Wind Turbine Design and Implementation Phase III Senior Design May Team Andrew Nigro (EE) Chad Hand (EE) Luke Rupiper (EE) Ryan Semler (EE) Shonda Butler (EE) Advisor: Venkataramana Ajjarapu

Problem Statement The objective of the senior design project is to simulate an environment in which a wind resource provides renewable energy. The electricity generated from the wind turbine can be used to power a direct load and potentially be integrated into the Iowa State University power grid.

System Block Diagram Overview of the Wind Power System

Operating Environment Ideally would be mounted to the roof of a building Controlled environment inside power lab in Coover Wind simulation with AC motor controlled by LabVIEW Input data provided by wind sensors

Requirements Functional The turbine will generate a 24V DC output The turbine will generate a 400W peak output The test-bed connection will serve to simulate the load The motor will simulate outdoor wind speed The sensors used to gather wind data will be an anemometer and wind vane The RPM sensor will accurately reflect the speed of the motor within ±5% The wind turbine will supply a load after charging the batteries to 23V The user interface will display accurate measurements of DC voltage and current, RPM, and real power produced Non-Functional The project will comply with all state and federal electrical regulations The turbine will be remounted to a new stable operating platform The project will be documented through technical manual and in-depth schematics Wiring and connections will be redone in a professional manner

Mounting & Platform Old platform issues: Stability Vibration Bowing Materials: 80/20 Inc. Rectangular Extruded Aluminum Rods ¾” slab of Medium Density Fiberwood L-Brackets and Hex Screws Aluminum Plate Cost: $40-50 – Extruded aluminum $10 – Aluminum plate $25 – MDF platform $5 – Misc – Screws and Washers 20$/hour Installation – 5 Hours Bowing Strapped For Stability

CAD Model Turbine Mount CAD Model Construction Cut aluminum plating to cover faceplate of the turbine Cut extruded aluminum rods to match CAD measurements Bolt motor to aluminum rods Connect rods to faceplate to stabilize L bracket brace 90 degree connections Screw to MDF board

Wind Turbine & Inverter Southwest Windpower AirX 400 Turbine Designed to charge batteries Minimum of 7V DC input to power on Regulation Mode maximum 27V DC input Wind input will be simulated through a coupled 3 phase motor Outback GTFX2524 Inverter 24V DC input 120V AC output Internal controller for stable output Specifications are able to handle the 24V DC output from the turbine and the 120V AC, 10A load Hybrid, stand-alone or grid connected modes

Sensors: Anemometer & Wind Vane Data from wind sensors are collected from a transceiver that were provided by Senior Design Team SD Dec10-05 Wind profile data collected from a self-healing mesh network on the roofs of Coover and Durham Each node in the network uses an anemometer, a wind vane, a microcontroller, and a wireless transceiver Real-time data is averaged every 10 seconds in order to avoid excessively ramping the motor for short fluctuations Sensors’ output transmitted through a transceiver with a range of 1-2 km Transceiver output is passed through the microcontroller and then connected to our interface through USB Microcontroller support software exports sensor data to a text file Text file is imported into LabVIEW by analyzing each line as a string then passing this data to our LabVIEW interface

Sensors : CT & Voltage Hall effect current transducer Powered by 12V DC power supply Calculate current from wind turbine Calculate current to inverter Tested with multi-meter across resistor Voltage divider gives safe voltage to DAQ Tested with multi-meter

Rpm Sensor Hall Effect Sensor Digital Output Powered by DAQ Tested by passing magnet causes a change in voltage LabVIEW uses edge counter to calculate RPM. Pull up resistor of 2.2KΩ gives ≈5V output Sensor gives ≈0V output when magnet is near

User Interface

Motor Control LabVIEW interface takes in text file from wind sensors and uses it for motor speed This was tested by running several different profiles through the interface.

Full System Testing LabVIEW Control of Motor Test that LabVIEW controls the motor at given wind speed Verify the RPM sensor matches with expected RPM

Full System Testing Turbine Testing On/Off testing - Spin turbine by hand while shorting turbine leads to test breaking ability. Battery Connection Testing - Connect appropriate leads to the terminals and observe if the indicator light turns on. Rotation Response Testing - Spin the turbine with motor while keeping the turbine under 500RPM indicator light should be off. Rotation Response Testing - Spin the turbine with motor while keeping the turbine over 500RPM indicator light should come on which indicates power is being generated.

Full System Testing Battery Testing Batteries measured to determine if they held the rated charge of V each using a multi-meter. Series connection of batteries yields V maximum.

Full System Testing Inverter Testing 18V DC needed to operate – confirmed through multi-meter, LEDs, and LabVIEW interface Jumper connects to pins to make operational LEDs show the status of the inverter Inverter Modes Courtesy of Outback

Full System Testing Load Testing Inverter being switched on will automatically switch on 1x75W light bulb and power the additional outlet Light switch controls additional 75W light bulb Multiple devices will be plugged in to the outlet Circuit breaker stops power from being delivered to load if 30A current is run through load

Project Continuation Direct real-time connection from wind sensors Dedicated computer Connection to grid Mounting on roof of Coover

Project Members Luke Rupiper – Project Leader Motor Control lead Andrew Nigro –Equipment Procurement Task Leader Mounting and Construction lead Shonda Butler – Communications Task Leader Wind Sensor lead Ryan Semler – Website Task Leader RPM Sensor lead Chad Hand – Documentation Task Leader LabVIEW lead

Acknowledgements Advisor: Dr. Ajjarapu Client: Iowa State University Department of Electrical & Computer Engineering Coover Hall Parts Department: Leland Harker Wind Sensor Design Team: SDDEC10-05 Senior Design Group: SDMAY10-17 National Instrument Forums