Appendix A: CAD drawings
Appendix B: Velocity over Airfoils
Figure: Contours of velocity magnitude, m/s, over the NACA 63-018 airfoil.
= 18.8, Va = 24.2m/s
Figure: Forces on the airfoils, Vw=6m/s, TSR = 3
1 []
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
110.00
F1[N]
-4.75
-4.74
-4.33
-3.47
-2.00
0.12
1.85
3.61
4.77
5.14
4.77
3.61
F2[N]
1.85
0.12
-2.00
-3.47
-4.33
-4.74
-4.75
-4.31
-3.80
-3.19
-2.43
-1.52
F3[N]
-0.46
0.63
1.45
1.73
1.46
0.62
-0.47
-1.55
-2.49
-3.31
-3.99
-4.39
Favg, cycle [N]
Vt [m/s]
Ftot [N]
-3.36
-3.99
-4.89
-5.22
-4.88
-4.00
-3.37
-2.25
-1.51
-1.36
-1.65
-2.30
-3.23
18.00
Power [W]
1
0
10
20
30
40
50
60
70
80
90
100
110
F1
-2.51
-3.57
-3.33
-2.59
-2.53
-1.11
0.36
2.16
3.27
3.62
3.27
2.16
2
120
130
140
150
160
170
180
190
200
210
220
230
F2
0.58
-1.11
-2.53
-2.59
-3.33
-3.57
-2.51
-1.41
-1.06
-0.87
-0.83
-1.18
3
240
250
260
270
280
290
300
310
320
330
340
350
58.16
F3
-0.61
0.03
-0.65
0.87
-0.65
0.03
-0.61
-1.18
-0.83
-0.87
-1.06
-1.41
Ftot
-2.54
-4.64
-6.50
-4.31
-6.50
-4.64
-2.76
-0.42
1.38
1.88
1.38
-0.42
Favg, cycle -2.34
Vt
13.41
Power
-31.41
Figure: Total power output with rpm = 140, TSR = 2.3, Vw=6 m/s
11
Appendix C: Airfoil Specification
Table: Coordinates for a NACA 63-018 airfoil with a 12 cm chord length.
Coordinates are given in meters.
0
0.0006
0.0009
0.0015
0.003
0.006
0.009
0.012
0.018
0.024
0.03
0.036
0.042
0.048
0.054
0.06
0.066
0.072
0.078
0.084
0.09
0.096
0.102
0.108
0.114
0.12
0
0.001687
0.002061
0.002647
0.003705
0.005235
0.00637
0.007278
0.008672
0.009657
0.010319
0.0107
0.010795
0.010611
0.010174
0.009526
0.008705
0.007748
0.006682
0.005547
0.004381
0.003229
0.002145
0.001184
0.000419
0
Note: These calculations were used to size the wind turbine to optimize feasibility and
output
max power output as a function of wind speed/ turbine
dimensions
Turbine Dimensions
diam (ft)
3
4
5
6
7
height (ft) 4
5
6
7
8
diam (m)
0.9
1.2
1.5
1.8
2.1
height (m) 1.2
1.5
1.8
2.1
2.4
2
area (m ) 1.1
1.9
2.8
3.9
5.2
12
8
9
2.4
2.7
6.7
velocity
(m/s)
2
3
4
5
6
7
8
9
10
11
12
13
14
Power (W)
2.1
3.6
7.2
12.0
17.1 28.5
33.4 55.7
57.8 96.3
91.8 153.0
137.0 228.3
195.1 325.1
267.6 445.9
356.1 593.5
462.3 770.6
587.8 979.7
734.2 1223.6
5.4
18.1
42.8
83.6
144.5
229.4
342.5
487.6
668.9
890.3
1155.9
1469.6
1835.5
7.5
25.3
59.9
117.1
202.3
321.2
479.5
682.7
936.5
1246.4
1618.2
2057.4
2569.7
10.0
33.7
79.9
156.1
269.7
428.3
639.3
910.2
1248.6
1661.9
2157.6
2743.2
3426.2
12.8
43.3
102.7
200.7
346.8
550.6
821.9
1170.3
1605.4
2136.7
2774.1
3527.0
4405.1
max power output as a function of wind speed/ turbine
dimensions
Turbine Dimensions
diam (ft)
3
4
5
6
7
height (ft) 6
7
8
9
10
diam (m)
0.9
1.2
1.5
1.8
2.1
height (m) 1.8
2.1
2.4
2.7
3.0
2
area (m ) 1.7
2.6
3.7
5.0
6.5
velocity
(m/s)
Power (W)
2
3.2
5.0
7.1
9.6
12.5
3
10.8
16.9
24.1
32.5
42.1
4
25.7
40.0
57.1
77.1
99.9
5
50.2
78.0
111.5 150.5 195.1
6
86.7
134.9 192.6 260.1 337.1
7
137.7 214.1 305.9 413.0 535.3
8
205.5 319.6 456.6 616.5 799.1
9
292.6 455.1 650.2 877.7 1137.8
10
401.3 624.3 891.9 1204.0 1560.8
11
534.2 831.0 1187.1 1602.6 2077.4
12
693.5 1078.8 1541.1 2080.6 2697.0
13
881.7 1371.6 1959.4 2645.2 3429.0
14
1101.3 1713.1 2447.3 3303.8 4282.8
13
Appendix D: Aluminum Axis Rod and Support Bar Calculations
Torque Calculations of aluminum axis rod:
Note: These torque calculations were used to determine the minimum wind speed
necessary to induce rotation and design the support structure
Equations used
Torque : = * I
1
2
m(rOR
rIR2 )
2
= rpm
I=
2
a = ( * rOD
) ( * rID2 )
Inner
Diameter
(IN)
0.25
0.50
1.00
Inner
Radius
(FT)
0.02
0.04
0.08
Outer
Diameter
(IN)
1.32
1.32
1.32
Outer
Radius
(FT)
0.11
0.11
0.11
Length
(IN)
54.00
54.00
54.00
Area
0.04
0.03
0.02
Volume
(a*L)
1.96
1.74
0.86
Mass
(LBS)
4.61
7.06
5.46
Inertia
(Ix)
(.5*m*r^2)
0.03
0.04
0.03
Angular
Acceleration
(rpm)
200.00
200.00
200.00
Aluminum Axis Buckling and Deflection
Buckling Calculations
Check worst case scenario- how much axial force can be added without buckline?
Pcritical =
Use
2 EI
L2
I= .03 in^4
E = 10.1x 10^6
L = 72
Pcrit= 1025.54 lb
This force is approximately 40 times the load of 25 lbs that we plan to put on the pipe.
I=
(r0 ri )
Where Ro=.5 inches and Ri= .37 inches.
14
Torque (Ix*)
5.54
8.48
6.55
And under deflection, which was modeled as a static load for simplicity.
ymax = FL3/(3EI)
Which yields a maximum deflection of 1.364 inches, which is close to the observed
deflection at maximum rpm.
Aluminum Support Arm
Maximum Bending Calculations
PL3
ymax =
3EI
Bars have a cross sectional dimension 1.75 x .75 and a length of 34
Weight of foil is assumed to be 5lb
ymax= .0795
The bars will bend a very small amount.
Further, the axial deformation is given as
PL
EA
This yields a maximum axial deformation of .0043 inches.
When given the image in section II.V.I This yield an I of .081 in^4.
15
Appendix C: Specs and Technical Data
Manufacturing specifications:
Motor Case Size 5"Long x 4"
No-load speed 1100 rpm @ 0.260 amp
Diameter
Diameter
Main Shaft Size 1.9 Long x .625
With a 100 oz-in load the shaft speed was 900 rpm @ 2.3 amp.
Rear Shaft Size .375 Long x .1875 Diameter
the output was 5.8 amps @ 12 VDC
When tested as a generator at 1000 rpm,
Permanent magnet 38 VDC
nominal. Reversible
Permanent magnet DC motor rated 38 VDC
Motor has five #10x32 tpi tapped holes on front cap
flexible wires, Some with Plug and some without
Part#. 116868-00
Electrical connections are via 3-1/2" long
Terminal resistance 20 ohms +-20%
Armature current before permanent
demagnetization is 12 amps
Very Popular for Wind Generators, Water Generators, Battle Bots, and Robotics. Rear Shaft Can
be Used for Tachometers, Encoders, Servo Motors, and Many Other Things.
These are the specifications of the generator given by the seller.
16
Appendix D: Generator Power Curves
Load 1: 17 ohms 4.4A
Load 2: 76 ohms 2.8A
RPM
Volts
Amps
Power
RPM
Volts
Amps
Power
637
6.67
0.36
2.40
427
8.47
0.11
0.93
1025
10.55
0.59
6.22
575
13.46
0.18
2.42
1300
13.44
0.76
10.21
615
21.32
0.28
5.97
1450
22.50
1.24
27.90
780
25.98
0.34
8.83
1660
25.02
1.42
35.53
980
32.32
0.43
13.90
1860
27.97
1.58
44.19
1095
36.15
0.48
17.35
2040
30.34
1.72
52.18
1380
44.70
0.59
26.37
2180
32.05
1.82
58.33
1520
49.60
0.66
32.74
2420
35.15
2.00
70.30
1665
55.00
0.73
40.15
2630
37.66
2.14
80.59
1845
60.10
0.80
48.08
2840
40.70
2.31
94.02
Load 3: 52ohms 3.3A
Load 4: 89ohms 2.2A
RPM
Volts
Amps
Power(w)
RPM
Volts
Amps
Power
400
13.75
0.26
3.58
380
8.84
0.10
0.88
575
20.00
0.37
7.40
555
19.40
0.23
4.46
720
24.28
0.45
10.93
800
26.72
0.31
8.28
990
32.12
0.60
19.27
920
30.69
0.36
11.05
1160
38.04
0.71
27.01
1120
36.98
0.43
15.90
1290
41.70
0.78
32.53
1300
43.20
0.51
22.03
1490
47.50
0.89
42.28
1620
53.10
0.62
32.92
1620
51.70
0.97
50.15
1800
59.10
0.69
40.78
1785
56.30
1.05
59.12
2050
66.80
0.78
52.10
1920
60.80
1.15
69.92
Raw data for generating the generator power curves. Measurements were taken over
different resistance loads.
Turbine Output Power
Load
(ohms)
Volts(I) Amps(A) Power(W)
17
5.50
0.07
0.39
89
1.68
0.02
0.03
76
1.60
0.03
0.05
44
1.50
0.02
0.03
52
1.61
0.03
0.05
Raw data for power output of generator over various resistance loads.
17
Appendix E: Testing Environment
Wind map and raw data. The map is taken directly facing the opening of the wind tunnel
and symmetry was assumed. The wind turbine is assumed to be in the center of the grid.
Data map: Location of Each Data Point Used in Mapping Wind Profile
Distance in X direction (ft)
Distance in y
1.5
4.5
7.83
4.75
3.25
Direction (ft)
Tables of wind speed and standard deviation at each setting of the wind tunnel.
40 Hz
Location V avg
Stand.
(m/s)
Dev
0.2156
0.1051
2.3357
0.448
0.0194
0.0579
2.76
0.1305
0.2191
0.1301
0.3859
0.1726
45 Hz
Location V avg
1
Stand.
(m/s)
Dev
18
1.0581
0.3744
3.08
0.1625
0.1497
0.1084
1.651
0.359
50 Hz
Location V avg
Stand.
(m/s)
Dev
0.2147
0.1194
1.3417
0.2616
0.1484
0.0932
4.1772
0.1957
0.2218
0.0693
0.5326
0.3161
55 Hz
Location V avg
Stand.
(m/s)
Dev
0.0704
0.1031
2.6387
0.4258
0.155
0.0746
4.6408
0.3555
19
0.2277
0.1089
0.8089
0.3726
60 Hz
Location V avg
Stand.
(m/s)
Dev
0.6718
0.1269
2.3784
0.386
0.5882
0.1569
4.3267
0.2052
0.7515
0.225
6.5363
0.278
20
Wind profiles at a variety of settings on the wind tunnel.
Velocity Profile of Wind at 40 Hz
Wind speed (m/s)
2.5
2
1.5
1
0.5
0
8
6
6
4
4
Vertical distance (ft)
2
2
Horizontal distance (ft)
21
Velocity Profile of Wind at 45 Hz
Wind speed (m/s)
4
3
2
1
0
8
6
6
4
4
2
2
Vertical distance (ft)
Horizontal distance (ft)
Velocity Profile of Wind at 50 Hz
Wind speed (m/s)
5
4
3
2
1
0
8
6
6
4
4
Vertical distance (ft)
2
2
Horizontal distance (ft)
22
Velocity Profile of Wind at 55 Hz
Wind speed (m/s)
5
4
3
2
1
0
8
6
6
4
2
2
Vertical distance (ft)
Horizontal distance (ft)
Velocity Profile of Wind at 60 Hz
Wind speed (m/s)
8
6
4
2
0
8
6
6
4
4
Vertical distance (ft)
2
2
Horizontal distance (ft)
23
Appendix F: Budget and cost analysis
Unit
Total
Item Company
Catalog #
Description
Unit
Qty
Price
Price
McMaster
2737T315
1" Sprocket: 45 Teeth
11.70
$11.70
McMaster
2737T111
1/2" Sprocket: 15 Teeth
5.83
$5.83
McMaster
2737T331
1/2" Sprocket: 54 Teeth
13.65
$13.65
McMaster
2737T123
5/8" Sprocket: 18 Teeth
6.17
$6.17
McMaster
6261K14
10' ANSI 25 Chain
32.91
$32.91
McMaster
6261K108
Connection Links
3.60
$18.00
McMaster
1658T55
Alloy 6063 Al Tube 1.00" OD
12.36
$12.36
McMaster
1658T45
Alloy 6063 Al Tube .500" OD, 1
5.76
$5.76
1.37
$8.22
Fabric
84.00
$84.00
2060 Epoxy Hardener
26.75
$26.75
2000 Epoxy Resin
9.98
$9.98
22.75
$22.75
10.34
$10.34
31.40
$31.40
5.62
$5.62
17.79
$17.79
8620 Alloy Steel Rod 3/16"
9
McMaster
8930K1
OD
3K, Plain Weave Carbon Fiber
10
Fibre Glast 2210-A
2060-A 1/2
11
Fibre Glast pint
2000-A
12
Fibre Glast Quart
Flying
13
Foam
1.3#2x24x36 EPP Foam
Banded SingleRow Thrust
14
Applied
908756
MSC
15
Direct
Ball Bearing Flange Units ID:
57131203
MSC
16
Direct
Direct
1"
Needle Roller 2-Bolt Flange
7174345
MSC
17
Bearing, ID: 0.4530"
Bearing ID: 0.5"
Single Row Taper Roller
43336940
Bearings, ID:0.9842"
24
18
Ebay
Generator
70.00
$70.00
Subtotal $393.23
25
Total
$393.23
Balance
$106.77