to ground. Generally as shown in figure 3.3, the main components of this turbine are:
 Blades
 Shaft
 Generator
Figure 5.2: Main components of VAWT
5.3.1 ROTOR BLADES
Savonius blades are a crucial and basic part of a wind turbine figure 3.4. They are mainly
made of aluminium, fibre glass or carbon fibre. We selected the fibre glass alloy as
recommended in the study because they provide batter strength to weight ratio. Rotor blades
take the energy out of the wind; they capture the wind and convert its kinetic energy into the
rotation of the hub.

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The arc angle was selected based on the pervious study, which recommended an angle of 160°,
but due to difficulties in manufacturing, we went on with arc angle of 180°.
Figure 5.3: Rotor Blades of VAWT
5.3.2 SHAFT
The shaft is the part that is turned by the turbine blades. It in turn is connected to the generator
within the main housing. A solid works tools have been used in designing the blades and the
shaft as shown in the below figure:
Figure 5.4: Shaft of turbine

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5.3.3 Radial & Thrust Bearings
The bearing is integral part of the overall system. The lubricant and sealing elements
also play a crucial role. To enhance bearing effectiveness in the system, the right
type should be selected. However the procedure of the selection is a science but we
restricted on three simple steps:
1- Confirm operating conditions and operating environment.
2- Select bearing type and configuration.
3- Select bearing dimensions.
The correct amount of an appropriate lubricant must be present to reduce friction in
the bearing was consider. As long as the sealing elements are important because of
the environment surrounding our project and keep the lubricant in, and away from
the dust and contaminants. On another side, the low speed of the system was
consider too in the selection with axis and radial forces which is the weights of upper
system.
As result we came up with two ball bearing 6004RS where can function as thrust and radial
bearing (sealed and self-lubricant) and can carry the Static Load Rating and Dynamic Load
Rating 5 KN and 9 KN respectively and the distance between the two bearings was based on
as simulation Xpress done by Central University Campus[26].
5.3.4 Electrical Parts
The turbines are connected to electrical parts in order to get the required power. These parts
are as shown in the below table 5.1.

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Table 5.1: Electrical Parts
Parts Function
Electrical Generator Converting the rotating speed to an electrical energy.
Battery Charged electrically to provide a static potential for power or
released electrical charge when needed.
Fuse An electrical device that can interrupt the flow of electrical
current when it is overloaded.
Converter Converting DC current to AC current or vice versa.
Consumption reading Reading battery percentage.
5.3.5 Generator and Rectifier:
The conversion of rotational mechanical energy to electrical energy is performed by
generator. Different types of generator have been used in wind energy system over the years.
For large, commercial size horizontal-axis wind turbines, the generator is mounted in a
nacelle at the top of a tower, behind the hub of the turbine rotor. Typically wind turbines
generate electricity through asynchronous machines that are directly connected with the
electricity grid. Usually the rotational speed of the wind turbine is slower than the equivalent
rotation speed of the electrical network - typical rotation speeds for wind generators are 5-
20 rpm while a directly connected machine will have an electrical speed between 750-3600
rpm.. This also reduces the generator cost and weight. The generator used for the prototype is
the Low RPM permanent magnet AC generator and is a step generator with max. current
output of 5A. The generator must be connected to bridge rectifier to obtain current in DC and
to charge the battery.
Figure 5.5: bridge rectifier12 V 5 A

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The current generator can only operate continuously with a current of 1.5 amperes and at a
max of 1.5 minutes with a current of 5 amperes the below figures explains the generator
parts.

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5.3.6 Battery
The battery that we used (once) in our project is WPL150-12N rechargeable power guard
sealed lead acid battery as shown in the below table 5.2.
Table 5.2: Battery Specifications
Item Weight 25.5kg
Capacity 150Ah
Dimensions 19.02 x 6.7 x 9.5
Maximum Discharge Current For (5 sec) 1500A
Design Life 5 years

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CHAPTER 06
Engineering Design and analysis
6.1) THEORETICAL WIND TURBINE POWER CALCULATION
Wind Power depends on:
 amount of air (volume)
 speed of air (velocity)
 mass of air (density)
Taking in consideration the turbine Power coefficient, power in the wind is calculated using
this formula:
P = Power in watts
ρ = Air density “At sea level ‘air density’ is approximately 1.2 kg/m^3
A = Turbine Area in m^2, which can be calculated from the length of turbine blades
(A = 0.52*1.05*3.142 = 1.716 m^2)
Cp max = 0.2837 for φ = 160° and 0.2617 for φ = 180°
V = velocity in m/s

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Table 6.1: Theoretical Gained Power Calculations
Theoretical Gained Power Calculations
Wind Speed (V) Power (watts)
0.5 0.131
0.6 0.227
1.3 2.301
1.5 3.542
3 28.374
5 131.378

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Figure 6.1: Graph V vs P th
Power calculated taking account of actual parameters neglecting Cp resulted in slightly
different result, which are plotted below:
Figure 6.2: Graph V vs P real
0
5
10
15
20
25
30
35
40
0 1 2 3 4 5 6
V vs P (In presenceof Cp)

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Co-efficient of performance was examined against TSR and yielded results are plotted below:
Figure 6.3: Graph Cp vs TSR
Theoretical Specimen Calculation:
N (rpm) = 280 V= 5 m/s Swept area = 1.716m^2
ρ = 1.225 kg/m^3 Cp = 0.2617
Power (th) = 0.5 x ρ x A x V^3 = 131.9 watts
Power (Act) = 131.9 x Cp = 34.35 watts
ω =
2∗𝜋∗𝑁
60
= 29.3 rad/s
TSR =
𝑅∗𝜔
𝑣
= 1.52

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For different TSR, theoretical efficiencies for Ideal VAWT can be calculated using the
following relations provided in the table 6.1 [27]:
Table 6.2: Theoretical efficiencies for TSR
Ƞ th = 0.055 x ƛ + 0.399 = 0.48 or 48%
Input = T* ω = 4.48 * 29.3 = 131.26
Output = V*I = 21* 1.6 = 33.62
Ƞ act = Output / Input = 33.62/131.26*100 = 26%
6.2) Study of blade arc angle and effect on Cp
The study aims to increase the efficiency of helix wind turbines by analysing the effect of the
blade arc angle on the turbine performance and to find the optimal arc angle corresponding to
the maximum efficiency.
Co-efficient of performance Cp had great influence on this project as this leads to increased
power conversion and higher turbine efficiency. Participants of the project were aided by some
previous case studies and research conducted in the past and their personal conducted work
contributes to the study of maximizing Cp.

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Parameters definition
The two-dimensional schematic view and geometrical parameters of a two-bladed Savonius
wind turbine are presented in table 6.2, where U is the wind velocity, θ is the azimuth angle
of the blade, and φ is the blade arc angle, v is the rotation velocity of the turbine, r is the
blade radius, and D is the turbine diameter.
Figure 6.4: Two-dimensional schematic diagram of Helix turbine.
Table 6.3: Dimensional Parameters
Case D(m) R(m) Φ
1 0.52 0.26 150
2 0.52 0.26 160
3 0.52 0.26 170
4 0.52 0.26 180
5 0.52 0.26 190
6 0.52 0.26 200

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Computation domains and boundary settings
In order to allow a full development of the flow as well as decrease the blockage effect, the
computational domain was a rectangle of 18D*12D. The rotor was placed in the symmetry
axis of the top and bottom boundary and at a distance of 6D from the left boundary
The overall domain is split into two subdomains, including an external station domain and an
internal rotation domain containing the rotor. In the simulations, the internal rotation domain
rotates with the rotor angular velocity v.
The boundary conditions employed consist of a constant velocity inlet (7 m/s) on the left side,
a pressure outlet on right, and two-symmetry boundary condition on top and bottom.
Figure 6.5: Computing domains and boundary conditions.
For each case listed in table, several simulations were carried out with the tip speed ratio
varying from 0.6 to 1.4. Tip speed ratio represents the ratio of the blade tip speed to the wind
speed.

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Each simulation lasted for three revolutions. The time step used was set as 1°/step, that is, the
rotor turned 1°in each time step, and each time step takes 100 iterations.
Results obtained and extracted from previous studies are presented in the table 6.3:
Table 6.4: Maximum coefficient of power for each case.
Case Blade Angle Cp max
1 150 0.2687
2 160 0.2836
3 170 0.2835
4 180 0.2617
5 190 0.2521
6 200 0.2271
Results concluded that turbine with a blade arc angle of φ =160° has the highest coefficient of
power, 0.2836, which is 8.37% higher than that from a conventional turbine with φ = 180° [28].
6.3) Aspect ratio and Overlap ratio of wind turbine:
To maximize the power coefficient, the rotor’s aspect ratio should be as small as possible. As
aspect ratio diminishes, there are two advantages: the local Reynolds number rises and
simultaneously the rotational velocity diminishes.
Overlap ratio helps to increase the efficiency of helix wind turbine in certain cases. Eccentricity
helps to attain the turbine cut-in speed and self-starting capabilities.
Eccentricity =
𝑒−𝑒′
𝑑

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6.4) Design and Simulation (Solid Works):
Designing and simulation of wind turbine for result forecasting was next phase in our project.
At first, the final design of helix wind turbine was designed on Solid Works and PTC Creo at
expense of preliminary sketches. Turbine blades, Shaft, generator, base pipe and other
components were designed on these softwares. Figure below shows different parts and
complete assembly of helix wind turbine.
The turbine has length of 1.05m (no generator) and diameter of 0.52m. Base pipe has minimum
length of 2m as turbine should be mounted on minimum height of 2m to achieve solidity σ =
Nc/R > 0.4 to achieve self-start capability and as lowest minimum start-up speed.
Simulation was based on calculation of velocity @ 10 m/s and atmospheric pressure. Velocity
at different axis, bladed, generator and assembly along with pressures were simulated and
results were obtained.
Figure 6.6: Wind turbine design SOLIDWORKS

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Mass Properties:
Table 6.5: Goal plotting in solid works
flowsimulation aseembly.SLDASM ( Highway Wind Turbine)
Goal Name Unit Value Averaged Value Minimum Value Maximum Value Progress [%] Use In Convergence
GG Av Static Pressure 1 [Pa] 101325.9896 101325.9898 101325.9873 101325.9917 100 Yes
GG Max Static Pressure 1 [Pa] 101417.6611 101416.3879 101414.539 101417.6611 100 Yes
GG Av Total Pressure 1 [Pa] 101386.2354 101386.2352 101386.2316 101386.2376 100 Yes
GG Max Total Pressure 1 [Pa] 101469.1899 101468.1634 101467.0552 101469.4498 100 Yes
GG Av Dynamic Pressure 1 [Pa] 60.23296224 60.23250831 60.23140691 60.23334022 100 Yes
GG Max Dynamic Pressure 1[Pa] 77.28454215 78.17777898 76.52830514 79.35285612 100 Yes
GG Av Velocity 1 [m/s] 10.00047671 10.00042937 10.00038679 10.00049627 100 Yes
GG Max Velocity 1 [m/s] 11.33076675 11.39602258 11.27520381 11.48135906 100 Yes
GG Av Velocity (X) 1 [m/s] -0.001869393 -0.001750614 -0.001869393 -0.001584249 100 Yes
GG Max Velocity (X) 1 [m/s] 3.715045254 3.651804658 3.531426979 3.791130572 100 Yes
GG Av Velocity (Z) 1 [m/s] 0.00894482 0.009190797 0.00894482 0.009456413 100 Yes
GG Max Velocity (Z) 1 [m/s] 3.279235727 3.314252065 3.279235727 3.351298703 100 Yes
GG Av Mach Number 1 [ ] 0.029141585 0.029141447 0.029141323 0.029141642 100 Yes
GG Av Turbulence Intensity 1[%] 1.758871896 1.758649829 1.757821316 1.759142193 100 Yes
GG Force (Y) 1 [N] -29.21727554 -29.19617711 -29.22736297 -29.15218775 100 Yes
GG Friction Force (Y) 1 [N] -25.84695482 -25.84828628 -25.86071591 -25.84216782 100 Yes
GG Torque (Y) 1 [N*m] -2.148796572 -2.076650687 -2.148796572 -1.996751876 100 Yes
SG Av Total Pressure 1 [Pa] 101313.4898 101313.5551 101313.4541 101313.6591 100 Yes
Iterations: 54
Analysis interval: 21

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Design Report:
Figure 6.7: Design report of helix wind turbine

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Velocity:
Figure 6.8: Velocity profile SOILDWORKS
Figure 6.9: Velocity

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Turbulence Intensity:

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6.5) Design and Simulation (Ansys):
The next phase of project was to analyse the design, simulate, and then interpret the results
using ANSYS Software version 14.2. The drawing of blades was designed in solid works and
was then imported to ANSYS. After making enclosures and adding Boolean operations, 3D
model looked as figured below:
Figure 6.1: Design Modular Ansys
After complete 3D model, named selections were created as inlet, outlet and boundary wall. In
the next step, we generated mesh of the 3D Model using fine relevance options. Meshing also
contains different options and best options were selected to make the most precise meshing. In
this regard, sliding meshing technique was utilized and meshing was obtained as figured below:

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In the next phase, we utilized double precision method to calculate results. Mesh motion with
480 rpm was given as value in cell boundary conditions. Viscous laminar model with (K-
Epsilon 2 eqn) realizable model. Input velocity of 5 m/s was given along with zero absolute
pressure at outlet. Calculation activities included CFD-Post compatible analysis with the
parameters to be known.100 iterations with 0.001 time step size and 20 number of time steps
was given as input for calculations.

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Velocity Contour:

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Turbulence Kinetic Energy:
Density:

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CHAPTER 07
Fabrication of Highway Wind Turbine
7.1) Overview
The original turbine blades were manufactured by a local engineering firm based on model and
drawings provided to them by project members. Main shaft was built at local iron & steel
factory using mapped drawings. Generator was bought from market. The bearing selection was
made by conducting an analytical comparison of bearings commonly used in turbine
applications. The experimental testing of the turbine blades and arms against the fast rotating
fan was used to further develop the theoretical model from which the bearing analysis, material
selection, CFD analysis, cost analysis were developed.
7.2) Material Selection
The material chosen for blades of turbine after careful feasibility analysis and previous studies
was glass fibre along with small constituent of basalt. The fibres and the matrix materials like
polyesters, vinyl esters, epoxies etc., are combined into the composites. These composites have
good properties like mechanical, thermal and chemical properties.
Firstly, the glass fibres are amorphous with isotropic properties. Most glass-reinforced products
are made with E-glass (electrical glass), which has good electrical and mechanical properties
and high heat resistance. E-glass is available as chopped fibre, milled fibre, continuous roving,
woven roving, woven fabric, and reinforcing mat. Glass fibres for composites have good
properties like moderate stiffness, high strength, and moderate density.
The blade design is made of fibreglass and epoxy resin. Its unique feature is its curvature like
tip, which allows it to catch low wind speeds. The turbine blades made of carbon fibre are

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lightweight, has a razor sharp edge, which allows it to literally cut through the wind, and makes
it almost silent. The material of the blade is glass fibre -basalt.
It is less expensive than carbon composite. Fibreglass composites are insulators, which mean
they do not respond to an electric field and resist the flow of electric charge. Fibreglass might
not have high tensile strength but has certainly low tensile modulus, which allows it to bend
and take more strain without breaking.
Table 7.1: Strength Parameters of fibreglass
Parameter Value Unit
Tensile Strength 4137 MPa
Tensile Modulus 242 GPa
7.3) Description of Turbine
The turbine parts are mainly fabricated by conventional methods of cuttings. Support arms
were manufactured using casting method. Main shaft is composed of iron with paint coating to
prevent it from rust.
Figure 7.1: Helix wind turbine

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The prototype focuses only on testing the turbine blades and support components of the turbine
and segregates them from the rest of the design. Two turbine blades are attached to main shaft
using four arm supports.
Figure 7.2: Main shaft of turbine
Carbon steel galvanized pipe was used to construct the base of turbine which hold the turbine
and generator.
Figure 7.3: Flanges of turbine

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The vertical shaft that held the turbine was manufactured out of quarter inch stainless steel with
press fits designed to attach to the generator. It also had two setscrews, which kept the shaft
connected to both instruments as well as a setscrew in the middle to lock turbine in place.
Figure 7.4: Complete assembly of helix wind turbine

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7.4) Discussion
Studies (experimentally and theoretically) present a review on the performance of Savonius
wind turbines and show the gap between the actual and ideal output power, where a several
factors have affected clearly on the actual performance, these factors are due to external factors,
lack of resources, process, geometrically, or due to human error. These factor resulted in drop
of 31~ 35% between the theoretical and experiment results.
Moreover, Negligence of blades surface friction and dust contamination gained the ideal
efficiency a level up comparing with the actual. The assumption of the frictionless in the
rotating parts bearings, rods generator shaft beside the resistless assumption in generator wires.
On geometrically side, Uniformed arc angle in each blade, where could be due the lack of skills
in manufacturing. In addition, unexpected vibration happed led to disturbance in the turbine.
These are the major factors have been played a real role of dropping the helix rotor
performance, perhaps some factor been hidden due to the limitation in time and suffering of
financial support to provided advance equipment in analysing. This was probably the most
educational portion of this project. It was extremely difficult.
As mechanical engineers, all of the members of the team deeply wanted the satisfaction of
creating an entire large functioning turbine. Engineering is so much about detail and small
modifications. Engineering is oftentimes tedious and meticulous. Although it is more fun to go
off and build a turbine that spins and brightens an LED, without scientific backing and
mathematical modelling, these ventures are little more than arts and crafts.

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CHAPTER 08
Testing and Evaluation of Highway Wind Turbine
8.1) Overview
These types of testing were necessary to complete this project: CAD testing, theoretical
analysis and real time experimentation. The theoretical analysis was performed taking into
consideration the speeds recorded by the anemometer during field-testing and the theoretical
turbine designed after the simulation and CAD testing. Theoretical testing models were chosen
and applied. This theoretical design made cost analysis and computational fluid dynamics
analysis possible.
Results & Conclusions:
Data has been collected by the use of digital anemometer at different location on the highway
medians. The changes were recorded at different height and different location. The graph given
below gives the actual data collected in highway for wind velocity at different height during
certain interval of time.
Figure 8.1: Graph between wind speed v/s time.

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Experiment 01:
Table 8.1: Experimental Readings (Normal winds)
Experimental Readings
Experiment # 01 (Normal winds)
Wind Speedm/s
Voltage (V) Current (I) Power (VI) watt
0.6 0.6 0.1 0.06
1.3 1 0.61 0.616
1.5 1.2 0.8 0.96
3 4.5 1.6 7.21
5 15 2.1 31.6

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Experiment 02:
Table 8.2: Projected Readings (Windy day)
Projected Readings
Experiment # 02 (Windy day)
Wind Speedm/s
Voltage (V) Current (I) Power (VI) watt
7 19.2 3.3 65.36
8 21.5 4..06 87.43
10 22.6 4.4 99.84

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Table 8.3: Theoretical vs Experimental Calculations of Gained power
Density Area Wind
Speed
Power
Coefficient
Theoretical
Power
Experimental
Power
1.225 1.716 0.6 0.2617 0.227 0.06
1.225 1.716 1.3 0.2617 2.301 0.61
1.225 1.716 1.5 0.2617 3.542 0.96
1.225 1.716 3 0.2617 28.37 7.21
1.225 1.716 5 0.2617 131.37 31.61
Figure 8.2: Theoretical vs Experimental Calculations of Gained power
0
20
40
60
80
100
120
140
0 1 2 3 4 5 6
Theortical vs Experimental Values
− Theoretical − Experimental
Power
in
Watt
Velocitym/s

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CHAPTER 09
Design Considerations
9.1) Health and Safety
It was understood that there would be a certain level of scepticism surrounding this project due
to its proposed location. The highway and the dangers it holds intimidate many people. People
are hesitant to accept a rotating object lining their daily commute because it seems different
and intimidating. This project was even referred to as other students as “the bird blender”
because of the potential harm it could cause birds who may accidentally fly into its path.
Although these concerns are understandable, they do not really hold any merit. The pole that
would serve as the base for the VAWT would be no more dangerous than the telephone poles
that now commonly line highways. If someone hits a power-line, they could be in for a lot more
danger via electric shock than if they were to hit one of our theoretical turbines.
For the theoretical calculations, it was stated that the blades would begin four feet above the
ground. This may be too low. Many people and vehicles would be in the path of the turbine
blades. It may be considered safer to increase the distance from the ground to the bottom of the
blades by a couple of feet. The turbines would not be exceedingly heavy or spinning at
excessive speeds, therefore it is doubtful that they would cause any harm to existing area
wildlife.

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9.2) Assembly and Disassembly
One of the primary advantages of the VAWT over the HAWT as mentioned earlier in the report
is that the generator for the VAWT is located conveniently at the base of the structure and is
typically more easily accessible than that of a HAWT. Out of all of the components in a VAWT,
the only one that should require routine maintenance or that might have systematic problems
would be the generator. The other elements considered in this report: turbine blades, linkage
arms, and bearings would be victim only to fatigue unless they were exposed to an abnormal
situation.
9.3) Maintenance of the System
It is estimated that the systems would require little regular maintenance and instead would need
more spread out maintenance due to fatigue of parts and components.
9.3.1) Regular Maintenance
Regular maintenance would probably occur mostly for the generators, which would need to be
replaced more than other components of the VAWT. Monthly or bimonthly inspection would
likely be implemented in order to ensure the best performance of each machine.
9.3.2) Major Maintenance
Major maintenance would occur every two to three years on the components studied within
this report. Reinforced plastics is well rated for fatigue and this characteristic would probably
not require the replacement of the linkage arms. Bearings often become less effective and this
could cause a significant reduction in efficiency if the bearings are not well maintained and
replaced as needed.

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The turbine blades would be subjected to more potential small damages such as nicks and
scratches that could negatively affect their performance. These small blemishes would have to
be touched up, but the entire turbine blades would most likely need replacement after about
three to four years as approximated previously in the report.
9.4 Environmental Impact and Sustainability
A major goal in this project was to better understand the feasibility of harnessing wind energy
along highways in Pakistan. There is great potential for wind energy. The power of the wind
has been recognized for centuries and it is time to re-evaluate it as a viable energy source. Not
enough is being done to prepare society of the future for their energy needs and requirements
in a sustainable manner. Pakistan is especially behind other nations in adopting wind energy
into its national grid. Many other countries have already recognized wind as one of the major
players in sustainable energy of the future and have invested large sums of time, money, and
energy into improving wind technology and better understanding its application for their
countries.
9.5 Economic Impact
There is always great economic appeal for sustainable energy because after all, the source of
the energy is free and renewable. However, many times harnessing that energy can be
extremely expensive and may lack enough efficiency to justify the investment in the
manufacturing of the equipment to advantage this energy. Admittedly, it does take a great deal
of energy to manufacture the components necessary to build the theoretical VAWTs that this
project has designed, but this manufacturing could lead to a lot of jobs in a positive way. These
jobs could be sustained by the profits made by companies manufacturing turbines.

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CHAPTER 10
Design Experience
10.1)Overview
This project required the team to call on knowledge learned in all different types of courses
throughout each member’s engineering curriculum. This project was very valuable in our
education because it presented us with challenges seldom seen within the classroom and
allowed us to apply our learnings to an outside situation to which we felt had meaning and were
interested in.
10.2) Standards Used in this Project
This project forced skills to be recalled from statics, dynamics, mechanics of materials,
mechanical design, Renewable energy systems, fluid dynamics and wind power engineering
and many other courses taken at University of Management and Technology. The team made
a dedicated effort to back up each of our actions with numerical.
It was very tempting, as was mentioned throughout the paper, to use the resources available to
us to make a more colourful and less scientific project. It had to be learned and understood that
sometimes the experiments and models that we as engineers wanted to build, would not
contribute to the greater goal which we wished to achieve. Engineers must take small,
calculated steps and that was what was done for this project.
10.3) Contemporary Issues
Everyone knows that renewable energy and environmentally conscience practices are a huge
discussion today. Everywhere from international politics to first grade classrooms has become
a platform to recognize these issues. However, too little is being done to address said issues.

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There are some fantastic minds on the planet right now that could most likely do wonders to
help the globe skirt around its energy crisis. This project was not only rewarding in its ability
for self and team education, but also to know that we were able to contribute in some extremely
small way to the challenge of understanding the natural resources we have and how we can
best use them to provide a better tomorrow for our posterity.
10.4) Life-Long Learning Experience
There is a lot that can be taken away from this project. Working with such a small group for an
entire year has presented many times of group unity and even more of complete group disarray.
In such a long and multidimensional project, it is difficult to equally distribute the work to all
parties at all times. Actually, that level of fairness is nearly impossible. Learning how to work
with others for such an extended period and come out of the situation amicably was
challenging, but also rewarding. It must be seen that failure of one member of the group
generally indicates failure of the other group members on some level. This shortcoming could
be in the form of lack of communication, clarity, or even connection.
Our team experienced all of this during this project. We can all look back and say that we could
have handled many situations differently, but realize that these situations were presented as
learning opportunities and it is necessary to simply be grateful for them. This project made us
realize that engineering must be backed up with numbers and must have a goal. Engineering
with no goal or direction, really cannot be considered engineering at all and is more like a
random science project.
This project showed us all that work is more rewarding and fulfilling if there is purpose to the
work for which you are proud upon its completion. A small contribution to a meaningful field
is infinitely more satisfying than revolutionizing something that just does not matter to you.

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CHAPTER 11
Conclusion and Future Recommendations
11.1) Conclusion
It was determined that the best combination for efficiency was the utilization of helix wind
turbine combined with the longer support arms. The bearing selected for the theoretical model
also ensured satisfactorily efficiency. The project was successful as an introduction to the
research and experimentation with VAWTs for group members. One member will continue his
study of these turbines into his career and the two others will maintain their interest in wind
technology despite not focusing on it directly. Final Year Project forced us to be held
accountable to our impending title: mechanical engineers.
The helix wind turbine constructed by our team has the following features:
 The turbine is self-starting.
 It do not require pointing in the direction of the wind.
 The lower blade rotational speeds indicate lower noise levels.
 Perceived as being more aesthetically pleasing.
 The increased blade configuration solidity and torque assists the machine in self-
starting.
 Easy access to all mechanical and structural elements of the machine.
 Permanent magnet suspension generator is used and there are no gearboxes with the
machine having only one moving part.

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11.2) Specifications
Start-In wind Speed 4.68 km/h
Cut-In wind Speed 9 km/h
Rated Wind Speed 36 km/h
Safe wind speed limit Max wind speed < 144 km/h
Blade Height 1050 mm
Generator Three phase permanent magnet suspension
Mount Height 2 -12 m
Blade/ Material Fibre glass
Rated Power 100 watt ( depending upon conditions)
Rotor diameter of blades 520mm
11.3) Future Recommendations
It is hoped that our contemporaries perform more testing and investigation into the performance
of VAWTs. There is potential in the renewable wind energy field and hopefully this potential
is realized in our lifetimes.
The next part to this project should be the mathematical modelling of wind patterns on a
program such as MATLAB in order to better understand the ideal angle alpha and other
parameters of VAWTs. The turbine is 0.52 meter in diameter and 1.05 meters in height to reach
the requirements it must satisfy. It will have four arms that clamp and two additional clamps
can be used for existing light posts. The cut in wind speed for the turbine will be 2.5 m/s while
spinning at 160 rotations per minute.

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At the optimal level, the turbine will be able to produce 50% of the wattage to power an LED
street light saving the government around $100 per streetlight per year.
Figure 11.1: Future applications of highway wind turbine
Figure 11.2: Design concept of modern wind turbines

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Futuristic application also includes installing helix wind turbine on stadiums, mobile towers
and roads.
Figure 11.3: Application of highway wind turbine

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