FIFTEENTH WEEK ASSIGNMENT

APPLICATIONS AND IMPLICATIONS

Assignment

Propose a final project that integrates the range of units covered.
Projects can be separate or joint, but need to show individual mastery of all of the skills
Where possible, you should make rather than buy the parts of your project

This week we answer a series of questions about the final project:

- what will it do?

WIND GENERATOR
- DIDACTIC MODULE-

I chose to make a wind generator for educational use, focussing on how to generate electricity.

The final project will be an axial generator based on permanent magnets, to be used in the laboratory of electrical machinery and renewable energy.

- who's done what beforehand?

Companies dedicated to the manufacture and sale of teaching equipment have products such as:
- www.labvolt.com

There are also youtube videos about people building their own wind generator:
- muddymuddymuddmann
- MissouriWindandSolar

- what materials and components will be required?

- Manufacture of the shaft of the wind turbine.
    * Metal bar 25cm in length by 5cm in diameter.
    * Use of lathe to produce the patterns designed
       on Inventor.
    * Keys.

- Manufacture of the stator.
    * Reels for coils using 3D printer.
    * Manufacture of 200 turns coil with enamelled
    copper. (24 AWG)
    * Mold for placing coils in right position, using shopbot.
    * Mold for manufaturing stator using shopbot.
    * Epoxy resin to manufacture the stator.

- Manufacture of the rotor.
    * 3mm thick metal plate 30x20 cm.
    * Use of plasma cutter and lathe to produce the
   patterns designed on Inventor.
    * 24 magnets avilable in our workshop.
    * Use of Laser cutter for the spacers and fasteners
   for the magnets.

- Manufacture of the case
    * Manufacture front and back covers of the
generator, and their separators. With shopbot.
    * Bolts and nuts

- Adapt base for tests on simulator
    * Manufacture front lid with laser cutter.
    * Connectors and terminals diode bridge, plastic bands.

- where will they come from?

I will only use material and components available at FabLab or in workshops and labs at TECSUP.

- how much will it cost?
In making my final project I have just bought the nuts and bolts. The materials and services I have found in the workshops of TECSUP and inventory TECSUP Fab Lab.

If tubiera to do outside these environments the approximate costs would be:

Manufacture of the shaft of the wind turbine .......................... 80 $
Manufacture of the rotor ......................................................... 80 $
Manufacture of the stator ....................................................... 80 $
Adapt base for tests on simulator ............................................ 60 $ TOTAL Aprox 300 $

- what parts and systems will be made?

Only the manufacture of the shaft and the two metal discs will be performed by personnel specialized in the use of the lathe machine and plasma cutter.
Everything else will be made by me at Fab Lab TECSUP.

- what processes will be used?

First designe the wind generator in INVENTOR.
Laser Cutter to make spacers for magnets.
Laser Cutter to make front lid of the case.
3D Makerbot printer for coil reels.

ShopBot to make molds for the stator.
EagleCAD for designing the fabduino.
MODEL and Fab modules to burn the fabduino.
Fabricate card of USB-FTDI.

- what tasks need to be completed?

The manufacture of the shaft is the most critical since it depends on the availability of lathes part in the workshops, and people right now are using all teams

- what questions need to be answered?

The manufacture of the shaft is critical because we depended on the availabily of lathe machine at the workshops and of skilled personnel.

I have no doubt that the wind generator will generate electricity but the question is:

How much electricity will it generate?
This is a piece of teaching equipment therefore it is not a priority to produce much electricity. 50W and 24V max

What are the mechanical limits?.
The intention is to spin up to 1800 rpm.

Is there vibration?

- what is the schedule?

The project should be implemented during next week.
The design with inventor was defined weeks ago, but I have been running test all along.
Regarding the manufacture of the coils, many hours of practice are needed to have a good final result.
I dedicated the previous week to the manufacture of the discs for the magnets and the shaft since availability of equipment at workshops is sometime an issue.

- how will it be evaluated?

To evaluate this equipment, it needs to be placed in the machine lab where we can run the following tests:
   * Study of the functioning of a system of wind power generation:
   * Display of sine waves and polar tension.
   Mapping characteristic curves Generator.
   or three-phase voltage according to the rotational speed.
   or DC voltage depending on the rotation speed.
   or torque as a function of the generated current.
   or three-phase active power according to the rotation speed.
   or DC power in function of the rotation speed.
   or three-phase reactive power according to the rotation speed.
   Calculation of constant or torque / current and voltage / generator rotational speed.
   o Implement the vibrational analysis, etc.

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