Introduction to
Engineering and Technology
CCRI ENGR-1020-104
Fall 2007
Phase 3 Wind Turbine Project
Team Members
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Starting Wind Turbine
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Improved Wind Turbine
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Turbine Open Circuit Voltage Test Results
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Detail description |
Detail Photo |
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Phase 3 assembled and tested 2 Pico Turbine kits. Both kits worked accordingly. The team opted to manufacture a 3 phase VAWT turbine. Several designs were researched online for the rotor style, and Phase 3 settled onto a tri-wing design similar to one on the www.windstuffnow.com website. |
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Phase 3 started by constructing a base made of 18 x 18 x Ύ wood and routed to fit a quantity of 9 28AWG magnet wire coils at 325 wraps each. The coils were set in place, then soldered and covered with plexiglass. The bottom pivot point in the base is made up from a t-nut pressed into the wood and a machine/wood screw is facing point up from that. The top of the turbine was also constructed using wood, and the upper pivot point is constructed using a machine/wood screw point down and various nuts and washers to allow for positioning. |
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Coils were wound using a homemade jig and turned from a large spool of 28awg magnet wire. Each coil was wound 325 turns and compressed tight by wrapping in electrical tape pulled taut. Each coil was measured for resistance, and each measured between 9.8 and 10.2 ohms. |
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The rotor was constructed using .060 sheet metal, 10/24 threaded rod, 10/24 nuts, star nuts, and cup point set screws as adjustable center pivot points. The rotor blade mounting plates were made with sheet metal using a metal shear, break press used to bend mounting brackets, and drill press. The rotor blades were constructed using .030 sheet plastic, formed using a custom bending template and heat gun. The blades were mounted to the rotor/stator using 6/32 pan head locking screws and corresponding 6/32 kep nuts. Twelve magnets were used. They are a Neodymium Iron Boron 1.5 x .75 x .25 thick block magnet, Grade N42, 12900 Gauss with an advertised 27 lb pull. They were bonded to the base plate using very high strength double sided auto adhesive. |
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The final assembly was completed by attaching the two halves using two baffle boards to help direct airflow into the scoops of the rotor assembly, and two 1 dowels in the other corners, and centering the rotor on center pivot screws. The assembly was secured using countersunk wood screws. |
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The Phase 3 turbine required either the purchase or manufacturing of a rectifier. Our team chose to manufacture the rectifier. The rectifier design incorporated a switch to include a capacitor for pure DC, or bypass the capacitor for full wave rectified measurement. |
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After initial construction and testing, an experiment was conducted by adding a Savonius style design inside the original rotor construction. The idea was to utilize the open area between the original design scoops to capture any airflow that would not be captured by the scoops. Once the addition was in place, another test was run and a noticeable increase in rotor rpm and consequently, voltage increase was realized. The final design now includes this hybrid rotor design. |
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Other changes: During the initial construction of the Phase 3 Turbine, we originally were going to use the existing ceramic magnets (qty 12) and 26AWG coils for more current. When the first 26 gage coils were wound, we found that the bundle diameter was considerably larger and only allowed us to wrap 225 turns. After the first tests, we found that we were not getting enough voltage to satisfy the requirements as we understood them, so new coils were created using 28 gage wire, and 325 turns were possible in the same bundle diameter. As it turns out, this diameter was still quite a bit larger than the original kit coils that came from Picoturbine, which supposedly had 300 turns by their literature. After performing an autopsy on their coil, it was determined that they only had 220 turns per coil. |
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Parts |
Qty. |
Cost |
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Pico
Wind Turbines |
2 |
$80.00 |
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10/24
threaded rod |
3ft |
$3.00 |
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10/24
star nuts |
10 |
$2.00 |
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Magnets |
12 |
$38.16 |
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Magnet
wire 28awg |
2000ft |
$18.84 |
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Magnet
wire 26awg |
1500ft |
$17.86 |
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$159.86 |
Testing was done using a heavy duty fan, a hand held turbo meter, hand held tachometer and 2 multi meters to measure ohms and voltage.
Tests were performed by having one team member control wind speed via a dimmer switch connected to the fan, while monitoring the turbo meter for accuracy. Another team member controlled and monitored the tachometer to record RPM readings and the last team member monitored 2 multi meters for ohms and voltage then collected data in the engineering journal.
Turbine Open
Circuit Voltage Test Results
Starting out with the kit built Picoturbine gave us a great idea of how the conversion from wind to electrical energy worked. We found it amazing that such a simple cardboard and paper device could easily produce a voltage. Creating a larger scale, more powerful design was very exciting at first, and we started off great, figuring that this would be a snap. But, as with many design projects, its the little things that get you. Taking as large a hit in voltage drop going to 26awg wire was a surprise, causing us at the last minute to make new 28awg coils was a setback. Working separately and only getting to work together once a week was also another setback. Though, we were able to get our whole group together each week, which worked out well and was a pleasure. Even though we lost one of our original four members early, the three of us were able to pull together and produce a decent design. Overall, the experience was enjoyable, and seeing a product come to fruition is always a pleasure. Working in a group where all members pull their weight in both research and design is also a real pleasure.
Phase 3 Team Members
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Kevin Lamoureux Work: Entegris Inc. 10 Forge Prkwy |
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Objective |
Obtain
Associate Degree in Manufacturing Technology |
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Education |
CCRI Present |
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Awards
received |
First Place;
RI High School Indoor/Outdoor Archery League 1991-1994 First Place;
RI State Indoor Archery Tournament 1992 |
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Interests
and activities |
Music
(listening and playing), Indoor and Outdoor Gardening, Skateboarding,
Snowboarding, Mountain Biking, Hiking, Movies, Theater, Art. |
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Languages |
English |
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Work experience |
Extraction
Systems 1995-2005 Machine Operator,
Cell Leader Entegris Inc. 2005-present Plant Supervisor,
Lean Facilitator, Machine Maintenance Coordinator. |
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Volunteer
experience |
NAACP
1991-1992 |
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Professional
memberships |
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Accreditations
and licenses |
Electric Fork
Lift Operators License Certificate
of completion in Leadership Skills |
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401-233-2802 Home 508-880-4819 Work TCloutier@cox.net Home |
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Objective |
Lead
Mechanical Design Engineer at a established company |
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Education |
Graduated UMass Lowell
- Various night school
courses 1990s Multiple in-house
courses at General Dynamics |
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Awards
received |
Excellence
Award in drafting in my senior year in High School Multiple Excellence
Awards at General Dynamics for superior performance on differing programs. |
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Interests
and activities |
Photography,
Guitar, |
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Languages |
English |
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Work
experience |
1979-1982 Ingersoll-Rand Heavy Pulp Machinery: Drafting, Light design work 1982-1995 Lockheed Martin Electronic Countermeasures: Design and Drafting 1995-1998 Insight Technology Night Vision equipment and Laser Aiming
Modules: Design 1998-2000 Kinetrix
Inc. Electronic Chip Handlers: Lead Mechanical Design 2000-Present General Dynamics Military Communications: Lead Mechanical Design |
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Volunteer
experience |
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Professional
memberships |
Equine Photographers
Association |
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Accreditations
and licenses |
None |
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Dante Catoni 401-555-1212 dcatoni@yahoo.com |
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Objective |
To work as an electronics technician |
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Education |
Our Lady of |
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Interests and activities |
GM Automobiles, drag racing, autocrossing,
philosophy |
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Languages |
English |
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Work experience |
Nicks Auto Body auto paint technician Equipment Service Field technician for
automotive service equipment (brake lathes, wheel balancers, tire changers,
lifts, air compressors). Installed and repaired many types of mechanical,
pneumatic, hydraulic, electrical and electronic systems. Radio Shack - salesperson |
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Accreditations and licenses |
CompTIA A+ computer repair |