Professional Documents
Culture Documents
Table of Contents
Objectives ....................................................................................................................................... 3
Theory of Operation ........................................................................................................................ 4
Diagrams and Photographs ............................................................................................................. 5
Bill of Materials .............................................................................................................................. 7
Description of the Design Process .................................................................................................. 9
Electrical System ......................................................................................................................... 9
Blade Structure .......................................................................................................................... 10
Mechanical Load Bearing Structure .......................................................................................... 10
Narrative of the Build and Testing Process .................................................................................. 11
Discussion of Features included (and not included) in the Product.............................................. 13
Measurements, including Graphs and Illustrations ....................................................................... 15
Measurements of Prototype Turbine ......................................................................................... 15
Measurements of Final Turbine ................................................................................................ 16
Summary, Conclusions, and Next Steps ....................................................................................... 18
Objectives
The purpose of this project was to build a working wind powered generator from basic
components under the constraints of assembly time and cost effectiveness. Additionally, the
following objectives were included from the project description:
1. Solve an engineering problem by incrementally developing solutions
2. Apply CAD software skills and electronics knowledge to develop a product.
3. Apply math and physics principles to a real-world situation.
4. Understand the basics of electrical generation and wind turbines.
5. Work in a team, coordinating development and responsibilities.
6. Document your results in a notebook and a formal written report.
7. Deliver an oral presentation on your project.
Figure 3
Figure 1
Figure 6 Cal-EPower
Figure 5
Figure 8
Figure 9
Figure 10
Figure 11
Bill of Materials
Qty
1
1
2
1
1
1
1
1
1
1
3
1
1
1
1
1
1
6
1
1
1
1
8
8
8
1
1
6
*
1
2
1
1
10
1
1
Cost * Qty
2' x 2' x .25" particle board
salvaged
3/8" OD 24" drive shaft
$13.76
3/8" ID Fafnir S3PP ball bearing
$6
1" painters tape
salvaged
plastic foam project panel
$5
electrical tape
salvaged
hot glue + hot glue gun
Dr. Hall
JB Weld epoxy
salvaged
Gorilla brand tape
salvaged
Kraft paper roll
salvaged
Nuvo newspaper
salvaged
roll of 2' wire mesh
salvaged
leatherworking needle
salvaged
spool of leatherworking thread salvaged
holepunch
salvaged
miter box + saw
Dr. Hall
drill + bitset
salvaged
unopened soup cans
salvaged
compass (magnetic)
salvaged
compass (drafting)
salvaged
3 in 1 silicon oil
salvaged
roll of paper towels
salvaged
1" x .25"neodymium magnets
Dr. Hall
PVC retaining rings (PVC pipe) salvaged
1" OD fender washers
$1.36
oscilloscope
Dr. Hall
digital multimeter
Dr. Hall
silicon diodes
Dr. Hall
resistors - for measurement
Dr. Hall
coping saw
salvaged
triangles
Dr. Hall
Sharpie
salvaged
jumper wire
salvaged
index card shims
salvaged
Sta-Flo starch
salvaged
Elmer's Glue-All
salvaged
8
quarters
1
heatgun
1
1 ton press
coil winding rig
1
vice
1
hand drill
1
1" OD socket
2
circular foam board cutouts
1.5
rolls of magnet wire
frame
1
2" x 2" x 1' piece of wood
4
mild steel tabs with hole
2
~2' mild steel angle iron
1
welder
2
wood screws
2
bolts
2
washers
2
nuts
1
spool of thin cord
4
screw eyes
Total Spent:
$2.00
salvaged
salvaged
salvaged
salvaged
salvaged
salvaged
Dr. Hall
salvaged
salvaged
salvaged
salvaged
salvaged
salvaged
salvaged
salvaged
salvaged
salvaged
$28.12
10
Blade Structure
Our research into the blade structure of our turbine consisted of Abraham and Plourdes
Small Scale Windpower and Caleb Engineerings videos on VAWTs available on YouTube. An
early design, inspired by a minidocumentary on California Energy and Power (figure 6),
involved a concentrator and Savonius style blades. We decided on a 3 bladed Darrieus style
structure. This is because Darrieus style blades operate using lift and not drag, and are more
efficient in harnessing the winds energy. We chose 3 blades because according to Caleb
Engineering, an odd number is easier to balance and diminishing returns occur when more blades
are added to a design (figures 2, 8).
Mechanical Load Bearing Structure
The primary design consideration of our mechanical load bearing structure was to
eliminate excess weight, and extraneous motion in non-productive directions. The design
manifested itself as a steel drive shaft, which doesnt rotate, mounted to a frame that can tolerate
the vibration produced from a rotor that is not precision balanced. The coupling of rotor to drive
shaft is accomplished through ball bearings that are held up by a thin layer of tape adhered to the
shaft. Another consideration was to keep the magnets from flying off due to centrifugal force.
This was accomplished using PVC retaining rings that were adhered to the rotor with JB Weld.
The overall assembly was placed along the diagonal axis of the particle board base to
maximize room for an optional concentrator (figure 5).
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12
9. Adhered bearing to center of plastic foam rotors using JB Weld, hot glue, and PVC electrical
tape
10. Cut magnet retaining rings from 1 inner diameter PVC pipe.
11. Adhered retaining rings and washers for magnets using JB Weld.
12. Put magnets into retaining rings.
13. Preliminary assembly of above components.
14. Catastrophic failure of wood and glue frame due to accidental drop.
15. Welded new frame from angle iron and iron tabs
16. Drilled holes and bolted frame to base with bolts, nuts, washers.
17. Screwed rod holder to top of frame using wood screws.
18. Reassembled rod, rotors, and frame.
19. Aligned rotors using soup cans.
20. Balanced rotors with stack of quarters.
21. Stitched tops of Darrieus style blades to upper rotor
22. Gorilla-taped bottoms of Darrieus style blade to lower rotor
23. Wound coils using homebrew winder (see figure 3)
24. Adhered coils to base using Gorilla-tape and index card shims (to minimize airgap).
25. Routed coils into desired 3-phase Wye configuration with electrical tape and jumper wire.
26. Wrapped tape to couple rotors to rod at correct height.
27. Adjusted airgap by shimming coils with index cards
13
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magnets relative to the coils, and the airgap between magnets and coils. Like a gear system, our
system behaves like a lever, without losses due to friction between gears. In a full size VAWT, a
gear system may be more efficient due to material and space constraints.
The S3PPs were press fit into a segment of PVC pipe so that they could later be reused
in other projects without the potential of being rendered inoperable by adhesives.
The electricity produced by our turbine can be rectified and potentially used to charge a
single battery cell.
A prominent features that was not included in our final product was a concentrator
(figures 5, 6). A concentrator is a parabolic surface that protects the return side of the blade while
channeling an increased amount of air from the test fan onto the productive side of the turbines
blades. This feature was not included in the final test because 1) the designers felt it was too
risky to include an untested component that could result in unforeseen results; 2) a concentrator
eliminates the VAWTs ability to be rotated by the wind from all directions; 3) the test fan was
able to be positioned only on the productive side of the blades; however additional airflow is
unable to be redirected productively.
We were unable to include a rectifier because our output waveform was not sinusoidal,
and thus our output was not usable.
15
16
17
3 2
Where R is the sum of the resistance of two phases and V is the voltagerms measured
across those two phases.
The measurement of our rebuilt wind turbine was 114 milliwatts at 1.75 Vrms. The
designers assume that several coils were installed incorrectly. The resulting rectified 3 phase
waveform should have resembled figure 11; the separate phases plotted together should have
looked like figure 10.
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