SDMAY11-01 Advisor: Dr. Ajjarapu Team Members: Luke Rupiper Shonda Butler Andrew Nigro Ryan Semler Chad Hand

Project Description 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.

Specifications Functional Requirements 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 sensors to gather wind data are 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 DC The user interface will display accurate measurements of DC voltage and current, RPM, and real power produced Non-Functional Requirements: The project will comply with all state and federal electrical regulations The turbine has been 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

Project Plan Goals: To understand the previous two senior design groups work. Recognize the constraints and restrictions that we might run into as a group. Estimate costs and assemble a system block diagram. Map out tasks, operation, uses, and propose our approach to completing our objectives. Overview: Problem statement – Simulate an environment in which a wind resource provides renewable energy. System Description – Air X Turbine, OutBack Inverter, 24V Battery Bank, AC power supply and motor, mounting system, computer with LabVIEW software. Operating Environment – Inside the power lab in Coover, but ideally mounted on the roof. User Interface – LabVIEW to control motor inputs and outputs Functional/Non-Functional requirements Constraints – hardware/software Scheduling – Task object, approach, expected results, and timeline Cost Estimation – Budget = $400

Mounting Problem: Previously the motor and wind turbine were coupled together on separate mounting systems. Issues we experience with this system include bowing wood, wind turbine movement during operation, and inaccurate coupling height.

Mounting Design Alternative A wood base with extruded aluminum mounting Two aluminum rods braced and connected to the wood mounting board go up directly to the face of the turbine to hold it in place. An extruded aluminum mounting box braced and connected to the wood matches up to the two rods bracing the turbine. Materials: 3x M5x35 SS socket Head Screws ~ $3 Extruded aluminum mounting brackets ~$50 L brackets ~ $10 ¾” MDF or Birch Plywood sheet ~ $25 Round rubber gasket ~ $5 1 ½” Schedule 40 Steel Conduit – Grounded as per NEC , item 5 and NEC , item A ~$5 Total Cost ~ $98

New Turbine Platform Turbine/Motor Mount Light Switches Current/Voltage Sensors NI DAQ Terminal Block Load Resistive

LabVIEW Interface Have completed wind profile simulation from text file simulating wind speeds over a given time. Are in the process of creating a direct connection via USB to allow for a more accurate simulation. Wind sensors are completed and can be interfaced but need reprogramming to allow for direct connection.

RPM Sensor Feedback to LabVIEW of actual RPM Digital output Powered by DAQ Prefabricated holes for our mount Long leads Magnets mounted to coupling

System Testing Unit Level Testing: 1. Wind data reception Connection to Anemometer LabVIEW input of data 2. LabVIEW control of motor Communication with power supply Motor response to the desired output 3. Wind turbine functionality Manufacturer supplied testing methods 4. Battery charging Charging ability from 12V charger on individual cells 5. Inverter functionality POST : LED’s indicate status and function 6. Sensor functionality RPM Sensor: varying sensor voltage when magnet is near Current Transducer: Voltage changes as current is passed through wire Full System Testing: Verify system runs as expected All units function as expected and system is automated

Semester Schedule Tasks: Task 1:Complete mount fabrication and construction Task 2:Reorganize wiring for turbine and sensors Task 3:Complete hall sensor installation Task 4:Text file wind data gathering Task 5:Real-time wind data gathering Task 6:Load curve and wind profiling via MATLAB Task 7:Variable load control and voltage regulator Task 8:Full system test with wind sensors mounted outside Task 9:Project Documentation Manual Task 10:Project Display Poster Week:Week 1Week 2Week 3Week 4Week 5Week 6Week 7Week 8Week 9Week 10Week 11Week 12Week 13Week 14Week 15Week 16Task Completed Anticipated Task 1: X Actual Task 1: X Anticipated Task 2: Actual Task 2: Anticipated Task 3: Actual Task 3: Anticipated Task 4: X Actual Task 4: X Anticipated Task 5: Actual Task 5: Anticipated Task 6: Actual Task 6: Anticipated Task 7: Actual Task 7: Anticipated Task 8: Actual Task 8: Anticipated Task 9: Actual Task 9: Anticipated Task 10: Actual Task 10: