Design and Manufacture of 1kW Wind Turbine Blades

To meet sustainable development goals and address concerns on climate change, much of the world's energy demand is expected to be delivered from clean alternative energy sources. Small-scale wind turbines have proven to be applicable for off-grid electrification. The objective of this study is to present the details on the design and manufacture of a 1 kW wind turbine blade for specified conditions. Blade element moment theory is adopted in the design of the geometry of the blade. Accordingly, the aerodynamic analysis on NACA 64A410 airfoil resulted in a blade radius of 1.95m, an overall twist angle of 31°, and a gradually tapering chord length of 0.062m at the root and 0.247m at the tip of the blade. Then, the wind turbine blades are manufactured from fiberglass (mat350g), resin, catalyst, and gelcoat.  Experimental results reveal the wind turbine blades started producing power at a cut-in wind speed of 3m/s. The maximum power achieved during the testing process was 900W at a hub wind velocity of 9m/s. This is lower than the expected 1000W theoretical power output due to not perfect workmanship in the manufacture of the wind turbine blades. This study will help in building local manufacturing facilities and enhance rural electrification through off-grid technologies.