Beruflich Dokumente
Kultur Dokumente
5m/s)
2Blades(Carbonfibre),1.8MetreDiameter
&InductionmotortoPMAconversion
Abstract
A1kW@12.5m/s(2kW@17m/s),1.8metrediameterwindturbinewasdesignedandconstructedusingcarbonfibrecomposites.Thegeneratorwasbuilt
by converting an induction motor into a permanent magnet generator. Blade power and efficiency have been measured at different tipspeedratios and a
maximumefficiencyof30%ataTSRof11.6wasrecorded.Theseresultsverifytheaccuracyofcalculationsfromthebladecalculatorsoftware.Totalcostof
thegeneratorandbladeswaslessthanAU$200.
Keywords:Windpower,PermanentMagnetGenerator,InductionmotortoPMAconversion,1kwwindturbine,carbonfiberwindturbineblades
LISTOFFIGURES
Figure
Page
40Ampcaralternatorrotorwithmagnetsattached
40Ampcaralternatorrotorwithmagnetsfibreglassedinplace
40Ampcaralternatorstatorwithshielding
Completedconversionofthe40Ampcaralternator
Completedconversiona1/4hpinductionmotor
Windturbineairfoilcrosssections
Turbineairfoilcrosssectionsboltedtoframe
Positivemouldsofwindturbineblades
Negativemouldsofwindturbineblades
10
1.8mbladeset
11
Turbinetesting
12
MeasuredTSRvsefficiency
13
MeasuredPower
1.ConstructionofthePermanentMagnetGenerator
Designofapermanentmagnetgeneratorwasnecessarytotestandcharacterisethebladeset.Conversionofa40ampcar
alternatortoapermanentmagnetgeneratorwasattempted.
Thealternatorsrotorwasturneddownonalathetoaccommodate
neodymiummagnets.
Figure3.40Ampcaralternatorstator
withshielding
Figure1.40Ampcaralternator
rotorwithmagnetsattached
Figure2.40Ampcaralternatorrotorwith
magnetsfibreglassedinplace
Themagnetswerefibreglassed
inplacewithtwostripsofcarbon
fibre.
DesignYourCustomWindTurbineBlades
Figure5.Completedconversionofa
1/4hpinductionmotor
Figure4.
Completed
conversionof
the40Amp
caralternator
Thesametechniquewasusedtoconvertalarger1/4hpinduction
motorintoa8pole/3phasePMG.
Poweroutputwasmeasuredto
belessthan500wattsatthe
Power output was measured to
be more than 2000 watts at the
rpmofthedesignedblades.The
rotational speed for the designed generatorwillnotproduce
blades. This generator produces
enoughpowerforthe1.8mdiameterblades.
enoughpowerforthe1.8m
diameterblades,itismoresuited
Thegeneratorhaszerocogging,thisisduetotheangledmagnetsand
to1.0mdiameterbladeswitha
the 2mm air gap between the rotor and
stator. It is configured for 3
hightipspeedratio.
phase,eachphasemeasuring5.6ohms.Outputvoltageis130Vrmsat
1333rpm,increasinglinearlywithrpm.
2.Calculatinggeneratorefficiency
Given:The3phasesareisolatedandconnectedas3singlephaseoutputs.
EachoutputisrectifiedtoDCusingasinglephasebridgerectifier.
V=IRrearrangedto
V/R=I
At666rpm,
generatorvoltage
Vs=65Volts.
Rs=resistanceofeach
phaseofthegenerator
(5.6Ohms)
Voltageacross
Rs=6548
Vs=17Volts
Currentintobattery=17/5.6
I=3ampsperphase
CalculatepowerusingP=VI
Powerintobattery=48x3
P=144wattsperphase
(432wattsforall3phases)
Ploss=V2/R
Efficiencyofgenerator=144/(144+51.6)
PowerLost=172/5.6
Efficiency=73.6%
Ploss=51.6wattsperphase
3.Designandconstructionofthewindturbineblades
The wind turbine blades were designed using the warlock
engineering blade calculator program. The airfoil chosen was
NACA2412andatwobladedturbinewasdesignedtohavea
tipspeedratioof10.
Figure6.Windturbineairfoilcrosssections
Theairfoilcrosssectionswerecutoutof3mm
aluminiumsheets.Thesesheetswereboltedto
asteelframe,spacedatappropriatedistances
andaligned.
Figure7.Windturbineairfoilcrosssectionsboltedtoaframe
Figure8.Positivemouldsofwind
turbineblades
Figure9.Negativemouldsofwind
turbineblades
Carefuldetailingofthepositivemouldproducedaperfectnegative
mould. This final negative mould was waxed and mould release
was applied. CSM fibreglass (220 g) with vinyl ester resin was
applied to each mould. The two mould halves were clamped
togetheraftertheresinhadgelledandthebladewasremovedafter
curing.
The blades were sanded and wrapped in carbon fibre, using an
additional carbon fibre layer around the hub section. The finished
bladesareextremelylightweight.
Figure10.1.8mbladeset
4.Testingthewindturbine
Thewindturbinewasboltedtoatrailerandtherpm,voltageandtsrwasmeasuredbyconnectingthegeneratortoaveryhigh
powermultitapresistor.Theturbinewasallowedtospeeduptoanopencircuitvoltageof65V(666rpm)beforetheresistor
loadwasconnected.
Measurementofresultsfromthewindturbine
Note:Ourmethodofturbinetestinggeneratedturbulentwind,affecting
efficiency.Theresultsshouldbeusedasaguideonly
Rsistheresistanceofthegeneratorwindingsplusthepowercable5.75ohms
Rlistheresistanceoftheload6.6,10,15,21.5and25ohms
Figure11.Turbinetesting
Oncethebladeshavebeencharacterized
anewgeneratorwillbedesigned.
Powergeneratedbythebladeswascalculatedbydividingmeasuredpowerbytheefficiencyofthegenerator.
Powergeneratedbythebladesiscalculatedusingthefollowingmethod:
Voltageacrosstheresistorloadwasmeasured(Vl),
Vs=Vlx[(Rs+Rl)/Rl]
Powerproducedbybladesandlostingenerator,powercableandresistorloadisgivenby
P=V2/R
P=Vs2/(Rs+Rl)
Theresultsfromthewindturbinetestareincludedbelow.
25ohm
21.5ohm
15ohm
30km/h
820
766
809
40km/h
1302
1363
851
645
50km/h
1753
1676
1489
1291
1105
2365
2098
1744
1607
60km/h
10ohm
6ohm
Rotationalspeed(rpm)
25ohm
21.5ohm
15ohm
30km/h
208
205
300
40km/h
524
649
332
252
50km/h
950
981
1017
1008
940
1953
2019
1873
1990
60km/h
10ohm
6ohm
21.5ohm
15ohm
278
260
275
40km/h
441
463
289
218
50km/h
595
569
506
438
375
803
712
592
546
60km/h
10ohm
6ohm
Power(watts)
25ohm
21.5ohm
15ohm
30km/h
0.23
0.23
stalled
40km/h
0.24
0.30
0.15
stalled
50km/h
0.22
0.23
0.24
0.24
stalled
0.27
0.27
0.25
0.27
60km/h
25ohm
30km/h
10ohm
6ohm
Tipspeed(km/h)
25ohm
21.5ohm
15ohm
30km/h
9.2
8.7
9.2
40km/h
11.0
11.6
7.2
5.5
50km/h
11.9
11.4
10.1
8.8
7.5
16.1
14.2
11.8
10.9
60km/h
10ohm
Tipspeedratio
Bladeefficiency
6.Totalcostofthe
windturbine
Systemcost(AUD)
Inductionmotor$15
Magnets$80
Moulds$72
TwoBlades$14
Totalcost$181
Figure12.EfficiencyvsTSR
6ohm
Conclusion
The carbon fibre blades
maintainedapeakefficiencyof
27% for all TSR values
between 10:1 and 14:1. The
maximum power generated
was 2.0 kW at 60 km/h wind
speed.
By comparison, the typical
TSRforwoodcarvedbladesis
7:1.Althoughtheyarecheaper
toproduce,woodbladesrotate
at half the RPM, reducing the
generators power output to
25%
Figure13.MeasuredPower.Power(Watts)vsSpeed(m/s)
TopWindTurbineArticles
10kW,15PhaseAxialFluxPancakeGeneratorfor2BladeWindTurbine[HTML]
10kW(13m/s),5MetreDiameterCarbonFibreBladesforWindTurbine[HTML]
1.8MetreDiameterCarbonFibreWindTurbineBladesandGenerator[HTML]
Designcustombladesforyourgeneratorandcalculate
poweroutputateachwindspeed.
1.4MetreDiameter3BladeWindTurbineConstruction[HTML]