1. Transmission for Horizontal Axis Windmill
Alexander Davis
ET 494
Dr. Junkun Ma
Dr. Cris Koutsougeras

3. Purpose
The purpose of this project is to design and build a fully functioning transmission for the windmill currently placed in the sustainability center at Southeastern.
Replace current pulley system with constant velocity rotation system

4. Current system

5. Possible different replacements
Standard Transmission
Reduction Gear system
CVT
Combination of types

6. Standard Transmissions
Bulky / Too large / Heavy
Too many rotating parts
Cost

7. Reduction gear system

8. CVT- Continuously Variable Transmission
Many different types
Cost effectiveness
Dynamic Ranges

9. Combination Of Types
Reduction gear series with CVT

10. CVT calculations

11. Spool Calculations

12. Design CVT portion

13. Gear Set Analysis

14. Planetary Gear

15. Material: Polycarbonate
Polycarbonate is widely used in the automotive, aerospace, medical and other industries, offering accuracy, durability and stability in 3D Printed parts so that they can withstand functional testing. Polycarbonate has superior mechanical properties compared to ABS and other Thermoplastics.

16. Lubrication
For Planetary gear selection, lubrication must be used to prevent friction damage and wear upon gears.
Using NLGI 2 type grease will be used in the gear train, due to high heat resistance (-20 to 250 degrees Fahrenheit), as well as having an ability to withstanding a rotational speed of up to 300,000 rpms.

17. Deliverables

18. Digital Testing Finished 3D model will be converted into Comsol.
Maximum Stresses for Designed Windmill will be tested.
Extreme possibilities will be tested (Hurricane force winds)

19. Construction
Parts were designed using Solidworks 3D drawing system, and will be tested using Comsol.
Parts will be created using SELU new 3D printer, therefore exact precision can be made with high grade finish.
Completed Parts will be assembled and mounted on current windmill system on SELU’s sustainability center

20. Conclusion
In conclusion, this project was suggested by Dr. Kris, with prompting from Dr. Junkun Ma, to test my theoretical knowledge of mechanical systems, and possible design ideals and practices that can fit within industry standards and current technologies.

21. Timeline Finalized 3D model of Transmission System March 1st, 2016
Comsol Digital Testing March 22nd, 2016
Completed Printed Parts March 29th, 2016
Assembly and Retrofitting April 26th, 2016
Finalized Prototype Fitting and Adjustments May 2nd, 2016