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Joe Jachlewski-ME- Team Leader Aaron Bailey-ME Paul Kingsley-ME Brian Nealis-ME Matt Rose-ME

Multidisciplinary Engineering Senior Design Project 05307 Wind Solar Project 2005 Critical Design Review May 13, 2001. Joe Jachlewski-ME- Team Leader Aaron Bailey-ME Paul Kingsley-ME Brian Nealis-ME Matt Rose-ME Pam Snyder-ME Chris Wall-ME Customer: Dr. P. Venkataraman

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Joe Jachlewski-ME- Team Leader Aaron Bailey-ME Paul Kingsley-ME Brian Nealis-ME Matt Rose-ME

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  1. Multidisciplinary Engineering Senior DesignProject 05307 Wind Solar Project2005 Critical Design ReviewMay 13, 2001 Joe Jachlewski-ME- Team Leader Aaron Bailey-ME Paul Kingsley-ME Brian Nealis-ME Matt Rose-ME Pam Snyder-ME Chris Wall-ME Customer: Dr. P. Venkataraman Mentor: Dr. E. Hensel Coordinator: Dr. W. Walter

  2. Project Background • Recent push for “green” power sources • NYSERDA Proposal • The long-term goal of this project is to create a marketable wind/solar hybrid power generation system that can be applied to outdoor lighting and other applications. 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  3. Mission Statement The mission of the 2004-2005 Wind Solar Team is to design and build a prototype of an outdoor lighting system that is powered solely by wind and solar energy. The team will test the prototype for a minimum of one week and evaluate the system performance. The prototype will be safe and easy to modify. 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  4. Desired Outcomes • Safe operation • Integration of wind turbine, solar panel, a light, an energy storage system, support structures, and signal processing equipment. • Ability for Turbine interchangeability for future testing 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  5. Key Requirements & Critical Parameters • Complete first design • Build first prototype • Test prototype for at least a week • Evaluate system performance • Provide recommendations for future designs • Power the light 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  6. Design Process Feasibility Assessment Project Definition Concept Development Analysis & Synthesis of Design Preliminary Prototype Design Build Prototype System Testing and Evaluation Future Recommendations 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  7. Concept Development 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  8. Concept Development 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  9. Feasibility Assessment Total power required for each concept Required size of the power generation system 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  10. Feasibility Assessment Concept C was selected for further design. 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  11. Synthesis of Design • Light Selection Color: Warm White Diameter: 4.80” Height: 4.76” Current: 76 mA Wattage:9.2 W Brightness: >43000 LUX Nominal Current: 20 mA Nominal Voltage: 3.0~3.6 V Manufactured by: Light Waves Concepts Par 38 120 LED 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  12. Design Point Synthesis Of Design Power Generation System Design Space *Based on a 20 Watt power requirement and a 15 % efficient turbine 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  13. Synthesis of Design • Solar Panel Selection Model #: BP SX 10 Maximum power: 10 W Warranted power: 9 W Voltage at maximum power: 16.8 V Open-circuit voltage: 21.0 V Current at maximum power: 0.59A Short-circuit current: 0.65 A 12 year Warranty for 90% output 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  14. Synthesis of Design • Wind Turbine Design • Savonius Turbine • 1.46 m2 swept area • Assuming 15 % efficiency, theoretical 13 Watt mechanical power production • Two-stage, gapless, constructed with 0º/90º woven E-glass and epoxy • PVC central shaft *A tubular rib was added to increase the stiffness of the top and bottom plates 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  15. Analysis of Turbine Deflection without supporting ribs Deflection with supporting ribs *Under gravitational loading 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  16. Voltage-RPM Calibration Current-Torque Calibration Synthesis of Design • Generator Selection and Calibration • Donated by team member • 40 VDC nominal *The motor was manufactured by Ametek, and is currently out of production, so motor specifications were not available from the manufacturer. 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  17. Energy storage Minnkota Sealed Lead Acid Dual Purpose Nominal Voltage: 12 Volts Capacity: 72 Ah (at 20 hr rate) Recommended charging voltage: 12.4 Volts Internal Resistance: 0.17 Ohms Supply power to the light for 3-5 days Electrical Conditioning 12VDC to 120VAC inverter (purchased) DC step up circuit DC voltage leveling charge pump was purchased for charging the SLA battery. Synthesis of Design 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  18. Wood Post 6”x6”x16’ Pressure treated lumber safety factor of 3.3 Stationary Shaft 2” Aluminum Rod Stock 6’ long safety factor of 4.60 = 47.17 MPa Analysis and Synthesis of Design Support Structures 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  19. Gears Stationary Shaft Chain Rotating Bearing Collar Generator Adaptor Stationary Shaft Mount Generator Mount Chain Tensioner Synthesis of Design • Drive Train • 1:1 Gear Ratio Selection • To maximize efficiency of the turbine 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  20. Final Design Installed April 27th and still operating • Insert video 100_0417 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  21. Testing and trouble shooting • What we observed • What changes were made • What we measured • Desired vs. Actual Outcomes • What we learned 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  22. What we observed… • The chain was loose and the gear offset was wobbly - the chain fell off the gear • The top and bottom plates on the turbine fractured and caused vibration problems • Bolts became loose due to the unanticipated vibrations • Power generation from the turbine was significantly lower than expected 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  23. What we changed… • Machined a new gear offset with tighter tolerances • Added a chain tensioner • Modified the turbine to minimize vibrations (with the help of the wind) • Added Locktite to all bolts and screws • Disconnected generator from charging system as a trouble shooting measure 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  24. What we measured… 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  25. Desired Outcomes • Actual Outcomes 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  26. Conclusions - What we learned… 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  27. Recommendations for Improvement • Generator should be optimized for lower speeds • Use DC LED array • Locking nuts should be used in the event of vibrations in high winds • Permanently seal the battery box and generator protective case. • Use a stiffer material for the turbine • Higher quality anemometer • Permanent weather proof data logger • System should be optimized for overall system efficiency, not just turbine efficiency 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  28. Opportunities for Future Research • Obtain values for the amount of sunlight incident on the ground • Illuminance map for the LED light source • Other turbine configurations should be tested. • Engineering Economics for changing to autonomous system • Predict the life of the system • Predict the year-round performance • Develop a comprehensive system model 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  29. For a Marketable Product… • Solar Panel and Turbine size need to be optimized based on cost, aesthetics, and size • Stronger, more durable materials should be used for the turbine • Power generation system incorporated into a permanent lighting structure • Design for Manufacture, Profitability, Maintenance and Performance • A final market must be selected • Environmental impact study 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  30. Team Accomplishments • Designed, developed and built a prototype • The prototype was installed 2 and a half weeks ago, which allowed ample time for debugging the systems and learning more about the systems. • Provided accurate documentation of recommendations for future development • Came in under budget and on time - we spent $1600 out of the available $3000. • Completed comprehensive background research that would be invaluable for future teams • Developed a design space representing the tradeoffs between turbine size and solar panel size 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  31. Acknowledgements • Dr. Hensel for his invaluable guidance and mentoring • Dr. Venkataraman for his initial concept and continued input throughout the project • Dave Hathaway and Steve Kosciol – Machining and Part ordering assistance • John Wellin – assistance with the DAQ system • Dave Harris and the rest of Facilities Management Services for their support throughout the installation process • Electrical help was provided by Dr. Wayne Walter, Dr. Daniel Phillips, and Dr. David Borkholder. • Joel Slavis from Light Waves Concept, Inc provided the LED arrays at a discount. 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  32. References • B. F. Blackwell, R. E. Sheldahl, and L.V. Feltz. “Wind Tunnel Performance Data for Two- and Three- Bucket Savonius Rotors.” Sandia Laboratories. SAND76-0131. (July 1977). 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  33. Questions 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  34. Torque for 1, 2 and 3 stage turbines 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  35. Budget= $3000 Epoxy: $140 per m2 Solar Panels: $5.40 per Watt Battery: $0.08 per Watt-Hour Cost Assessment 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  36. Power Production Vs. Consumption 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  37. Project Plan for SD2 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  38. Power available from the wind for various wind speeds and efficiencies. 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  39. Power Produced vs. Power Consumed 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

  40. Post Anchoring • Strong but temporary • The base of the post is buried 3’ in a 1’ diameter hole, which is filled with cement. • Additional guy wires were anchored into 5 gallon buckets filled with cement and buried 1 foot deep • This provided restraints on the pole to ensure that it will not fall down. • After testing the cement segments can be dug up and the whole system can be relocated to the engineering test area 05703 – Wind-Solar Hybrid Project Critical Design Review 5/13/05

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