Download Critical Design Review Wind Turbine with Gearbox

Critical Design Review
Wind Turbine with Gearbox
Team G:
Nick Koerner (Lead), Meteb Almutairi, Chris Batsch, Mike
Villamar
Project Objectives
● The Main Goal is Control
o The Arduino Mega Microcontroller will serve as the
control center of the wind turbine.
o Items that are being controlled by the microcontroller:
 Transistor Switching
●
●
E-Brake
Voltage Monitor
 Physical Hydraulic Brake Controlled by Servo
 Frequency Detection
●
Simple Voltage regulator being used to protect
microcontroller
● Efficiency and Power Output
o High Efficiency is desired
 Switching Regulator
o 5V, 2A, and 10W of Power
Modes of Operation
● Generation Mode
o The E-brake switch will be open, and voltage monitor switch
will be closed.
o This allows for the generator to spin freely, and the battery
bank to connect to the generator.
● Shutdown Mode
o The E-Brake switch will be closed, and the voltage monitor
switch will be open.
o The generator will be shorted:

Slows down the generator and dumps energy into the dump load.
o The hydraulic brake will be activated by the servo, and cause
the wind turbine to come to a complete stop.
o Generation will be reactivated after a delay, or battery bank
needs charging, or manual override.
Functional Decomposition
Full Circuit Schematic
Subassemblies
Battery Bank Sub Specs:
● Batteries
○ Lithium Ion Battery
■ 2800mAh
○ Battery Bank provides
■ 9 V, 2.16 A
● Capacitor
○ 1000 uF
Generator Sub Specs:
● Bridge Rectifier
○ RS402L
○ MAX: 100 V, 4 A
● IGBT
○ ISL9V3040P3
○ MAX: 430 V, 17 A
● Power Resistor
○ 50W
● Generator
○ ElectriFly Ammo
● Frequency Detection Voltage Protection
○ 1N4742 Zener Diode
○ Max: 12 V, 1 W
Subassemblies
Load Sub Specs:
● Step Down Switching Regulator (2 Options)
○ L4978 IC
■ Requires 8 V to 55 V input
■ Produces 5 V and 2 A output
■ ~90% Efficient
■ Simple and all values given
○ NR887D IC
■ Requires 4.5 V to 18 V input
■ Produces 5 V and 2 A output
■ ~90% Efficient
■ Not all values given, further testing once
obtained
● Voltage Monitor (R6 & R7)
○ Simple Voltage Divider for 5 V Analog Pin
Brake Sub Specs:
● Turnigy Digital Metal Gear
Servo
○ 6 V Input
○ Torque: 17 kg/cm
Construction Plan
● Structural Hardware:
o Much of the structural hardware used in the previous wind
turbine project will be recycled in this current design, therefore
the plan is to build on top of that.
● Previous components Used:
o The Blades, Shaft, Gearbox, Generator, and Hydraulic Brake
will be reused.
● Battery Bank
o Brackets and metal tabs will be used to connect the batteries in
the correct setup.
● The new components that are chosen will fit on the
aluminum platform (shown on next slide).
● What does not fit, will rest a platform on the ground.
Additional Fabrication Plans
● Proto-Boards
o
The current plan is to use the EECS shop provided
vector proto-boards to place the circuits upon.
● The Goal
o
o
To make custom PCB circuit boards using the EECS
shop’s PCB milling machine.
Depending on the time, and Eagle CAD training, the
task can be completed before the deadline.
Testing
● DC Motor for in Lab Wind
Simulations
● Wind Tunnel for Final Testing
o The Max Wind Speed
Tested is 34 MPH
● Tests the Generation and
Shutdown Modes
o >40 MPH Shutdown Feature
o Can or will be Adjusted
● Input/Output Efficiency
In Lab Wind Simulation Data
from Testing
Wind Speed
[MPH]
Voltage [V]
RPM of
Generator
[RPM]
Frequency
[Hz]
11.18
1.79
1005.82
16.76
22.37
3.46
2012.53
33.54
33.55
4.50
3018.35
50.31
Schedule
Task
Proposal
DC Motor for Wind Simulation
Preliminary Research
Analyze Wind Turbine Design
PDR
Detailed Overview Research
Circuit Schematic
CDR
Order Parts
Programming Microcontroller
Construction
Wind Tunnel Testing
Project Completion
Projected Completion
2/4/2015
2/13/2015
2/20/2015
2/20/2015
2/20/2015
3/13/2015
3/13/2015
4/1/2015
4/3/2015
4/17/2015
4/17/2015
4/24/2015
5/6/2015
Org Chart
Challenges/Risks
Programming
● Programming the
microcontroller will take
some time and research.
Scheduling
● Meeting times due to
different schedules of
everyone in group is a
conflict.
Batteries
● Potential risk of explosion
and or fire.
Components
● Size, rating, and cost must
be considered for
durability and because
structure from last year is
being used.
Testing
● Availability of wind tunnel
and making sure wind
simulation matches actual
wind tunnel performance.
Questions?