10kW (13m/s) 5m diameter carbon fibre blades for wind turbine

 

Download PDF Verson of this document

 

 

Abstract

 

A 10kW wind turbine blade set has been built for use with the 10 kW, 15f Axial flux pancake generator, when attached the turbine is estimated to produce approx 4-5kW electrical power at 50% efficiency with 8-10kW of mechanical power driving the generator. The total cost of the turbine blades was AU$405 and the blades were constructed with typical “home-workshop” tools.

 

Keywords: Wind power, Wind turbine blade construction, 10kw wind turbine

 

 

 

LIST OF FIGURES

 

Figure

 

Page

1

Steel blade core

2

2

Skeleton airfoil blade one

2

3

Skeleton airfoil blade two

3

4

Skeleton filled with polyurethane foam

3

5

Polyurethane foam blade after sanding

3

6

Blade after being covered in chop strand matt fibreglass

4

7

Blade after being covered in bi-axial glass cloth fibreglass

4

8

Blade after being covered in uni-directional carbon fibre

4

9

Blade after sanding the carbon fibre

5

10

Completed 5m wind turbine blades

5

 

 

 

 

1. Constructing the interior of the wind turbine blades

 

 

 

 

Figure 1. Steel blade core

 

The airfoil shapes were printed using a computer, the printouts were glued on 1mm sheet metal and cut out. The steel airfoils cut-outs were welded on steel tube, with the angle set by using a protractor against a plumb line.

 

 

 

 

 

Figure 2. Skeleton airfoil blade one

 

 

 

 

 

 

 

Figure 3. Skeleton airfoil blade two

 

 

 

Figure 4. Skeleton filled with polyurethane foam

 

The skeleton was filled with expanding polyurethane foam (1kg Suprasec 5005, 1kg Daltolac GP33) and sanded into shape.

 

 

Figure 5. Polyurethane foam blade after sanding

 

2. Constructing the exterior of the wind turbine blades

 

 

 

Figure 6. Blade after being covered in chop strand matt fibreglass

 

 

The blade was coated in a layer of vinyl ester resin and one the resin had cured, 220g chop strand matt fibre glass was used to fibreglass the blades, this was does several times with sanding to ensure a smooth finish.

 

 

Figure 7. Blade after being covered in bi-axial glass cloth fibreglass

 

 

400g bi-axial glass cloth was wrapped around the blade and fibre glassed in place. It was lightly sanding before applying another layer of chop strand matt.

 

 

Figure 8. Blade after being covered in uni-directional carbon fibre

 

 

Chop strand matt was sanded into shape before applying the final layer of 197g uni-directional carbon fibre. The carbon fibre lightly sanded to form smooth flat blade

 

 

Figure 9. Blade after sanding the carbon fibre

 

 

 

Figure 10. Completed 5m wind turbine blades

 

 

 

3. Calculated output of the wind turbine system

 

Output of system at maximum generator output (generator efficiency of 50%)

 

 Wind speed = 13m/s

TSR = 9

Blade Efficiency = 0.4

Mechanical Power = 10,525.7 Watts

Rotational Speed = 446.9 RPM

Rotational Torque = 224.91 N.m

 

Running at a TSR of 9, the generator should output 2kW electrical power, requiring 4kW mechanical power

  

A TSR of 12.5 is a better match to the generator

 

TSR = 12.5

Blade Efficiency = 0.3

Mechanical Power = 7894.3 Watts

Rotational Speed = 620.7 RPM

Rotational Torque = 121.45 N.m

 

Running at a TSR of 12.5 the generator should output 4kW electrical power, requiring 8kW mechanical power

 

 

4. Total cost of the wind turbine blades

 

System cost (AUD)

Steel $25

Polyurethane $40

Matt, cloth, resin and initiator (MEKP) $220

Carbon fibre (increased strength, not essential) $120

 

Total cost $405

 

 

4. Equipment used

Arc welder

Grinder

Drill

Wood saw

Sand paper

Fibreglass rollers

Paint brushes

 

5. Conclusion

 

At a total cost of $1,278 including the generator, a wind turbine capable of producing 4-5kW electrical power makes a very cheap alternative for power production especially in remote areas.