1. Critical Design Review Wind Turbine with Gearbox
Team G:
Nick Koerner (Lead), Meteb Almutairi, Chris Batsch, Mike Villamar

2. Project Objectives The Main Goal is Control
The Arduino Mega Microcontroller will serve as the control center of the wind turbine.
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
High Efficiency is desired
Switching Regulator
5V, 2A, and 10W of Power

3. Modes of Operation Generation Mode Shutdown Mode
The E-brake switch will be open, and voltage monitor switch will be closed.
This allows for the generator to spin freely, and the battery bank to connect to the generator.
Shutdown Mode
The E-Brake switch will be closed, and the voltage monitor switch will be open.
The generator will be shorted:
Slows down the generator and dumps energy into the dump load.
The hydraulic brake will be activated by the servo, and cause the wind turbine to come to a complete stop.
Generation will be reactivated after a delay, or battery bank needs charging, or manual override.

4. Functional Decomposition

5. Full Circuit Schematic

6. 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

7. Subassemblies Brake Sub Specs: Turnigy Digital Metal Gear Servo
6 V Input
Torque: 17 kg/cm
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
Not all values given, further testing once obtained
Voltage Monitor (R6 & R7)
Simple Voltage Divider for 5 V Analog Pin

8. Construction Plan Structural Hardware: Previous components Used:
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:
The Blades, Shaft, Gearbox, Generator, and Hydraulic Brake will be reused.
Battery Bank
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.

9. Additional Fabrication Plans
Proto-Boards
The current plan is to use the EECS shop provided vector proto-boards to place the circuits upon.
The Goal
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.

10. Testing DC Motor for in Lab Wind Simulations
Wind Tunnel for Final Testing
The Max Wind Speed Tested is 34 MPH
Tests the Generation and Shutdown Modes
>40 MPH Shutdown Feature
Can or will be Adjusted
Input/Output Efficiency

11. In Lab Wind Simulation Data from Testing
Wind Speed [MPH]
Voltage [V]
RPM of Generator [RPM]
Frequency [Hz]
11.18
1.79
16.76
22.37
3.46
33.54
33.55
4.50
50.31

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

13. Org Chart

14. Challenges/Risks Programming Components Scheduling Testing Batteries
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.

15. Questions?