Critical Design ReviewWind Turbine with GearboxTeam 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 Outputo High Efficiency is desired

Switching Regulatoro 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 Modeo 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

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

Battery Bank Sub Specs:● Batteries

○ Lithium Ion Battery■ 2800mAh

○ Battery Bank provides■ 9 V, 2.16 A

● Capacitor○ 1000 uF

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-Boardso The current plan is to use the EECS shop provided

vector proto-boards to place the circuits upon.● The Goal

o To make custom PCB circuit boards using the EECS shop’s PCB milling machine.

o 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 Modeso >40 MPH Shutdown Featureo 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

ScheduleTask Projected Completion

Proposal 2/4/2015DC Motor for Wind Simulation 2/13/2015Preliminary Research 2/20/2015Analyze Wind Turbine Design 2/20/2015PDR 2/20/2015Detailed Overview Research 3/13/2015Circuit Schematic 3/13/2015CDR 4/1/2015Order Parts 4/3/2015Programming Microcontroller 4/17/2015Construction 4/17/2015Wind Tunnel Testing 4/24/2015Project Completion 5/6/2015

Org Chart

Challenges/RisksProgramming● 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?