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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 - PowerPoint PPT Presentation
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05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Multidisciplinary Engineering Senior DesignMultidisciplinary Engineering Senior Design
Project 05307 Wind Solar ProjectProject 05307 Wind Solar Project2005 Critical Design Review2005 Critical Design Review
May 13, 2001May 13, 2001
Joe Jachlewski-ME- Team LeaderJoe Jachlewski-ME- Team LeaderAaron Bailey-MEAaron Bailey-MEPaul Kingsley-MEPaul Kingsley-MEBrian Nealis-MEBrian Nealis-MEMatt Rose-MEMatt Rose-ME
Pam Snyder-MEPam Snyder-MEChris Wall-MEChris Wall-ME
Customer: Dr. P. VenkataramanCustomer: Dr. P. VenkataramanMentor: Dr. E. HenselMentor: Dr. E. Hensel
Coordinator: Dr. W. WalterCoordinator: Dr. W. Walter
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Project BackgroundProject 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 ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Mission StatementMission Statement
The mission of the 2004-2005 Wind Solar The mission of the 2004-2005 Wind Solar Team is to design and build a prototype of Team is to design and build a prototype of an outdoor lighting system that is powered an outdoor lighting system that is powered solely by wind and solar energy. The team solely by wind and solar energy. The team will test the prototype for a minimum of one will test the prototype for a minimum of one
week and evaluate the system performance. week and evaluate the system performance. The prototype will be safe and easy to The prototype will be safe and easy to
modify. modify.
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Desired OutcomesDesired Outcomes
Safe operationSafe operation Integration of wind turbine, solar panel, a Integration of wind turbine, solar panel, a
light, an energy storage system, support light, an energy storage system, support structures, and signal processing structures, and signal processing equipment.equipment.
Ability for Turbine interchangeability for Ability for Turbine interchangeability for future testingfuture testing
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Key Requirements & Critical Key Requirements & Critical ParametersParameters
Complete first designComplete first design Build first prototypeBuild first prototype Test prototype for at least a weekTest prototype for at least a week Evaluate system performanceEvaluate system performance Provide recommendations for future designsProvide recommendations for future designs Power the lightPower the light
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Design ProcessDesign ProcessProject
DefinitionConcept
DevelopmentFeasibility
Assessment
PreliminaryPrototype
Design
BuildPrototype
Analysis & Synthesis of Design
System Testing and Evaluation
Future Recommendations
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Concept DevelopmentConcept Development Concept A Concept B Concept C Light source 400W HID Bulb 175 W HID Bulb 10 W LED array Percent of Technologies Accommodated
80% 20% <1%
Maximum Energy Requirement
7500 Wh/day 3000 Wh/day 150 Wh/day
Approximate Turbine Swept Area
11-52 m2 4.4-21 m2 0.22-1.0 m2
Approximate Solar Panel Wattage
580-1200 W 230-470 W 11-23 W
Battery System Array of 12V SLA batteries
Array of 12V SLA batteries
SLA battery or array of NiMH batteries
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Concept DevelopmentConcept Development
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Feasibility AssessmentFeasibility Assessment
0
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Concept A
Concept B
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Solar Panel Wattage
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^2)
Concept AConcept BConcept C
(A)
(B)
(C)
Total power required for each Total power required for each conceptconcept
Required size of the Required size of the power generation system power generation system
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Feasibility AssessmentFeasibility AssessmentStrengths Weaknesses
Concept A Light output comparable to existing outdoor area lighting.
Power generation system size too large for self-contained design.Cost of power generation and storage exceeds budget.
Concept B Light output comparable to existing outdoor area lighting.
Power generation system size too large for self-contained design.Cost of power generation and storage exceeds budget.
Concept C Power generation system size lends itself to self-contained design.Cost of power generation system and storage within budget.
Expected light output less than existing outdoor area lighting.
Concept C was selected for further design.
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Synthesis of DesignSynthesis of Design
Light SelectionLight SelectionColor: Warm WhiteColor: Warm White
Diameter: 4.80”Diameter: 4.80”
Height: 4.76”Height: 4.76”
Current: 76 mACurrent: 76 mA
Wattage:9.2 WWattage:9.2 W
Brightness: >43000 LUXBrightness: >43000 LUX
Nominal Current: 20 mANominal Current: 20 mA
Nominal Voltage: 3.0~3.6 VNominal Voltage: 3.0~3.6 V
Manufactured by:
Light Waves Concepts
Par 38 120 LED
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Synthesis Of DesignSynthesis Of DesignPower Generation SystemPower Generation System
Design SpaceDesign Space
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0 10 20 30 40 50 60 70 80 90 100 110 120
Solar Panel Wattage (W)
Req
uir
ed T
urb
ine
Sw
ept
Are
a (m
^2)
Design Point
*Based on a 20 Watt power requirement and a 15 % efficient turbine
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Synthesis of DesignSynthesis of Design
Solar Panel SelectionSolar Panel SelectionModel #: BP SX 10Model #: BP SX 10
Maximum power: 10 WMaximum power: 10 W
Warranted power: 9 WWarranted power: 9 W
Voltage at maximum power: 16.8 VVoltage at maximum power: 16.8 V
Open-circuit voltage: 21.0 V Open-circuit voltage: 21.0 V
Current at maximum power: 0.59ACurrent at maximum power: 0.59A
Short-circuit current: 0.65 AShort-circuit current: 0.65 A
12 year Warranty for 90% output12 year Warranty for 90% output
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Synthesis of DesignSynthesis of Design Wind Turbine DesignWind Turbine Design
– Savonius TurbineSavonius Turbine– 1.46 m1.46 m22 swept area swept area– Assuming 15 % efficiency, Assuming 15 % efficiency,
theoretical 13 Watt theoretical 13 Watt mechanical power mechanical power productionproduction
– Two-stage, gapless, Two-stage, gapless, constructed with 0º/90º constructed with 0º/90º woven E-glass and epoxywoven E-glass and epoxy
– PVC central shaftPVC central shaft
*A tubular rib was added to increase the stiffness of the top and bottom plates
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Analysis of TurbineAnalysis of Turbine1
MN
MX
X Y
Z
-.878E-03.083315
.167507.251699
.335892.420084
.504276.588469
.672661.756853
MAY 6 200510:49:42
NODAL SOLUTION
STEP=1SUB =1TIME=1UZ (AVG)RSYS=0DMX =.756855SMN =-.878E-03SMX =.756853
1
MN
MX
X Y
Z
-.003322
1.6283.259
4.8916.522
8.1549.785
11.41713.048
14.679
MAY 6 200510:36:49
NODAL SOLUTION
SUB =1TIME=1UZ (AVG)RSYS=0DMX =14.679SMN =-.003322SMX =14.679
Deflection without Deflection without supporting ribssupporting ribs
Deflection with Deflection with supporting ribssupporting ribs
*Under gravitational loading
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Synthesis of DesignSynthesis of Design Generator Selection and Generator Selection and
CalibrationCalibration– Donated by team memberDonated by team member– 40 VDC nominal 40 VDC nominal
y = 0.0336x
R2 = 0.9996
0
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0 100 200 300 400 500 600 700 800
Motor Speed (rpm)
Ou
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t V
olt
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e (V
)
Voltage-RPM Calibration
y = 0.3404x - 0.2608
R2 = 0.9989
0
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Torque (in-lbs)
Cu
rre
nt
(A)
Current-Torque Calibration
*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 ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Synthesis of DesignSynthesis of Design Energy storageEnergy storage
– Minnkota Sealed Lead Acid Dual Minnkota Sealed Lead Acid Dual PurposePurpose
– Nominal Voltage: 12 VoltsNominal Voltage: 12 Volts– Capacity: 72 Ah (at 20 hr rate)Capacity: 72 Ah (at 20 hr rate)– Recommended charging Recommended charging
voltage: 12.4 Voltsvoltage: 12.4 Volts– Internal Resistance: 0.17 OhmsInternal Resistance: 0.17 Ohms– Supply power to the light for 3-5 Supply power to the light for 3-5
daysdays
Electrical ConditioningElectrical Conditioning– 12VDC to 120VAC inverter 12VDC to 120VAC inverter
(purchased)(purchased)– DC step up circuitDC step up circuit– DC voltage leveling charge pump DC voltage leveling charge pump
was purchased for charging the was purchased for charging the SLA battery.SLA battery.
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Analysis and Synthesis of DesignAnalysis and Synthesis of Design
Wood PostWood Post– 6”x6”x16’ Pressure treated 6”x6”x16’ Pressure treated
lumberlumber
– safety factor of 3.3safety factor of 3.3
Stationary ShaftStationary Shaft– 2” Aluminum Rod Stock2” Aluminum Rod Stock
– 6’ long6’ long
– safety factor of 4.60safety factor of 4.60
Support StructuresSupport Structures
Max Stress = 20.7 Mpa
Wind Speed = 74 mph
d = 15’ = 4.57m
x-section
s = 5.5” = 0.140m
s Max Stress
Wind Speed = 74 mph
= 47.17 MPa3
32
y
sstag
S
hAnPD
Mpa
s
dAV
I
Mc ssair 7.20
12
42
221
max
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Synthesis of Design Synthesis of Design Drive TrainDrive Train
– 1:1 Gear Ratio Selection1:1 Gear Ratio Selection To maximize efficiency of the turbineTo maximize efficiency of the turbine
Generator Mount
Stationary Shaft Mount
Generator Adaptor
GearsChain
Rotating Bearing Collar
Stationary Shaft
Chain Tensioner
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Final DesignFinal Design Installed April 27Installed April 27thth and still operating and still operating
Insert video 100_0417Insert video 100_0417
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Testing and trouble shootingTesting and trouble shooting
What we observed What we observed What changes were madeWhat changes were made What we measuredWhat we measured Desired vs. Actual OutcomesDesired vs. Actual Outcomes What we learnedWhat we learned
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
What we observed…What we observed…
The chain was loose and the gear offset The chain was loose and the gear offset was wobbly - the chain fell off the gearwas wobbly - the chain fell off the gear
The top and bottom plates on the turbine The top and bottom plates on the turbine fractured and caused vibration problemsfractured and caused vibration problems
Bolts became loose due to the unanticipated Bolts became loose due to the unanticipated vibrationsvibrations
Power generation from the turbine was Power generation from the turbine was significantly lower than expectedsignificantly lower than expected
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
What we changed…What we changed… Machined a new gear offset with tighter Machined a new gear offset with tighter
tolerancestolerances Added a chain tensionerAdded a chain tensioner Modified the turbine to minimize vibrations Modified the turbine to minimize vibrations
(with the help of the wind)(with the help of the wind) Added Locktite to all bolts and screwsAdded Locktite to all bolts and screws Disconnected generator from charging Disconnected generator from charging
system as a trouble shooting measuresystem as a trouble shooting measure
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
What we measured…What we measured…
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Desired OutcomesDesired Outcomes Actual OutcomesActual Outcomes
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Conclusions - What we learned…Conclusions - What we learned…
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Recommendations for ImprovementRecommendations for Improvement Generator should be optimized for lower speedsGenerator should be optimized for lower speeds Use DC LED arrayUse DC LED array Locking nuts should be used in the event of vibrations in Locking nuts should be used in the event of vibrations in
high windshigh winds Permanently seal the battery box and generator protective Permanently seal the battery box and generator protective
case.case. Use a stiffer material for the turbineUse a stiffer material for the turbine Higher quality anemometerHigher quality anemometer Permanent weather proof data loggerPermanent weather proof data logger System should be optimized for overall system efficiency, System should be optimized for overall system efficiency,
not just turbine efficiencynot just turbine efficiency
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Opportunities for Future ResearchOpportunities for Future Research Obtain values for the amount of sunlight incident Obtain values for the amount of sunlight incident
on the groundon the ground Illuminance map for the LED light sourceIlluminance map for the LED light source Other turbine configurations should be tested. Other turbine configurations should be tested. Engineering Economics for changing to Engineering Economics for changing to
autonomous systemautonomous system Predict the life of the system Predict the life of the system Predict the year-round performancePredict the year-round performance Develop a comprehensive system modelDevelop a comprehensive system model
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
For a Marketable Product…For a Marketable Product… Solar Panel and Turbine size need to be optimized Solar Panel and Turbine size need to be optimized
based on cost, aesthetics, and sizebased on cost, aesthetics, and size Stronger, more durable materials should be used Stronger, more durable materials should be used
for the turbinefor the turbine Power generation system incorporated into a Power generation system incorporated into a
permanent lighting structure permanent lighting structure Design for Manufacture, Profitability, Maintenance Design for Manufacture, Profitability, Maintenance
and Performance and Performance A final market must be selectedA final market must be selected Environmental impact studyEnvironmental impact study
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Team AccomplishmentsTeam Accomplishments Designed, developed and built a prototypeDesigned, developed and built a prototype The prototype was installed 2 and a half weeks ago, which The prototype was installed 2 and a half weeks ago, which
allowed ample time for debugging the systems and allowed ample time for debugging the systems and learning more about the systems.learning more about the systems.
Provided accurate documentation of recommendations for Provided accurate documentation of recommendations for future developmentfuture development
Came in under budget and on time - we spent $1600 out of Came in under budget and on time - we spent $1600 out of the available $3000.the available $3000.
Completed comprehensive background research that Completed comprehensive background research that would be invaluable for future teamswould be invaluable for future teams
Developed a design space representing the tradeoffs Developed a design space representing the tradeoffs between turbine size and solar panel sizebetween turbine size and solar panel size
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
AcknowledgementsAcknowledgements
Dr. Hensel for his invaluable guidance and mentoringDr. Hensel for his invaluable guidance and mentoring Dr. Venkataraman for his initial concept and continued Dr. Venkataraman for his initial concept and continued
input throughout the projectinput throughout the project Dave Hathaway and Steve Kosciol – Machining and Part ordering Dave Hathaway and Steve Kosciol – Machining and Part ordering
assistanceassistance John Wellin – assistance with the DAQ systemJohn Wellin – assistance with the DAQ system Dave Harris and the rest of Facilities Management Services for their Dave Harris and the rest of Facilities Management Services for their
support throughout the installation processsupport throughout the installation process Electrical help was provided by Dr. Wayne Walter, Dr. Daniel Phillips, Electrical help was provided by Dr. Wayne Walter, Dr. Daniel Phillips,
and Dr. David Borkholder. and Dr. David Borkholder. Joel Slavis from Light Waves Concept, Inc provided the LED arrays at Joel Slavis from Light Waves Concept, Inc provided the LED arrays at
a discount.a discount.
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
ReferencesReferences
1.1. B. F. Blackwell, R. E. Sheldahl, and L.V. Feltz. “Wind Tunnel Performance B. F. Blackwell, R. E. Sheldahl, and L.V. Feltz. “Wind Tunnel Performance Data for Two- and Three- Bucket Savonius Rotors.” Sandia Laboratories. Data for Two- and Three- Bucket Savonius Rotors.” Sandia Laboratories. SAND76-0131. (July 1977). SAND76-0131. (July 1977).
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
QuestionsQuestions
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Torque for 1, 2 and 3 stage turbinesTorque for 1, 2 and 3 stage turbines
-100
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-60 -40 -20 0 20 40 60 80 100 120 140 160
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-m)
Single Stage
Two Stages Offset 90
Three Stages offset 60
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Cost AssessmentCost Assessment Budget= $3000Budget= $3000 Epoxy: $140 per mEpoxy: $140 per m22
Solar Panels: $5.40 per WattSolar Panels: $5.40 per Watt Battery: $0.08 per Watt-HourBattery: $0.08 per Watt-Hour
CostCost
Concept AConcept A $9820$9820
Concept BConcept B $3910$3910
Concept CConcept C $189$189
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Power Production Vs. ConsumptionPower Production Vs. Consumption
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Power Produced by 10WSolar Panel
Power Produced by 15%Efficient Turbine, 1m^2Swept Area
Power Consumed byPrototype
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Project Plan for SD2Project Plan for SD2
Design and Drawing Completion
Testing
Motor Testing
DAQ System Requirements/Acquisition and Testing Protocols
PDR Revision
Fabrication and Build
Conference Proceedings
Write Remaining Components of Technical Report (CDR)
Presentation
Website
Poster
April 23, 2005 April 30, 2005 March 15, 2005 May 6, 2005
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Power available from the wind for Power available from the wind for various wind speeds and efficiencies. various wind speeds and efficiencies.
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/m^
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Betz Limit35% Efficient15% Efficient
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Power Produced vs. Power ConsumedPower Produced vs. Power Consumed
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Power Produced by PowerGeneration System
Power Consumed by Prototype
05703 – Wind-Solar Hybrid ProjectCritical Design Review
5/13/05
Kate Gleason College of EngineeringRochester Institute of Technology
Post AnchoringPost Anchoring Strong but temporaryStrong but temporary The base of the post is buried The base of the post is buried
3’ in a 1’ diameter hole, which 3’ in a 1’ diameter hole, which is filled with cement. is filled with cement.
Additional guy wires were Additional guy wires were anchored into 5 gallon buckets anchored into 5 gallon buckets filled with cement and buried 1 filled with cement and buried 1 foot deepfoot deep
This provided restraints on the This provided restraints on the pole to ensure that it will not fall pole to ensure that it will not fall down.down.
After testing the cement After testing the cement segments can be dug up and segments can be dug up and the whole system can be the whole system can be relocated to the engineering relocated to the engineering test areatest area