MAE 550 : Optimization of engineering design

Project proposal ( Part 1)

Motivation:
Our world is in dire need of alternate and renewable energy sources as it is running
out of fossil fuels by the day. Wind energy is one of the fastest growing sources of
renewable energy in the world. But, Initial cost for wind turbines is greater than that of
conventional fossil fuel generators per MW installed. Here is where optimization of
engineering design can be used to minimize the cost of designing a wind turbine.
Especially In developing countries like India , it is still in its infancy,therefore in need
of further design exploration. Taking up a conventional horizontal axis wind turbine design
and optimizing it would be the right way to go.
STEP 1:Project Description:
The Goal of our project is to design a horizontal axis wind turbine, such as to
maximize the cost efficiency at a predetermined set of wind speeds.
We intend to design both the tower and the rotor setup of the wind turbine. In the design
process for the tower, we consider a hollow circular tower with a linear taper from base to
the top with non uniform thickness. To avoid excessive complexity in the problem, we
assume standard aerofoil profiles like NACA 4415 for the turbine blades. A constant speed
generator is used. The gear box is like a continuously varying transmission gearbox where
infinite number of gear ratios may be obtained. For computation, the tower is assumed as a
vertical cantilever ,with a uniformly varying load due to wind, axial load due to weight of rotor
and blades. The material of tower and rotor blades is to be determined by assuming youngs
modulus as a design variable. After an optimal solution for the youngs modulus is obtained,
the material matching that value to the closest is selected for making the turbine.
(General Layout of Windmill)
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Step 2:Data and Information collection:
The scope of the problem is to optimize for the cost efficiency. The model to be
used is segmented model using handbook references (formulae) and simple FEA.
The possible independent variables are
Dimensions of tower
D
o
= Outer diameter of the base
Di= Inner diameter of the base
d
0
= Outer diameter of top
d
i
= Inner diameter of top
H= height of tower
Dimensions of rotor blades
L= blade length
t= thickness of blade
Expressions for Power generated by the turbine,
Bending stress, shear stress, deflection and buckling
must be found for the tower.

Step 3:Definition of design variables
=>Tentative design variables are
*D
o

*Di
*d
0

*d
i

*H
*L
*t
*n = Number of blades;
*G = gear ratio;
*Y= Material selection property ( youngs modulus)
Step 4:Optimization criterion
The objective function of our project is to maximize cost efficiency
I.e. cost efficiency = Expected power output of the turbine
cost input of the materials
The cost input of the materials is a function of mass of materials ,which is dependent on
volume of materials used ,which can be calculated separately for the tower and rotor.


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Step 5:Formulation of constraints
The possible constraints may be allowable loads, allowable stresses, allowable deflection for
the tower, maximum & minimum blade length, maximum and minimum feasible gear ratio,
upper and lower limits for height of tower, limits for radii of base and top of tower, range of
materials which can be used for design, minimum power requirement and possibly many
more.

Assumptions:
Keeping in mind that this is a class project and not a masters project, the complexity of the
problem is regulated such that it can be solved within the given time frame.
For example, the surface of the tower is assumed to be linear and not a curve. Designing of
aerofoil is pretty much left out as it calls for further complex structural analysis irrelevant to
optimization. A standard aerofoil is assumed for the blades. Vibration analysis is not
considered for design of the tower. The gyroscopic effect on the wind turbine due to the
rotary motion of blades is neglected.

Challenges expected:
Only a tentative estimate of the number of design variables and constrains is mentioned,
further study of the project case may add up variables and constraints. A thorough study of
materials used to design a wind turbine is to be done for selecting the range of youngs
modulus. Analysis software ANSYS is used for the stress and deflection analysis of the
tower. Often, structural optimization results in multiple solutions , out of which one(the
most practical) solution must be chosen and the selection must be justified.

References
1
Casas,V.D.,F.L.Pena,andR.J.Duro,AutomaticDesignandOptimizationofWindTurbineBlades,Integrated
GroupforEngineeringResearch,UniversityofCorunna(Spain).

2
Kenway,G.andJ.R.R.A.Martins,AerostructuralShapeOptimizationofWindTurbineBladesConsideringSiteSpecific
Winds,12thAIAA/ISSMOMultidisciplinaryAnalysisandOptimizationConference,Victoria,BritishColumbia,Canada,2008.

3
Tangler,J.andJ.D.Kocurek,WindTurbinePostStallAirfoilPerformanceCharacteristicsforBladeElementMomen
tumMethods,43rdAIAAAerospaceSciencesMeetingandExhibit,Reno,Nevada,2005.

4
http://en.wikipedia.org




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