EML 4905 Senior Design Project

A B.S. THESIS
PREPARED IN PARTIAL FULFILLMENT OF THE
REQUIREMENT FOR THE DEGREE OF
BACHELOR OF SCIENCE
IN
MECHANICAL ENGINEERING

Solar Powered Attic Fan

Final Report
Brent Houghton
Alejandro Osorio
Dominic Gayle
Advisor: Dr. Seyad Ebrahim Beladi

November 24, 2014

This B.S. thesis is written in partial fulfillment of the requirements in
EML 4905. The contents represent the opinion of the authors and not
the Department of Mechanical and Materials Engineering.

Ethics Statement and Signatures

The work submitted in this B.S. thesis is solely prepared by a team consisting of Brent
Houghton, Alejandro Osorio, and Dominic Gayle and it is original. Excerpts from others
work have been clearly identified, their work acknowledged within the text and listed in
the list of references. All of the engineering drawings, computer programs, formulations,
design work, prototype development and testing reported in this document are also
original and prepared by the same team of students.

Brent Houghton

Alejandro Osorio

Dominic Gayle

Team Leader

Team Member

Team Member

Dr. Seyad Ebrahim Beladi

Faculty Advisor

ii

Table of Contents
Ethics Statement and Signatures ......................................................................................... ii
Table of Figures .................................................................................................................. v
1.0 Introduction ................................................................................................................... 7
1.1 Abstract ..................................................................................................................... 7
1.2 Problem Statement .................................................................................................... 8
1.3 Motivation ................................................................................................................. 9
1.4 Survey of Standards .................................................................................................. 9
1.4 Literature Survey .................................................................................................... 10
1.4a Photovoltaic Cells ............................................................................................. 10
1.4b Fan..................................................................................................................... 13
2.0 Project Formulation .................................................................................................... 15
2.1 Project Objectives ................................................................................................... 15
2.2 Conceptual and Proposed Design ........................................................................... 16
Concept Design I....................................................................................................... 16
Concept Design II ..................................................................................................... 17
2.4 Environmental and Global Impact .......................................................................... 21
2.5 Project Timeline ...................................................................................................... 24
2.6 Project Overview .................................................................................................... 25
2.7 Task Breakdown and Involvement ......................................................................... 26
3.0 Analytical Background and Analysis.......................................................................... 27
3.1 Radiation Heat Transfer .......................................................................................... 27
3.2 Structural/Mounting Considerations ....................................................................... 35
iii

4.0 Prototype Development .............................................................................................. 39

4.1 Cost Analysis .......................................................................................................... 39
4.2 Prototype Manufacturing & Assembly ................................................................... 39
5.0 Model Testing ............................................................................................................. 43
5.1 Flow Simulation ...................................................................................................... 43
5.2 Stress Simulation .................................................................................................... 46
6.0 Conclusion .................................................................................................................. 50
7.0 References ................................................................................................................... 51
Appendix A: Component Specifications .......................................................................... 53

iv

Table of Figures
Figure 1 PV cell in sunlight generates electricity ............................................................ 11
Figure 2 Monocrystalline structure ................................................................................... 12
Figure 3 Polycrystalline structure ..................................................................................... 12
Figure 4 Centrifugal fan .................................................................................................... 13
Figure 5 Axial fan ............................................................................................................. 14
Figure 6 Schematic of proposed parts ............................................................................... 16
Figure 7 Solar Powered Attic Ventillator ......................................................................... 18
Figure 8 Air Vent Weather Wood ..................................................................................... 19
Figure 9 U.S. Sunlight Black Roof Power Vent ............................................................... 19
Figure 10 Gray Solar Attic................................................................................................ 20
Figure 11 Manufacturing processes of PV cells ............................................................... 21
Figure 12 Manufacturing processes of PV cells cont'd..................................................... 22
Figure 13 Acid Lead Recyclable Process ......................................................................... 22
Figure 14 Thin PV Cells ................................................................................................... 23
Figure 15 Project Timeline. .............................................................................................. 24
Figure 16 Initial Apparatus ............................................................................................... 25
Figure 17 Sun Path Regarding Seasonal Variations ...................................................... ...30
Figure 18 Latitude, hour angle, and Suns Declinations ................................................ ...31
Figure 19 Idealized model of housing loading .............................................................. ...36
Figure 19b Mesh Study .................................................................................................. ...37
Figure 20 Cost Analysis ................................................................................................. ...39
Figure 21 Cincinnati Precision Machinery .................................................................... ...40

Figure 22 Bending of sheet metal .................................................................................. ...41

Figure 23 Housing.......................................................................................................... ...41
Figure 24 Hinge mounting ............................................................................................. ...41
Figure 25 Assembled housing........................................................................................ ...42
Figure 26 Air speed within system ................................................................................ ...43
Figure 27 Air trajectories within system ........................................................................ ...44
Figure 28 Pressure distribution throughout system ....................................................... ...45
Figure 29 Von Misses stresses for tropical storm loading. ............................................ ...47
Figure 30 Safety factor distributions for tropical storm loading. .................................. ...47
Figure 31 Von Misses stresses for category 1 wind loading. ........................................ ...48
Figure 32 Safety factor distributions for category 1 wind loading. ............................... ...48

vi

1.0 Introduction
1.1 Abstract
Our team plans on designing and building a solar powered attic fan in which
photovoltaic technology will be implemented in powering a motor driven fan; operation
of this motor will be governed by an electronic controller and thermistor technology.
Although these devices have been available to the general consumer for some time, it is
our goal to greatly improve the performance of these systems with regard to heat removal
from household attics.
The initial design will consist of a rectangular shaped housing in which
photovoltaic cells will be placed on the surface. These PV cells will be mounted via
hinging. This will allow the end user the ability to angle the panels. An Aluminum
material will be used in the construction of the housing and the motor and other
components will be positioned beneath this housing, within the attic. The housing will be
fastened to the outer roof. Additionally, the fan will reverse its polarity at intervals. In
this way, it is believed that after expelling hot air within the attic, the fan will draw in
fresh air for a set interval.

1.2 Problem Statement

During times of temperature extremes, be it extreme heat or cold, air often times
is trapped within the attic of homes. As a result of this, there is an increased load on the
A/C system to maintain comfortable temperatures. The solution to this is the
implementation of an attic fan. The primary goal of this project is to expel heat from the
household attic in an efficient manner via implementation of photovoltaic technology.

1.3 Motivation
Solar powered attic fans are currently available on the consumer market and have
been for quite some time now. Our team has determined through our own experiences
and research and the advice of a current HVAC professional, that these devices have not
been widely implemented into South Florida homes because of lack of information and
aesthetical reasons.
With these concerns in mind, the team has tasked itself with designing a solar
powered attic fan possessing a geometric shape that allows for optimal performance,
regardless of placement on the roof. In this way, our design will stand apart from
currently available devices.
1.4 Survey of Standards
In order to ensure that the design choices conducted in this project are fit for their
tasks certain standards are adhered to. It is expected that throughout the duration of this
project, the following standards will be followed:
1. ASHRAE American Society of Heating, Refrigerating, and Air-Conditioning
Engineers
2. ASCE American Society of Civil Engineers
3. ASM - American Society for Metals
4. ASME - American Society for Mechanical Engineers
5. IEEE - Institute of Electrical and Electronics Engineers
6. ANSI American National Standards Institute

1.4 Literature Survey

Attic fans are generally used in warmer climates, particularly in the summer
months, to release trapped heat from attics. In South Florida, it is not uncommon for attic
temperatures to reach in excess of 160 F. On the other hand, during periods of extreme
cold, moisture and cold can lead to mildew growth in the attic as well. Attic fans are the
simplest, most effective means to resolve both these problems.
Solar powered attic fans are available to the general consumer at several retailers
and have been on the market for a while now. However, these are simply attic fans
accompanied by generic rectangular photovoltaic cells. As a result of this, the placement
of the fan and its performance is dictated by the placement of the solar panel.
Additionally, in spite of their effectiveness, solar panels are generally not very
aesthetically pleasing to homeowners.
The major components of the solar powered attic fan are: photovoltaic cells, fan,
and complimentary equipment.
1.4a Photovoltaic Cells
The absorption and transformation of light energy into electricity is known as the
photovoltaic effect. Certain materials, such as silicon, are said to be photoelectric. When
these materials absorb light they release electrons that cause a current to flow.
Photovoltaic cells need to be made from a minimum of two layers for successful
operation. The layers have a positive charge, the p-type and a negative charge, the n-type.
When the negative layer absorbs photons from the sunlight, electrons flow to the positive
layer. This leads to a voltage differential. Therefore, just like with a battery, when the

10

cells are connected to an external load, a current will flow. This process is depicted in the
figure below [1].

Figure 1 PV cell in sunlight generates electricity [1].

Silicon used to make photovoltaic cells are generally made from one of three type
of silicon structures: monocrystalline, amorphous or polycrystalline. There is a direct
correlation between the performance of photovoltaic cells and it structure.
Monocrystalline structures offer the highest efficiency, but are by far the most expensive
to manufacture. Polycrystalline structures are less efficient and are also cheaper to
manufacture. This is a tradeoff that must be weighed based on the specific application.
Figures 2 and 3 show monocrystalline and polycrystalline photovoltaic cells. Their

11

difference is apparent by color; the monocrystalline cells are of a much darker blue,
sometimes even appearing black.

Figure 2 Monocrystalline structure [5]

Figure 3 Polycrystalline structure [6]

12

Amorphous structures are used for significantly less energy demanding applications. For
example, they are used in calculators.
There is another structure used in certain applications called thin-film solar cells. Thin-film solar
cells are formed by deposition of a photovoltaic material on a substrate. Thin-film solar cells are
categorized based on the photovoltaic material. Two of the more popular materials are
amorphous silicon and cadmium telluride. Cadmium telluride thin-film solar cells are capable of
achieving between 8-13% efficiency [3].
1.4b Fan
Fans are used in many heating and ventilation systems to induce air movement in space
or through ducts. The two basic types of fans are: centrifugal fan and the axial fan as the figures
below depict.

Figure 4 Centrifugal fan [7].

13

Centrifugal Fans
These are ideal for large industrial applications because they can efficiently move large
volumes of air over a wide range of pressures. Centrifugal fans have an impeller that is rotating
within a scroll-type casing. The impeller imparts energy to the air or gas being moved. The
blades may be backward-curved, forward-curved, or radial. Each blade design has its own
advantages and disadvantages and is chosen based on the application [4].

Figure 5 Axial Fan [8].

Axial Fans
Axial fans have a propeller mounted parallel to the direction of airflow. The propeller
creates a pressure difference that causes a suction effect pulling air across its blade. Axial flow
fans are ideal because they can move high volumes of air at low pressures. Fan selection is a
complicated matter. Selection is based on available space, capacity (volume of air to be moved),
and noise concerns [4].

14

2.0 Project Formulation

2.1 Project Objectives
1. Design a tetrahedral shaped housing for solar cells that will allow maximum solar
absorption, regardless of positioning.
2. Selection and implementation of an axial fan capable of effectively moving the necessary
volume of air.
3. Utilize a charge controller to ensure proper current flow and prevention of complete
battery discharge during non-charging intervals i.e. during the night.
4. Ensure deep-cycle battery is capable of being completely recharged through current
generated by the solar panels.
5. Implement a method to control the fan speed based on the attic condition.
6. Ensure housing is structurally sound. In addition, design and select fasteners necessary to
safely mount equipment to roofing.

15

2.2 Conceptual and Proposed Design

Concept Design I
The tetrahedral shaped housing will be constructed of a lightweight, yet, conductive
material that most likely serves as Aluminum alloy in this case. This housing will reside
permanently on a household roof and will allow for airflow from the underlying attic. There will
be an opening on top of this housing to allow for air expulsion, (roughly 1 square inch in size).
We anticipate the diminishing volume from the bottom of the housing to the top will
create a jet like funnel in which a forced convection will occur with the assistance of a DC
battery driven fan from underneath. This fan will be controlled from a voltage controller/inverter
and be governed by a series of thermistor-based sensors. A photovoltaic film, which is placed on
the Aluminum housing, will generate current to recharge a deep-cycle battery through the use of
solar energy.

Figure 6 Schematic of proposed parts [9].

16

Concept Design II
The second design proposes the use of a rectangular housing. In order to allow the end
user the ability to place the housing in the position of choice the housing will possess hinges. The
solar cells will then be mounted on to these hinges. In this way, each solar panel can be oriented
up to 90 degrees with respect to the housing itself.
This design was ultimately decided because its construction is less complicated. Also,
with the hinges it would still be optimal in whatever position the consumer places it. The one
concession between this design and the prior is the decreasing area the other offers. However, it
was determined that for this application, a large volume of air is more advantageous to faster
flowing air.

17

2.3 Market Comparison

Household attics can potentially reach very high temperatures, which is not conducive to
storage. Additionally, depending on the time zone and the seasonal time of year, attics may also
attain extremely low temperatures during winter months. The observed problem is that attics may
not provide a feasible storage solution.
Options regarding solar energy are present in newly constructed homes across the nation,
governing such devices as water heaters and outdoor lighting. In fact, modernized home
upgrades involve the use of solar energy as well. Market chains such as Grainger, Lowes, and
Home Depot provide this equipment. Such a device is referenced below in Figure 4 as a solar
powered attic ventilator, provided by Grainger and manufactured by Broam. This 28-Watt
producing product delivers 537 CFM and a maximum work area operation of 2300 square feet.

Figure 7 Solar powered attic ventilator [10].

In addition, Lowes offers two different options that accommodate small and large attics.
Weather Wood Roof Powered Ventilation is a 25-Watt smaller unit delivering 800 CFM over a
maximum attic area of 1200 Square Feet. The unit is manufactured by Air Vent; a British
company that develops products of this type over a global market. Another larger product
18

available at Lowes is the Sunlight Black Roof Power Ventilation, 20-Watt unit delivering 730
CFM over 2400 square foot attic area. These devices are illustrated in Figures 5 and 6.

Figure 8 Air vent weather wood [11].

Figure 9 U.S. sunlight black roof power vent [12].

The Gray Solar Powered Attic Fan is manufactured by Remington Solar, an American
Company founded in 2007. They are known as the pioneers of photovoltaic products. This
device governs a 30-Watt electrical motor, handling 2200 CFM and operates over a 2500 square
foot attic area. This model serves as the largest of available fans on the market. This item is
displayed in Figure 7.

19

Figure 10 Gray Solar Attic [13].

Table 1 Technical Specifications for Current Market fans

Supplier

Brand

Name

Type

Watts

CFM

Max. Attic Area

Thermostat Temp. (F)

Grainger

Broan

Solar Powered Attic Ventilator

Solar Powered

28

537

2300

0-50

696

Lowes

Air Vent I NC.

Air Vent S olar Powered Vend

Solar Powered

25

800

1200

0-60

249.06

Lowes

U.S. S unlight

Black R oof Power Ventilation

Solar Powered

20

730

2400

0-50

445

Gray S olar Powered Attic F an

Solar Powered

30

2200

2500

0-60

449

Home D epot Remington S olar

Price ($)

20

2.4 Environmental and Global Impact

Photovoltaic cells can generate large amounts of electricity without producing any
pollution to the ambient surroundings or adding to global warming. In order to generate large
quantities of electricity it is necessary that a large amount of land be utilized. In this project a
small photovoltaic cells are sufficient to generate necessary electricity to power the electrical
motor. Despite the fact that PV cells produce no pollution during operation, the manufacturing
process of these cells can be hazardous to he environment. The manufacturing process involves
chemical substances like hydraulic acid, sulfuric acid and nitric acid. Manufacturing companies
must employ proper protocols to prevent exposure of these chemicals to the environment. In
addition, proper disposal methods must be utilized to ensure minimal environmental impact.
On the other hand, photovoltaic cells can have working lives of up to 30 years. It is
widely accepted that the pollution created in the manufacturing process is offset and
overshadowed by their durability. Figures 11 and 12 provide a visual guide for this
manufacturing procedure.

Figure 11 Manufacturing processes of PV cells [14].

21

Figure 12 Manufacturing processes of PV cells cont'd [15].

The solar attic fan that is being designed will operate on DC current. It will be suitable
for any location. A rechargeable battery will operate the electric motor. This battery will not
have to be replaced for a very long time. In addition, the battery that is being utilized is a lead
acid type that is 96% recyclable. Figure 13 illustrates the lead acid recycling process.

Figure 13 Acid lead recyclable process [16].

As seen from the figures above, the majority of the components being utilized for this
project pose very minimal threat to the environment. In fact, even the blades of the fan are made
from aluminum. This is also a 100% recyclable material.The final major component, the
thermistor, is highly reliable and as such is unlikely to fail. In the event that it does fail, the effect

22

of disposal is neglible. The electrical motor can be rewounded and also recycled due to the
copper material that it possesses.
Global Components
Wright Center for Photovoltaic Innovation and Commercialization PVIC is an
organitation created in 2007 on department of innovation at the state of Ohio. This organization
is a mix among of researches, experiment, studies and lots of works related to photovoltaic
products from universities like an Ohio, Toledo and Bowling Green. These convinated efforts
and more than 38 million dollars makes possible that photovoltaics products can be more
accessible to general costumers. Now days and thanks to advances on technology photovoltaic
cells are created thinner and lighter than the first one, they take less manufacturing process and
also less pollution to the ambient, also due to its flexibility there are more application in the
industry and construction to be used as an energy source. Figure 08 illustrates thinner pv cells.

Figure 14 Thin PV cells [17].

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2.5 Project Timeline

As is depicted in Figure 12, the testing portion of our design has initiated and proves to
be successful pertaining to functionality and performance of the key components; these include
solar panels, charge controller, and axial fan. As Figure 13 depicts, the simple apparatus is
composed of only one of four solar panels that prove to trickle charge the deep cycle battery. To
allow for the maximum flow rate of 2000+ CFMs from the fan, a speed controller will draw 10
Amps from the 35 Amp-hour deep cycle battery.
This battery is designed to handle over 100 full discharge cycles and proves optimal for
this configuration. As future testing continues, four solar panels will be configured in a parallel
formation, thus maintaining 12 Volts at 20 Watts/hour. The ultimate goal is to maintain the
battery at 35 Amp-hour capacity while ensuring intermittent, thermostat control of the fan to
expel hot air from the attic space. Once this is achieved, calculations will be performed to
determine the time intervals of operation based on the needs of the temperature control of the
attic.

Figure 15 Timeline

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2.6 Project Overview

The project can be broken down into several key stages. First, the literature survey was
done to determine the nature of the field and to gather an understanding of current technology.
Once that was done, a model of the prototype is to be created in SolidWorks where theoretical
testing and sizing was done. The housing was then constructed. Solar panels and supplementary
equipment will then be selected based on the housing dimensions and fan requirements. The final
aspect is to then test the apparatus. The initial apparatus can be seen in the figure below.

Figure 16 Initial Apparatus.

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2.7 Task Breakdown and Involvement

Table 2 Specific tasks by member

Task
Literature Review
Project
Oversight/Meetings
3D Model Creation
Flow Simulation
Stress Calculation
Bolt/Fastener Selection
Purchasing
Electrical Work
Manufacturing
Assembly
Testing
Report Formatting

Brent

Alejandro

Dominic

Total
Hours
6.5

X
X

X
X

X
X
X

15
3
3.5
2
4
0
5
4
10
12
8

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3.0 Analytical Background and Analysis

3.1 Radiation Heat Transfer
As pertaining to solar energy, two general ideals include the characteristics of energy
obtained from the sun and the response of the receiving surface to this energy. Radiation from
the sun, or thermal energy, is considered in terms of the transport of photons and the propagation
of electromagnetic waves. A general equation regarding the propagation of radiation within a
medium relates frequency and wavelength:
Equation 1

Where:
c is the speed of light in a vacuum, c = 2.998 x 108 m/sec
is the wavelength
v is the frequency.
The electromagnetic continuum is subdivided into different categories as a function of
wavelength. (Table 1.1)
Solar radiation has important impacts on the heat gains and losses of buildings, including
household attics. The magnitude of these effects greatly depends on both the current location of
the sun in the sky, the clearness of the atmosphere, and the orientation and nature of the building.
It is the overlapping of mostly infrared, ultraviolet, and all of the visible light that is referred to
as thermal radiation; this is part of the electromagnetic spectrum that results in a heating effect.
The total thermal radiation that impinges on a surface from all directions and sources is known as
global radiation and the units are Btu/(hr-ft2) or W/m2.
27

Table 3 Electromagnetic continuum and regimes.

Regime

Range

Gamma Rays

< 10-4 m

X-rays

10-4 < < 10-2 m

Ultraviolet

10-2 < < 0.4 m

Thermal Radiation

10-1 < < 102 m

Infrared

0.7 < < 102 m

Microwave

> 102 m

In addition to solar radiation, solar absorption and emission must be equally considered
when designing various types of solar energy related systems. In solar thermal collectors, a
selective absorber is a method of increasing the operation temperature and/or efficiency of the
solar collector plate. This selectivity is known as the ratio of solar radiation-absorption, , to
thermal infrared radiation-emission, .

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Table 4 Solar absorbpivity, emissivity and ratio for selected materials.

Surface

Solar Absorptivity, Emissivity, Ratio, /

Aluminum
Evaporated Film

0.09

0.03

3.00

Hard anodized

0.03

0.80

0.04

White Paint

0.21

0.96

0.22

Black Paint

0.97

0.97

1.00

Black chrome

0.95

0.15

6.47

Red Brick

0.63

0.93

0.68

Snow

0.28

0.97

0.29

Teflon

0.12

0.85

0.14

Vegetation (corn)

0.76

0.97

0.78

Table 5 Standard longitude for United States time zones

Degrees Longitude Time Zone

75

Eastern

90

Central

105

Mountain

120

Pacific

In order for one to gain an understanding of the suns position relative to the Earth, one
must become familiar with the sun path, the path traveled by the sun in relation to a specific
location on the Earths surface. As pertaining to the Earth-sun geometric relationship as
29

illustrated in Figure 1.1, the rotation of the Earth about its axis is oriented at an angle of 23.45;
this is with respect to the ecliptic orbital plane. It is due to this rotation angle that changes in
season occur approximately every three months.

Figure 17 Sun path regarding seasonal variations [18].

As for the quantitative considerations of solar energy applications, real time climate
information, as well as solar insulation, or irradiation, one may refer to The United States
Department of Energys National Renewable Energy Laboratory, (NREL).
Governing Equations
Heat gain and heat loss are both greatly impacted by the effects of solar radiation. These
effects are primarily related to the location of the sun in the sky, the clearness of the atmosphere,
and the orientation and nature of the building, including household attics. Thermal radiation
serves as the aspect of electromagnetic waves that causes the heating effect. The total thermal

30

radiation that impinges on a surface from all direction and from all sources is referred to as
global irradiation. The units of irradiation are Btu/(hr-ft2) or W/m2.
There are three fundamental quantities that accurately describe the suns rays. These
include, the location on the Earths surface, the time of day, and the day of the year. The latitude,
l, is the angle between line OP and the projection of OP on the equatorial plane. The hour angle,
h, is the angle between the projection of P on the equatorial plane and the projection on that
plane from the center of the sun to the center of the Earth.

Figure 18 Latitude, hour angle and sun's declination [19].

The suns declination, , is the angle between a line connecting the center of the sun and
the projection of that line on the equatorial plane.
= 0.3963723 22.9132745 cos N + 4.0254304 sin N 0.3872050 cos 2N + 0.05196728 sin
2N 0.1545267 cos 3N + 0.08479777 sin 3N
The solar altitude angle, , is the angle between the suns ray and the projection of that
ray on a horizontal surface; it is the angle of the sun above the horizon.
Sin = cos l cos h cos + sin l sin

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The suns zenith angle, Z, is the angle between the suns rays and a perpendicular to the
horizontal plane at point P.
+ Z = 90 degrees
The daily maximum altitude (solar noon) of the sun at a given location can be shown to
be
noon = 90 - l degrees
The solar azimuth angle, , is the angle in the horizontal plane measured, in the
clockwise direction, between north and the projection of the suns rays on that plane.
Cos = sin () cos (l) cos () sin (l) cos (h) / cos ()

The ASHRAE Clear Sky Model gives the value of the solar irradiation at the surface of
the Earth on a clear day
GND = [A / exp(B/sin )]CN
Where:
GND = normal direct irradiation, Btu/(hr-ft2) or W/m2
A = apparent solar irradiation at air mass equal to zero, Btu/(hr-ft2) or W/m2
B = atmospheric extinction coefficient
= solar altitude
CN = clearness number

32

3.2 Fan Components

A fan serves as an essential component of almost all HVAC related systems. The purpose
of the fan is to move air through ducts and to induce motion in the space. A wide variety of fans
exist and each possesses its own unique, fundamental quality.
The centrifugal fan is the most common type since it can move large or small quantities
of air over a large volume in an efficient manner. The operation is similar to a centrifugal pump
in which it contains a rotating propeller that transmits energy to an air or gas that is to be moved.
The impeller blades may be forward-curved, backward-curved, or radial. As will be discussed
later, the blade design influences the fan characteristics.
The vane axial fan is usually mounted on the centerline of the duct and produces an axial
airflow. Guide vanes are provided before and after the wheel to reduce rotation of the air stream,
which will usually maintain a laminar flow. Tube axial fans are similar to aforementioned vane
axial fans, however, it contains no guide vanes. Although axial fans are not capable of producing
pressures as high as those of centrifugal fans, they can move large quantities of air at low
pressure, and tend to produce more noise.
Generally, a fan will produce the least amount of noise when it is operated close to its
peak efficiency; operation beyond this point will produce noise. Both forward-curved and
straight blades tend to produce noise, especially at high speeds. Backward-curved blades may be
operated at both sides of the peak efficiency at high speeds and produce far less noise than other
types of fan blades. For this reason, backward-curved blades will be the focus of our fan design.

33

Governing Equations
Fan performance is generally given in a graphical form, displaying pressure, efficiency,
and power as a function of capacity; the energy that is transferred to the air via the impeller will
result in an increased static and velocity pressure. The sum of these two pressures equals the total
pressure. When a modified Bernoullis equation is applied to a fan, neglecting the effects of
elevation, and a constant density is assumed, the following result is obtained:

Equation 2

(
=

+
) =

Where:
P = static pressure, lbf/ft2 or N/m2
= mass density at cross section, lbm/ft3 or kg/m3
V = average velocity at a cross section, ft/s or m/s
g = local acceleration of gravity, ft/sec or m/s
gc = constant = 32.17 (lbm-ft)/(lbf-sec2) = 1.0 (kg-m)/(N-s2)
w = work, (ft-lbf)/lbm or J/kg
In this form, the equation expresses the decrease in total head of the air. Multiplying by g/gc
yields:
Equation 3

34

The primary consideration for any fan application should entail the required capacity,
usually expressed as cubic feet per minute, (cfm) and system total pressure within the design
point. The capacity depends on the heating/cooling load. In addition, the fan should consist of a
proper combination of efficiency, relative cost, acoustics, and physical size. The performance of
a fan for a variable air-volume system serves as a crucial consideration since the fan will operate
at partial capacity during a considerable time interval. Otherwise, there is a danger of operating
at the unstable (surge) region at a low flow rate unless proper fan selection is made and fan speed
is controlled.
3.2 Structural/Mounting Considerations
Components of the attic fan will be exposed to the elements of nature, particularly, the
housing. As such, the proper design choices must be made in order to endure the elements of
nature. In South Florida, hurricanes can occur frequently between the months of September and
November. During hurricanes, the majority of damage occurs as a result of the enormous wind
speeds. According to the Saffir Simpson hurricane wind scale, hurricanes fall within five
categories based on the speed of their winds. Wind speeds of category 5 hurricanes are in excess
of a 157 mph or 253 kmh. It is necessary that components exposed to these conditions be
properly fastened. In the case of this project, the housing that supports the solar panels will need
to be properly secured to the roofing.
For PV systems incorporated into a roof directly, it is possible to analyze them as a roof would
normally be analyzed using ASCE 7-05 standards. The most accurate method would be to
perform wind tunnel testing in accord with ASCE 7-05. For the purposes of this project, the PV
system analysis will be treated as a two-dimensional system in which winds hit the surface
directly.

35

The general formula for wind loading is as follows:

Equation 4

1
= ! !
2
Where is the density of air, V is the velocity of air, A is the area upon which the force
acts and Cd is the drag coefficient. Cd is a dimensionless coefficient specific to each geometrical
shape. In order to determine the Cd for our specific geometry it would be necessary to perform
wind tunnel testing on the shape. That is beyond the scope of this application. Cd will be chosen
based on historical data and trends. According to various websites, Cd of a flat plate based on
width and length is anywhere between 1.2 and 1.65. To be as safe as possible, Cd will be
assumed to be 1.65. As seen in the idealized figure below, the fastener must oppose the torque
produced by the loading.

Figure 19 Idealized model of housing loading conditions.

36

The table below shows wind-loading values for wind speeds associated with several
categories, from tropical storms to category 4 hurricanes.
Table 6 Wind Loads

Category
Storm
1
2
3
4

Wind Speed (m/s)

32
42
49
58
70

Wind Loading
(N)
165.58
285.24
388.24
543.96
792.33

Wind Loading
(lbf)
37.29
64.24
87.44
122.51
178.45

Figure 19b Mesh Study

With the limited capability of the SolidWorks file, it was necessary to suppress certain
aspects from the analysis. Further, the wood material base to which the housing is secured is not
the common household plywood material. This material was not readily available within the
software. As such, the decision was made to use a wood close enough in properties so as to
determine the stresses the fasteners would need to withstand.

37

The values of wind loading from Table 5 were used for the wind loading. As a result of
this, the decision was made to utilize galvanized deck screws. More specifically, a #6 or #8 deck
screw. With this, the fastening is adequate and recommended for up to a category 1 hurricane.
Beyond this level of wind loading, it is recommended that the housing be removed for fear of
property damage.

38

4.0 Prototype Development

4.1 Cost Analysis

$98.00

$95.00

$45.00
$28.00
$15.00
$0.10

$8.00

Figure 20 Cost Analysis.

4.2 Prototype Manufacturing & Assembly

Certain parts of the prototype were bought and as such did not require manufacturing.
These parts include: the fan, the hemispherical dome and the timers. The housing was the only
thing that was necessary to be manufactured.

39

Initially, the housing was supposed to look very similar to a pyramid. However, it was
decided that instead of making the housing a pyramid and the solar panels fixed, the housing
would be made rectangular and hinges inserted. With the solar panels connected to these hinges,
the solar panels will be able to come out up to a 90 degree angle. In this way, the end user is
capable of orienting the panels if they so elect.
The sheet metal was first measured to necessary specifications. Once done, the necessary
area was cut out. From there, a Brake machine was used to bend the sheet metal into the shape of
rectangle

and around

the edges for

mounting

positions.

Then, on

each corner,

the holes

were created

to mount the

hinges. From

here the

solar panel

and the

dome were

put in place.

The images

below
Figure 21 Cincinnati Precision Machinery.

highlight the major steps in the manufacturing of the housing and the assembly of the solar
panel.

40

Figure 23 Housing.
Figure 22 Bending of sheet metal.

Figure 24 Hinge mounting.

41

Figure 25 Assembled housing

42

5.0 Model Testing

5.1 Flow Simulation
The figures below represent the results of flow testing done on the housing to ascertain
air speeds and pressure throughout the housing. As seen in the figures, a hemispherical dome has
been placed atop the housing. This dome was chosen to prevent water from entering the system
and the household. With the fan operating within optimal regions, figure 21 below shows that air
speeds along the outlets --- the region that is slightly yellow --- will be between 2.220 m/s and
5.179 m/s.

Figure 26 Air speed within system

Further, it was the hope of this group to create a more efficient system to prevent water
entry into the system. However, due to time constraints, the dome was selected. The dome was
selected because it allowed for minimal back-pressure in the system. Additionally, the bowl has

43

an area of a 120 inches squared whilst the housing outlet has an area of a 122 inches squared.
Hence, even with the dome equipped, there is sufficient area for good flow out of the system.

Figure 27 Air trajectories within system.

44

Figure 28 Pressure distributions throughout system.

As expected, due to the smaller area, there will be an increase in the flow speeds out of
the system. As such the inner walls of the system around this area experiences higher pressure.
Nonetheless, because of the choice of materials, this will not pose a threat to the system integrity.

45

5.2 Stress Simulation

In section 3.2, analysis was conducted wherein the housing was fastened to a wood base,
balsa material --- plywood is not a material available within the educational version of
SolidWorks. In order for the analysis to be completed, it was necessary that parts be suppressed.
The analysis results obtained below are of the housing, excluding the wood base. The flanges
have been fixed.

46

Figure 29 Von misses stress for tropical storm wind loading.

Figure 30 Safety factor distribution for tropical storm loading.

47

Figure 31 Von Misses stresses for category 1 wind loading.

Figure 32 Factor of safety distribution for category 1.

48

In figure 29 above, it can be seen that the maximum stresses within the housing are
experienced at the seams where the aluminum has been bent. Under tropical storm loading, the
minimum stress within the body is 0.0008 psi.
In figure 30, it is seen that the minimum safety factor throughout the housing is 1.10.
These results signify that though the fasteners may retain the fasteners during a tropical storm,
the rest of the housing is at risk.
Figures 31 and 32 above demonstrate a completely different situation as compared to
tropical storm wind loadings. However, it does support the original analysis that under hurricane
conditions, the system should be removed.

49

6.0 Conclusion
It is our summary that this design will not only improve an existing product, but also
allow us to broaden our horizons as future engineers. Though we are confident in this
design/fabrication, we expect some issues to be had as it concerns photovoltaic technology. This
is not an area greatly covered in the mechanical engineering curriculum. With the help of our
advising professor and the aid of a current HVAC professional, we are confident we can meet
and overcome this challenge.

50

7.0 References
1. M. R. Patel, Photovoltaic Power, in Wind and Solar Power Systems Design, Analysis
and Operation, 2nd ed., CRC Press, 2005, chapter 8, pp. 143-161.
2. T. Jackson. (2012). Monocrystalline or Polycrystalline? [Online]. Available FTP:
http://blog.gogreensolar.com Directory: 2012/06/ File: monocrystallinepolycrystalline.html
3. M. A. Maehlum. (2013). Which Solar Panel Type is Best? Monocrystalline vs
Polycrystalline vs Thin Film [online]. Available FTP: http://energyinformative.org
Directory: best-solar-panel-monocrystalline-polycrystalline-thin-film/
4. F. C. Mcquiston, et al, Fans and Building Air Distribution, in Heating, Ventilating, and
Air Conditioning, 6th ed., Wiley, 2005, chapter 12, pp. 394-404.
5. Ningbo Best Solar. (2009). [Online]. Available FTP: http://cnbestsolar.88582.net/Highefficiency-solar-cells/mono5%E2%80%9D(r150)125s_Mono5%E2%80%9D(r150)125s-32.html
6. Panel Types Crystalline. (2011). [Online]. Available FTP:
http://www.solarpanelbuyersguide.co.uk/panel-types-crystalline/
7. Centrifugal fan. (2014). [Online]. Wikipedia.org. Available FTP:
http://en.wikipedia.org/wiki/Centrifugal_fan
8. Autodesk Seek. (2014). [Online]. Available FTP:
http://seek.autodesk.com/product/latest/agg/lorencookcompany/Loren-CookCompany/Lorencook-AVAD
9. Inhabitat. (2012). [Online]. Available FTP: http://inhabitat.com/v3solars-photovoltaicspin-cell-cones-capture-sunlight-all-day-long/

51

10. Grainger. [Online]. Available FTP: http://www.grainger.com/product/BROAN-Remote20AZ92?s_pp=false&picUrl=//static.grainger.com/rp/s/is/image/Grainger/20AZ92_AS01

?$smthumb$
11. Lowes. [Online]. Available FTP: http://www.lowes.com/pd_269916-228NPSP8WW_0__?Ntt=solar+attic+fans&UserSearch=solar+attic+fans&productId=31223
95&rpp=32.
12. Lowes. [Online]. Available FTP:
http://www.lowes.com/ProductDisplay?partNumber=569071-228-9920TR&langId=1&storeId=10151&productId=50146034&catalogId=10051&cmRelshp=req&rel=nofollo
w&cId=PDIO1.
13. Home Depot. [Online]. Available FTP: http://www.homedepot.com/p/Remington-Solar30-Watt-2200-CFM-Gray-Solar-Powered-Attic-Fan-SF30-GR/204225857.
14. Think-Solar-Power. [Online]. Available FTP: http://www.think-solarpower.com/Photovoltaic-Solar-Power.html.
15. Think-Solar-Power. [Online]. Available FTP: http://www.think-solarpower.com/Photovoltaic-Solar-Power.html.
16. Ecobat. [Online]. Available FTP: http://ecobatgroup.com/ecobat/rp/.
17. Treehugger. [Online]. Available FTP:
http://media.treehugger.com/assets/images/2011/10/thin-film-solar-rnd-rr001.jpg
18. Britanica. [Online]. Available FTP:
http://www.britannica.com/EBchecked/topic/645665/winter-solstice
19. Powerfromthesun. [Online]. Available FTP:
http://www.powerfromthesun.net/Book/chapter03/chapter03.html

52

Appendix A: Component Specifications

53

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