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1 | Program Name or Ancillary Text eere.energy.gov
Water Power Peer Review
Schneider Linear hydroEngine™ (SLH) Timing Belt Powertrain
PI: Abe SchneiderNatel Energy, [email protected] November, 2011FY 11 CH FOA Topic 1.1 Sustainable Small Hydropower, Innovative System Testing
2 | Wind and Water Power Program eere.energy.gov
Purpose, Objectives, & Integration
Project Purpose: – Develop a new high performance powertrain for the SLH utilizing a carbon-fiber
reinforced timing belt
Relation to program objectives:– Development of an enabling technology for efficient and low cost small hydropower
that can be quickly and efficiently deployed in low head/low flow existing waterways and constructed waterways.
– Creation of advanced SLH powertrain manufacturing methods and production of longterm mechanical performance test data, thus advancing the industry’s expertise in engineering, design, installation, and performance evaluation of low-head hydropower technology.
– Reduction of LCOE from low-head and constructed waterway projects built with hydroEngines™ to less than $0.07 per kWh.
3 | Wind and Water Power Program eere.energy.gov
Technical Approach
1. Complete design and testing of belt-type SLH powertrain components at 50 kW- and 500 kW-scales.– Component testing allows for cost effective, rapid iteration through prototypes; finite element modeling can help reduce
required number of physical prototypes. High-torque dynamometer endurance tests will enable evaluation of tooth/sprocket wear and effects of environmental conditions.
2. Phase I, System Endurance Testing: Integrate v1 belt/blade attachment design into small-scale (50 kW) SLH model and conduct long-duration laboratory testing, across a full range of potential operating scenarios.– Ensure technology meets performance specifications and performs as designed before full-scale commercial development.
3. Phase II, System Endurance Testing: Integrate v2 belt/blade attachment design into a 50 kW SLH model, and conduct long-duration laboratory testing.– Integrate lessons-learned from Phase I
testing; ensure improved technology meets performance specifications and performs as designed before full-scale commercial development.
Instron testing of belt coupon
Endurance testing setup at Alden
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Technical Approach
4. Design-For-Manufacture, both 50 kW and 500 kW scaleEnsure manufacturability of powertrain solution, minimizing cost while maintaining performance; prepare powertrain for commercialization.
5. Calculate LCOE of SLH, as a consequence of new belt powertrain.–Timing belt powertrain will substantially alter the mechanical architecture (and thus, capital cost structure) of the hydroEngine™, as well as change its operation and maintenance profile. Historic LCOE models must be updated accordingly.
5 | Wind and Water Power Program eere.energy.gov
Plan, Schedule, & Budget
Schedule:• Initiation date: Project awarded September, 2011 (project initiation will occur after
contract negotiations are completed) • Planned completion date: Project completion expected in 2012 (subject to final
contract negotiations)
Year Project Objective Activities
2011“v1” belt attachmentrecommendation
Component design & testing, both SLH10 & SLH100 scale.
“v1” belt attachment recommendation Dynamometer, fatigue tests
2012
Phase I: endurance testingInstall, commission, conduct tests, inspect, generate “v2” design recommendation.
Phase II: endurance testingRedesign as necessary, modify lab-model SLH10, reinstall, run endurance tests & inspections.
Design-for-manufacturingImprove design based upon DFM exercise.
LCOE update Update LCOE calculations
Prepare delivery of SLH100 (500 kW scale) belt prototype to irrigation district pilot customers.
Budget: • DOE anticipates awarding approximately $300k for this project, with an awardee cost
share of approximately $153k (subject to final contract negotiations)
