Professional Documents
Culture Documents
Team 2D
Kelsa Benensky
Taylor Berrian
Stephen Pitterle
Feng Qin
kmb6086@psu.edu
tsb5097@psu.edu
sjp5332@psu.edu
fzq5003@psu.edu
Executive Summary
The establishment of science in the elementary and middle school classroom is essential to
successful education reform in the United States. Schools are looking for alternative methods
that are both fun and educational to teach science to the young generation. Little Windy is a
vertical axis table top wind turbine (WT) that can be used to generate power from an ordinary
household fan. Customers indicated that they would prefer a product that had high educational
value, was low cost, and could perform well under a variety of operating conditions. Little
Windy is a memorable and interactive alternative to text book reading and worksheets because of
its interchangeable blades and ability to perform in varying wind conditions. Children and
educators will always remember Little Windy because of the fun they had creating their own
unique wind turbine.
Little Windy was designed utilizing a permanent magnet DC motor, safe, interchangeable blades,
vertical axis design, sturdy housing, and friendly user interface. The vertical axis design allowed
for the Little Windy design to be operated at varying wind speeds and directions, with the easy
flick of a switch. An interchangeable blade structure was chosen by the team because of its
potential for high educational value. This would allow children to use their own logic and
creativity to create the best design based on turbine efficiency. Little Windy is a versatile, long
lasting wind turbine that helps educators to create a memorable lesson plan that students will
carry with them for the rest of their lives. For a $75 retail price, the projected four year NPV of
production of 100,000 units a year for this project was $3.64 million. The Little Windy beta
prototype was able to produce 12.96 mW at wind speeds of 3.6 m/s.
Little Windy
Team 2D
Page 1 of 48
Table of Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
Introduction .
1.1.
Problem Statement ..
1.2.
Background Information .
1.3.
Project Planning ..
1.3.1. Design Process
1.3.2. Management Structure
Customer Needs and Specifications
2.1.
Identification of Customer Needs
2.2.
Design Specifications ..
Concept Development .
3.1.
External Search
3.2.
Problem Decomposition ..
3.3.
Concept Generation .
3.4.
Concept Selection
System Level Design ...
4.1.
Overall Description ..
4.2.
Preliminary Theoretical Analysis .
4.3.
Preliminary Economic Analysis
Detailed Design .
5.1.
Non-Editorial Changes to Proposal Section ..
5.2.
Final Theoretical Analysis
5.3.
Component & Material Selection Process for Mass Production Unit .....
5.4.
Fabrication Processes for the Mass Production Unit
5.5.
Industrial Design ...
5.6.
Detailed Drawings
5.7.
Economic Analysis ...
5.7.1. Unit Production Cost
5.7.2. Business Case Justification ..
5.8.
Safety Analysis ....
5.9.
Actual Construction Process of Beta Prototype ..
Prototyping and Testing ...
6.1.
Test Procedure and Plan ...
6.2.
Test Results and Discussion of Results ............
Conclusion and Recommendations ..
References
Appendices ...
A. Initial Theoretical Analysis ....
B. Project Management ...
Little Windy
Team 2D
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4
4
4
4
5
5
5
5
6
6
7
8
9
10
10
10
11
11
12
12
13
13
13
14
14
14
14
15
15
17
17
17
18
19
20
20
21
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C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
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23
26
27
31
33
36
36
38
39
40
44
46
48
Page 3 of 48
1. Introduction
1.1. Problem Statement
Recently, there has been a large push within the United States for public education reform. The
establishment of science within the elementary classroom is pivotal to the success of this reform.
Unfortunately, research by the University of California Berkeley and SRI International shows
that 40% of surveyed elementary school educators allocated an hour or less to science each
week; 13% allocated less than half an hour [1]. It is recognized more emphasis needs to be
placed on science education and 92% of surveyed principals believe that this education should
begin as early as kindergarten [1]. For the 2011 fiscal year, $897.2 billion dollars was invested
into U.S. education with increased funding devoted to the development of successful science
programs [2]. To address the need for an innovative, educational, and interactive solution, Team
2D has been asked to create a table top wind turbine (WT) for use by students aged 6 -12.
To ensure appropriate and successful project completion, several constraints have been identified
to appropriately complete the teams objective. The WT must be safe, portable, and easily
assembled by young students. For the WT to easily demonstrate educational concepts, it must be
able to operate at varying wind speeds and direction. The WT will use a permanent magnet DC
motor to generate electricity. Lastly, an integrated user interface will allow for an easy, safe shut
off and give indication of power generation.
Team 2D
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Thus far, the team has identified customer needs through surveys and benchmarking, chosen
initial specifications, generated concepts, and selected a final concept of an interchangeable
blade vertical axis wind turbine. Team 2D is utilizing a Gannt Chart (Appendix B) to track
project progress and upcoming milestones.
1.3.2. Management Structure
Members were selected as leaders in the technical areas of design and project management
(Appendix B). Although certain leaders have been selected, all team members are expected to
contribute to all aspects of the design process from project management, technical writing, and
completion of CAD models. This requires a large initial investment in time to make sure all
members are on the same page, but ultimately allows for the most flexibility in team member
schedules and less risk for overall project completion.
Customer Needs
Secondary Needs
Durable
Tertiary Needs
Simple Design
Performance
Easy to Assemble
Reasonable Sizes
Safety
Educational Value
Low Maintenance
Little Windy
Team 2D
Page 5 of 48
3. Concept Development
3.1. External Search
In order to design a functional and highly educational WT, external search was conducted to
familiarize the team with the fundamentals of wind turbines, power generation, and DC motors.
Our team also completed a thorough benchmarking process to aid with the generation and
selection of concepts for our final design. Many pre-existing designs were analyzed (Table 2)
and the best features of these designs were incorporated to create a state-of-the-art educational
WT kit. A complete analysis of the benchmarking results is available in Appendix D.
LEGO [4]
This product is
designed to educate
middle school aged
children while
working in small
groups. The turbine
has an electronic
interface that shows
various outputs.
The LEGO
construction of this
turbine is effective at
engaging students and
the electronic
interface is excellent.
Our team hopes to
incorporate features
such as the easily
changeable turbine
design and the
interactive display.
Cost: $99.95
Little Windy
Product Description
This product uses a
This product is highly
simple and attractive
versatile and
design to demonstrate experiments can be
the basic principles of conducted with
power generation
various gear ratios,
through easily visible blade angles, number
magnets and wire
of blades, and type of
coils connected to the output indication.
base and shaft of the
turbine.
Product Analysis
This design focuses
This design is very
more on the actual
effective due to the
process of converting high level of
wind energy into
interaction it presents
electrical energy. Our though the variety of
team hopes to imitate interchangeable
the simplicity of this
features. Our team
design but improve
would like to include
upon the educational
interchangeable
value.
features but at a lower
cost.
Cost: $49.95
Cost: $202.64
Team 2D
Primary Science
STEPS [7]
This product is
designed with 20
different possible
experiments that can
be performed. The
turbine is constructed
from easily
interchangeable parts
and safe for children 8
and older.
This design is very
versatile and highly
educational due to the
number of different
experiments that can
be performed.
However there are
over 100 parts, which
could lead to
confusion or difficulty
in setup.
Cost: $49.26
Page 6 of 48
For further analysis, a patent search was conducted to evaluate alternative blade designs for
vertical axis wind turbines. This search yielded valuable and more specific considerations for
future detailed design. A summary of this search can be found in Table 3 and full copies of the
patents are available in Appendix E.
Table 3 Patent Search
Extended Blades [8]
Vertically Extended
Sails [9]
Little Windy
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Little Windy
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Concept #
Net Score
Rank
Continue?
5
-2
5
N
6
-4
6
N
Four designs were selected for continuation based on concept screening results. A concept
scoring matrix was used to pick the best of these designs (Appendix G Table G.3). The
weightings used in the concept scoring matrix were generated using an Analytic Hierarchy
Process (AHP) shown also in Appendix G. The results of the scoring matrix indicated that
Concept 1 (Multi-Bladed Vertical WT) was the most promising design given the target
specifications. The team also decided to incorporate the interchangeable blade design from
Concept 3 (Interchangeable Blade Horizontal WT) which ranked second highest in our scoring
process. This combination ensures both educational value and high performance for our final
design.
Blades (4)
Shaft
DC Motor
Little Windy
Team 2D
Page 9 of 48
The tip speed ratio is defined as the ratio between the tangential speed at the blade tip and the
actual wind speed (Eq. 4). This is a very important parameter to consider when designing the
blades because it governs effect of blade design on system efficiency. Each design has an
optimal tip speed ratio at which the maximum power extraction is achieved.
Five different motors were considered to be used as a generator in our design. In class, the
performance of each motor was analyzed theoretically through measurements of speed, current,
efficiency, and output power as a function of torque. Based on the high rating of output power
and efficiency specified by our customer needs analysis, the Jameco 238473 DC Motor was
chosen. This motor has one of the highest efficiency ratings (75%) and a high torque at
Little Windy
Team 2D
Page 10 of 48
maximum efficiency (0.0183 Nm) [12]. Plots of torque vs. efficiency and speed vs. efficiency for
our selected motor are shown in figures 5 and 6 below.
5. Detailed Design
Little Windy
Team 2D
Page 11 of 48
3.5
0.6
3
0.5
Expected
Turbine Output
238473
1.5
1
Power (W)
Torque (mN-m)
2.5
0.4
0.3
0.2
y = 0.0004x - 0.1158
0.1
0.5
0
0
500
1000
Speed (rpm)
1500
500
1000
1500
Speed (rpm)
2000
The overall system efficiency can be determined by comparing the electrical output of the motor
to the maximum power available from the wind (Eq. 5):
(Eq. 5)
Little Windy
Team 2D
Page 12 of 48
Remember maximum power available from the wind was described in Section 4 Eq. 2. In our
analysis, the swept wind area is 70 in.2 and wind speed is expected to be 3.9 m/s, therefore an
efficiency of 2.6 % is expected for our product overall. Because this data was calculated using
alpha prototype values, we expect efficiency up to 15 30% with the mass production unit
because of the lighter materials utilized and a more precise design. Please see Appendix J. for
complete calculations.
5.3. Component & Material Selection Process for Mass Production Unit
Team 2D recognizes the importance of a safe, inexpensive, and environmentally friendly
product. Therefore, purchased materials and components were selected with the customer in
mind. All parts made in-house are made of ABS plastic through an injection molding process
with the exception of the WT end caps which are made of acryclic. Both ABS plastic and
acryclic are inexpensive and recyclable materials which minimalize costs and impact on the
environment. Purchased components were minimalized and selected for their perceived
performance. This ensures that each customer receives a product he or she can value. The
selection process can be found in Appendix K and Final Material and Component Selections can
be found in our Bill of Materials in Appendix M.
Little Windy
Team 2D
Figure 10 Interchangeable
Blade End Caps
Page 13 of 48
Team 2D
Page 14 of 48
and $200 Wind Trap models available. We believe that because our product is customizable and
easy to assemble, it will appeal to schools more than the less expensive Pico Turbine and
Primary Steps models ($50 each). By limiting the number of parts that can be lost or broken and
still allowing for quality levels of interaction for students and educators, Little Windy will be
more appealing to schools and still allow for a $3.640 million NPV to be achieved.
Little Windy
Team 2D
Page 15 of 48
factory. The next component to be made was the connector piece that connected the motor shaft
and the motor gear. The small shaft connector was machined from a brass rod using a lathe.
Little Windy
Team 2D
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Little Windy
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Little Windy
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8. References
3. Dorph, R., Shields, P., Tiffany-Morales, J., Hartry, A., McCaffrey, T. High hopesfew
opportunities: The status of elementary science education in California. Sacramento, CA:
The Center for the Future of Teaching and Learning at WestEd. 2011.
4. Chantrill, Christopher. "Government Spending Chart." US Education Spending. N.p., Feb.
2012. Web. 20 Oct. 2013.
5. Ulrich, Karl T, Eppinger,Steven D. (2012). Product design and development. New York:
McGraw-Hill/Irwin.
6. "Renewable Energy Add-On Set." LEGO Education. 18 Oct. 2013
<http://www.legoeducation.us/eng/product/renewable_energy_add_on_set/2101>.
7. "Savonius Wind Turbine V3." PicoTurbine International. 18 Oct. 2013
<http://www.picoturbine.com/savonius-wind-turbine-v3/>.
8. "Classroom Wind Turbine Kit." Classroom Wind Turbine Educational Kit. 18 Oct. 2013
<http://www.windtrap.co.uk/classroom-wind-turbine-kit-213-p.asp>.
9. "Wind Power: Renewable Energy Science Kit." Primary Science STEPs. 18 Oct. 2013
<http://www.primarysciencesteps.ie/index.php/shop/wind-power-renewable-energy-sciencekit/>.
10. Janiuk, Peter. Vertical Axis Wind Turbine with Self-Starting Capabilities Patent 8,550,786.
8 October 2013.
11. Betony, Joseph. Vertical Axis Wind Turbine with Twisted Blade or Auxiliary Blade.
Patent 8,468,665 25 June 2013.
12. Fite, David. Vertical Axis Turbine For Capturing the Force of Moving Gasses or Liquids
and a Method for its Use Patent 8,419,367. 16 April 2013.
13. Bernard Wesby, Philip. Vertical Axis Wind Turbine Patent D679,246. 2 April 2013.
14. "Jameco Part No. 238473." Jamesco Electronics. N.p., 2002. Web. 20 Oct. 2013.
<http://www.jameco.com/webapp/wcs/stores/servlet/ProductDisplay?search_type=jamecoall
>.
15. "Home." ISO 8124-1:2012. N.p., 2012. Web. 22 Nov. 2013.
16. "88/378/EEC." EUR-Lex. N.p., 3 May 1998. Web. 22 Nov. 2013.
Little Windy
Team 2D
Page 19 of 48
9. Appendices
Appendix A Initial Theoretical Analysis
A wind turbine will fall into either of two general classes depending on how it spins: horizontal
axis wind turbine (HAWT) and vertical axis wind turbine (VAWT). In the real word, HAWT
may be selected instead of VAWT because the vertical turbine blades cannot be easily elevated
high into the air where the best winds are found. However, for our product, the wind speed is
constant from a fan and the VAWT gives the advantage of operating at varying wind speeds and
directions. The key advantage of VAWT in our analysis is it will have a larger swept area than
HAWT for the same size wind turbine. The equation for the wind turbine power is described
below:
http://www.hnsa.org/
http://www. reuk.co.uk/
http://www.galco.com/
Little Windy
Team 2D
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Team 2D
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Leadership Role
Project Management
Taylor Berrian
Technical Design
Stephen Pitterle
Project Management
Feng Qin
Technical Design
Relevant Experience
Design Intern
Undergraduate Research
Assistant
Product Development Intern
Assembly of God (Chi Alpha)
Student Leader
Assistant Engineering Intern
Strengths
Technical Writing
Critical Thinking
CAD
Hands on Assemby
CAD
Technical Writing
Theoretical Analysis
Theoretical Analysis
CAD
Weaknesses
Hands on Assembly and
Machining
Technical Writing
CAD
Technical Writing
Kelsa has a comprehensive experience as a designer and innovative thinker. She works part time as a design intern at Schuf Fetterolf
and a research assistant at Penn State. As a designer, Kelsa was responsible for timely design completion of orders up to $75,000,
material allocation for expedited job orders, and the early implementation of a new manufactured parts tracking system. As an
undergraduate researcher under Dr. Ray, Kelsa gained skills including time management and hands-on experimental work.
Taylor has several skills that he adds to the team. Foremost, he has had experience in the field of product development. In the summer
of 2012, he worked for the sporting goods company Rawlings as a product development intern for their baseball glove line. In
addition, he is comfortable using AutoCAD and SolidWorks. Taylor has used AutoCAD for his job at Penn State the last two years.
This involved making maps of the branch campuses and updating any site work. One weakness, he stated, was his writing skills and
report writing.
As a prominent leader in the Assembly of God Chi Alpha student organization, Stephen has experience facilitating event planning and
group discussion. This experience is essential to the project management aspect of this project. As an experienced musician Stephen
adds creativity and innovation to the group and is often thinking of alternative approaches to problems. Through volunteer work with
local summer camps, Stephen has firsthand experience with the target age range for this project allowing him to accurately assess the
educational aspects of design.
Feng studied in China before he came to Penn State. Therefore, he can provide the team with unique ideas and think about problems
from different aspects. Feng has worked as an intern this summer in China as an assistant engineer. His duty was to find out the
mistakes made by other engineers in proposals or drawings and correct them. This experience allows Feng to perform work with full
patience and has unlimited energy.
Little Windy
Team 2D
Page 22 of 48
What do you know about windmills? Can you describe how a windmill works?
What do windmills do?
Where have you seen windmills?
Describe the parts of a windmill.
http://p.globalsources.com/IMAGES/PDT/B1039749725/Educational-Solar-Windmill-Kit.jpg
http://www.dhgate.com/product/6-in-1-solar-power-kits-educational-diy-toy/116202603.html
Little Windy
Team 2D
Page 23 of 48
4. Rank the following in increasing order corresponding to the one that you like best. Place one
word to describes each product next to your number.
http://ecx.images-amazon.com/
https://encrypted-tbn3.gstatic.com/
http://prairiewindtoys.com/
http://www.super-science-fair-projects.com/
http://www.robotstorehk.com/
Age
Relavant Occupation
Leigh Pitterle
Adult
Grace Pitterle
11
Lorraine Benensky
Adult
Andrew J. Benensky
13
Jojo Benensky
Little Windy
Team 2D
Page 24 of 48
Little Windy
width
weighs
height
Understood by
children
number of uses
before maitenence
required
number of
manufactured parts
suitable for
Parts capable of
withstand a fall of
Output
efficiency
Operating Speed
cost
number of parts
quantity of lights
number of people
engaged
colors of lights
number of sounds it
can make
number of colors
"6-12"
>1
>50
6+
Ag
e
0.75
Ag
e
>3 5
f t.
>2
ut
>500 >2
Team 2D
Page 25 of 48
lb
in
.
in
.
Po
Pi
n/
m
ph
nd
s
<90
se
co
Un
its
number of uses
before failure
assembly time
Appendix D Benchmarking
Table D.1 Needs-Metrics Chart and Benchmarking Analysis
Customer Needs
Easy to assemble
Simple Design
Low Cost
Durable
Durable
Low Maintenance
Low Maintenance
Performance
Performance
Educational Value
Educational Value
Educational Value
Safety
Number of parts
Needs to operate at
Reasonable size
Metric
Units
Target Spec
Assembly time
seconds
Number of parts
#
Cost
$
Number of uses before failure
#
Strength of materials
Number of uses before maintenance
#
Time to make a repair
minutes
Output Voltage
V out/V possible
Output Efficiency
Time students are engaged
Number of people engaged
Number of concepts learned
Suitable for an age range
Number of manufactured parts
Operating Speed
Fits in container provided
Pin/Pout
minutes
#
#
years
#
mph
<90
<10
<100
>100
>25
<5
0.9
0.75
>10
>4
>3
6+
1
20
Our Design
LEGO
Value of Metric percieved satisfaction of needs Value of Metric percieved satisfaction of needs
<90
X-X-X-X-X
300
X-X-X
<10
X-X-X
>4
X-X-X-X-X
<100
X-X-X-X-X
$99
X-X-X
>100
X-X-X
200
X-X-X-X-X
X-X-X-X
LEGOs
X-X-X-X-X
>25
X-X-X
50
X-X-X
<5
X-X-X
2
X-X-X
0.9
X-X-X-X-X
>2
X-X-X-X-X
0.75
>10
>4
>3
6+
1
20
X-X-X-X-X
X-X-X-X
X-X-X-X
X-X-X-X
X-X-X-X
X-X-X-X-X
X-X-X-X-X
X-X-X-X-X
15
4
3
8+
-
X
X-X-X-X-X
X-X-X-X-X
X-X-X-X-X
X-X-X-X
X-X-X
X
X-X
X-X-X
X-X-X
X-X-X-X
X-X-X-X-X
X-X-X-X
X-X-X
5
3
>3
12+
>4
9 to 44
Little Windy
X-X-X-X-X
X-X
X-X-X
X-X-X
X-X-X
X-X-X-X
X-X-X-X-X
X
Wind Trap
Value of Metric
percieved satisfaction
300
X-X-X
>5
X-X-X-X
$200
X-X-X
200
X-X-X-X
X-X-X-X
50
X-X-X
5
X-X-X-X-X
1.5 to 6
X-X-X-X-X
varies based on gears
>15
4
>3
Adult supervision required
15 to 20
Team 2D
X-X-X-X-X
X-X-X-X-X
X-X-X-X
X-X-X-X
X-X-X
X-X-X-X
X-X-X-X
Page 26 of 48
X-X-X-X-X
X-X-X-X-X
X-X-X-X-X
X-X-X-X-X
X-X-X-X
X-X-X
X-X-X-X
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Concept
Selection Criteria
Easy to assemble
Assembly time
Simple Design
Number of parts
Low Cost
Cost
Durable
Number of uses before failure
Durable
Strength of materials
Low Maintenance Number of uses before maintenance
Low Maintenance
Time to make a repair
Performance
Output Voltage
Performance
Output Efficiency
Educational Value
Time students are engaged
Educational Value
Number of people engaged
Educational Value
Number of concepts learned
Safety
Suitable for an age range
Number of parts
Number of manufactured parts
Needs to operate at
Operating Speed
Reasonable size
Fits in container provided
Sum +'s
Sum -'s
Sum 0's
Net Score
Rank
Continue?
Little Windy
0
0
+
0
0
+
+
0
0
0
0
0
+
0
4
2
10
2
1
Y
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
16
0
3
Y
0
0
0
0
0
+
+
+
0
+
+
0
5
4
7
1
2
Y
0
0
0
0
0
0
0
+
0
0
0
0
0
0
0
1
1
14
0
3
Y
0
0
0
0
+
0
0
+
0
+
0
3
5
8
-2
5
N
+
0
0
0
0
0
0
0
0
0
0
1
5
10
-4
6
N
Team 2D
Page 33 of 48
Table G.2 Analytical Heuristic Process (AHP) Chart for Weighting Criteria
1
1. Assembly time
2. Number of parts
1/3
3. Cost
5
4. Number of uses before failure
1
5. Strength of materials
1/3
6. Number of uses before maintenance 1/2
7. Time to make a repair
1/3
8. Output Voltage
1
9. Output Efficiency
1
10. Time students are engaged
1/2
11. Number of people engaged
1/4
12. Number of concepts learned
1/2
13. Suitable for an age range
1/3
14. Number of manufactured parts
1/3
15. Operating Speed
4
16. Fits in container provided
3
2
3
5
3
2
3
1
5
5
2
2
2
1
1
4
3
3
4
1/5 1
1/5 1/3
4
1/4
1/4 1/2
1/3 1
1/5 1/2
1
4
1
4
1/3 1
1/4 1/2
1/3 1
1/3 1/2
1/5 1/3
1/2 3
1
3
5
3
1/2
4
2
2
1
5
5
3
2
2
3
1
5
3
6
2
1/3
3
1
1/2
1
4
4
2
1
1
2
1
5
4
7
3
1
5
2
1
1
3
3
2
1
1
1
3
5
4
8
9
1
1
1/5 1/5
1
1
1/4 1/4
1/5 1/5
1/4 1/4
1/3 1/3
1
1
1/4 1/4
1/5 1/5
1/4 1/4
1/5 1/5
1/3 1/3
1
1
1/2 1/2
10
11
12
13
14
15
16
2
4
2
3
3
1/4
1/3
1/2
1/2
1/2 1
1
1/4
1/3
3
4
3
3
5
2
1
1
2
1
2
3
1/3
1/3
1/3
1/2
1/2
1/3 1
1/5
1/3
1/2 1
1
1/2 1
1/5
1/4
1/2 1
1
1
1/3
1/5
1/4
4
5
4
5
3
1
2
4
5
4
5
3
1
2
2
1
2
1/3
1/5
1/4
1/2
1/2
1/2
1/3
1/5
1/4
1
2
1
1/3
1/5
1/4
1/2 2
1
1/2
1/5
1/4
3
3
3
2
1/3 1
5
5
5
5
3
3
4
4
4
4
1
1/3
Total
28.78
7.18
49.00
19.42
8.18
12.78
8.98
48.00
48.00
17.12
9.68
13.12
13.02
19.87
54.50
39.33
Note: Based on Scale of Relative Importance: 1=Equal, 2=Slightly Important, 3=Moderately Important, 4=Very Important,
5=Most Important
Little Windy
Team 2D
Page 34 of 48
Weight
0.07
0.02
0.12
0.05
0.02
0.03
0.02
0.12
0.12
0.04
0.02
0.03
0.03
0.05
0.14
0.10
1 (vertical axis)
2 (horizontal axis) (REF) 3 (interchangable blades) 4 (3 blade vertical)
Selection Criteria
Weights Rating Weighted Score Rating Weighted Score Rating Weighted Score RatingWeighted Score
Easy to assemble
Assembly time
0.073
4
0.29
3
0.22
1
0.07
2
0.15
Simple Design
Number of parts
0.018
4
0.07
3
0.05
2
0.04
2
0.04
Low Cost
Cost
0.123
2
0.25
3
0.37
2
0.25
3
0.37
Durable
Number of uses before failure
0.049
4
0.20
3
0.15
3
0.15
3
0.15
Durable
Strength of materials
0.021
3
0.06
3
0.06
2
0.04
3
0.06
Low Maintenance Number of uses before maintenance 0.032
4
0.13
3
0.10
3
0.10
4
0.13
Low Maintenance
Time to make a repair
0.023
2
0.05
3
0.07
5
0.11
2
0.05
Performance
Output Voltage
0.121
4
0.48
3
0.36
4
0.48
3
0.36
Performance
Output Efficiency
0.121
4
0.48
3
0.36
4
0.48
2
0.24
Educational Value
Time students are engaged
0.043
2
0.09
3
0.13
4
0.17
3
0.13
Educational Value
Number of people engaged
0.024
2
0.05
3
0.07
4
0.10
2
0.05
Educational Value
Number of concepts learned
0.033
2
0.07
3
0.10
3
0.10
3
0.10
Safety
Suitable for an age range
0.033
3
0.10
3
0.10
3
0.10
3
0.10
Number of parts
Number of manufactured parts
0.050
3
0.15
3
0.15
5
0.25
4
0.20
Needs to operate at
Operating Speed
0.137
5
0.69
3
0.41
3
0.41
4
0.55
Reasonable size
Fits in container provided
0.099
3
0.30
3
0.30
3
0.30
3
0.30
Total Score
Rank
Continue?
3.44
1
Develop
3.00
3
N
3.15
2
Usable Concept
2.96
4
N
Note: Based on Scale of Relative Importance: 1=Much Less Satisfying, 2=Less Satisfying, 3=Equally Satisfying, 4= More Satisfying,
5=Much More Satisfying
Little Windy
Team 2D
Page 35 of 48
Expected Pricing
$8.00
$2.00/each
$4.00/each
$3.49
$5.00
$8.00/in3
Vendor
Learning Factory
PVC Piping-Home Depot
ME 340
Jameco
Learning Factory
Learning Factory
Retail Price: $50.00
Team 2D
Page 36 of 48
Little Windy
Torque
(mN-m)
0.75
0.75
0.45
0.45
1.03
1.03
1.03
0.82
Shaft
Speed
(RPM)
376
430
431
431
433
437
439
441
Torque
(mN-m)
0.82
1.27
1.30
1.30
1.30
1.27
1.30
1.27
Shaft
Speed
(RPM)
673
684
688
705
728
731
914
914
Team 2D
Torque
(mN-m)
1.81
1.83
1.81
1.83
1.81
1.81
2.54
2.54
Shaft
Speed
(RPM)
935
935
944
955
1021
1035
1046
Torque
(mN-m)
2.54
2.54
2.43
2.43
2.68
2.68
2.68
Page 37 of 48
)(
)(
)(
The power the turbine actually takes from wind is calculated using the power coefficient. The
power coefficient (also known as efficiency) is the ratio of captured mechanical power by blades
and the available power of the wind (Eq.3):
(Eq. 5)
Little Windy
Team 2D
Page 38 of 48
Figure K.1 Material and Component Selection Process for Mass Production Unit
Little Windy
Team 2D
Page 39 of 48
Little Windy
Team 2D
Page 40 of 48
Little Windy
Team 2D
Page 41 of 48
Little Windy
Team 2D
Page 42 of 48
Little Windy
Team 2D
Page 43 of 48
Part
No.
Purchased
Material
Cost
Manufacturing
Process
Assembly
(Labor)
Total Unit
Variable
Cost
Tooling
Costs ($K)
Tooling
Lifetime
(K units)
Total
Unit
Fixed
Cost
Total
Unit
Cost
Blade
(x3)
$0.36
Injection
Mold
$2.50
$2.86
$50.00
500
$0.10
$2.96
End Cap
(x2)
$1.23
Injection
Mold
$5.00
$6.23
$50.00
500
$0.10
$6.33
Shaft
$0.04
Injection
Mold
$3.00
$3.04
$50.00
500
$0.10
$3.14
Housing
Base
$2.15
Injection
Mold
$7.00
$9.15
$50.00
500
$0.10
$9.25
Motor
$3.49
Purchased
$3.00
$6.49
$6.49
Motor
Coupling
$0.05
Injection
Mold
$6.00
$6.05
$6.05
Shaft
Gear
$2.15
Purchased
$3.00
$5.15
$5.15
Motor
Gear
$2.07
Purchased
$3.00
$5.07
$5.07
On/Off
Switch
(2)
$2.98
Purchased
$1.00
$2.49
$2.49
LED
10
$1.30
Purchased
$1.00
$2.30
$2.30
Banana
Plugs
11
$0.72
Purchased
$1.00
$1.72
Bearing
(2)
12
$8.78
Purchased
$2.60
$6.99
Housing
Lid
13
Total
Direct
Costs
$18.72
$37.10
$55.82
Total
Cost
1
$6.99
$200.00
$0.40
$63.82
Little Windy
Team 2D
Page 44 of 48
Little Windy
Manufacturer
Mabuchi Motor Co.
Jameco Valuepro
SDP/SI
SDP/SI
Nice Bearings
Johnson/Emerson
NTE Electronics
Team 2D
Unit Price
$3.49
$1.49
$2.15
$2.07
$4.39
$0.72
$0.68
Quantity
1
1
1
1
2
1
1
Page 45 of 48
Q1
Development cost
Ramp-up cost
Marketing & support cost
Production cost
Production volume
Unit production cost
Sales revenue
Sales volume
Unit price
Period Cash Flow
PV, r = 10%
Little Windy
Q2
-150,000
-50,000
-10,000
-1,595,500
25,000
-63.82
1,875,000
25,000
75
119,511
119,511
Year 2
Q3
Q4
-50,000
-25,000
0
-15,000
-10,000
0
-2,500
-2,500
-2,500
1,595,500 1,595,500 1,595,500
25,000
25,000
25,000
-63.82
-63.82
-63.82
1,875,000 1,875,000 1,875,000
25,000
25,000
25,000
75
75
75
262,011
255,621
292,011
277,940
327,011
303,662
Team 2D
Q1
Q2
0
-2,500
-1,595,500
25,000
-63.82
1,875,000
25,000
75
327,011
296,256
Q3
0
Q4
0
-2,500
-2,500
-2,500
1,595,500 1,595,500 1,595,500
25,000
25,000
25,000
-63.82
-63.82
-63.82
1,875,000 1,875,000 1,875,000
25,000
25,000
25,000
75
75
75
277,000
244,828
277,000
238,856
Page 46 of 48
277,000
233,030
Q1
Development cost
Ramp-up cost
Marketing & support cost
Production cost
Production volume
Unit production cost
Sales revenue
Sales volume
Unit price
Period Cash Flow
PV, r = 10%
Q2
0
-2,500
-1,595,500
25,000
-63.82
1,875,000
25,000
75
277,000
227,347
Year 4
Q3
0
Q4
Q2
-2,500
-2,500
-2,500
1,595,500 1,595,500 1,595,500
25,000
25,000
25,000
-63.82
-63.82
-63.82
1,875,000 1,875,000 1,875,000
25,000
25,000
25,000
75
75
75
-2,500
-1,595,500
277,000
221,802
Q1
277,000
216,392
277,000
211,114
25,000
-63.82
1,875,000
25,000
75
277,000
205,965
Q3
0
Team 2D
-2,500
-2,500
-2,500
1,595,500 1,595,500 1,595,500
25,000
25,000
25,000
-63.82
-63.82
-63.82
1,875,000 1,875,000 1,875,000
25,000
25,000
25,000
75
75
75
277,000
200,941
277,000
196,040
Little Windy
Q4
Page 47 of 48
277,000
191,259
Equipment
This experiment requires measurements of motor output voltage and shaft speed. In experimental
procedure A, WT performance will be verified for varying direction of the wind source with
respect to the wind turbine. In experimental procedure B, WT performance will be determined
and verified for the chosen motor and gear pair by measuring the voltage across a 10 ohm
resistor. The experiment will be performed with the following equipment:
Experimental Procedure
1. Place box fan in a safe secure space within an area of at least 9 ft2 of room for the
experiment
2. Place the WT assembly 3 feet from the box fan and ensure a secure connection of the
10 ohm resistor to the motor. Connect the digital multimeter in series (fig. O.1) with
the 10 ohm resistor. Attach reflective tape to a selected wind turbine blade.
3. Turn on the fan and record if the WT is absle to start up autonomously
4. Once the WT has reached a steady state, record the voltage across the 10 ohm resistor
using the digital multimeter.
5. Using the phototachnometer, determine the speed of the turbine (rpm) using the
reflective tape as reference.
6. Make sure that measurements are accurate and turn off fan after measurements are
taken.
Digital Multimeter
Motor
Resistor
Little Windy
Team 2D
Page 48 of 48