WIND SAIL STATUS REPORT

• Investor Search:

a. Brian McCarthy, ESM, Japanese market.

The Japanese are interested in the design and technology but they

are not willing to invest in product development. If we complete

a prototype they would be willing to have us present it again.

b. Hugh O’Brien: Windmills in combination with oil pumps

c. Gary Philippi: Windmills in combination with oil pumps

d. Martin Bidart: Penn Engineering, interested in high volume

production of alternators. Owns Pittman Motors and MAE Motors

WIND SAIL STATUS REPORT

e. Martin Lin: Lin Engineering. Interested in high volume production of

alternators but wants to move the production to China.

f. Al Coddington: Arrgh Manufacturing. Interested in production of

electronics.

g. Jim McDermott – (son of senator from Washington state)

h. Jack McClure: interested in water purification systems

i. Venture capital firms contacted:

1. United Venture Partners

2. Several more via brokers

WIND SAIL STATUS REPORT

J. SBIR proposal via NREL – rejected for bogus reasons.

k. NREL Industrial Growth Forum: Applications rejected.

Due to Russian connection and no product ready for

market.

WIND SAIL STATUS REPORT

l. Brokers:1. Robert Coleman: seeks government funding2. Greg Henthorne: broker for Chinese companies3. Ron Weiner: VC access Seattle area4. Hancy Mohler: Harvey & Co.5. Brandon Walsh: Westgate Financial6. Hanna Smith: Sperry Mitchell & Co.7. Harry Hartz & Associates8. John Treese: Fina Financial Services9. Ed Margolin: First Consolidated Capital10. Abby Molano

11. David Bannister: Business Team

12. Bart Basi: CFT

WIND SAIL STATUS REPORT

m. Various Other Contacts:

1. Christopher Tilley

2. Steve Patterson (energy sales)

3. Christopher Lynch (Former Trade Counsel Bonn)

4. Russ Kennedy (North Bay Angels)

5. Mark Schmidt: (buying a company)

6. Alan Caldwell: (Prime Energy)

WIND SAIL STATUS REPORT

Via brokers, a number of VC contacts were made, resulting in zero response. Generally speaking the replies were: Russia is too risky.

We want to invest in the production phase, not in R&D.

Come back AFTER you have a revenue stream.

Since we are very early in the product development cycle, as business managers we have not been able to provide adequate answers to the

following questions:

WIND SAIL STATUS REPORT

What is the estimated Return on Investment? (ROI)

What is the time frame for return of capital?

What assurance can we give that capital will be returned?

What are projected revenues?

What are projected Gross Margins?

What are projected product costs?

What are projected operating costs?

Why should we believe we can do business in Russia?

WIND SAIL STATUS REPORT

Thus far we have to report no success in getting investors. As such, Empire Magnetics, Inc. and Rick Halstead have carried the financial load to date, but the reserves are now exhausted.

The last three years have been exceptionally brutal in the industry segment that Empire Magnetics, Inc. serves. Approximately 30% of distributors and customers we served in 1999 have gone out of business and many others are just hanging on. We do see a significant upswing in process, but it will be July 2004 before this converts into working cash for Empire Magnetics.

Without investment funds Empire will not be able to complete the terms of the existing CRADA agreement.

WIND SAIL STATUS REPORT

Empire Magnetics, with its subcontractor Uralmet, has been working on the design of the alternator for the 1500 and 3000 watt units. This design is still being revised as we resolve the mechanical issues of mating the alternator to the windmill. The ability of the bearing system on the windmill to maintain the air gap in the alternator is in question.

Three different approaches to the manufacture of the windings for the 3000 watt alternator are being explored. All are technically feasible. The exploration is focused on which approach will be cost effective in production.

WIND SAIL STATUS REPORT

A design of a magnetic bearing system has been done but initial review indicated the cost is too high for the small windmills. However, it does appear to be useful for larger windmills. Build of a prototype is waiting on funds.

Design work on a 30 Kw alternator is in progress. It builds upon the things we have learned in the design phase of the smaller units.

Electronics!

WPU Control

Empire Magnetics/Wind Sail Empire Magnetics/Wind Sail •• Lawrence Berkeley National LaboratoryLawrence Berkeley National Laboratory •• Makeyev State Rocket CenterMakeyev State Rocket Center

WPU Control

Rich McClellan, PhDRich McClellan, PhDWind SailWind Sail

707707--664664--96119611lichau@starband.netlichau@starband.netDecember 6, 2003December 6, 2003

To Discuss Today

• Prototype Control Electronics Objectives

• WPU Control Approach

• Electronics Simplified Block Diagram

Prototype Objectives

• Simple and Flexible– Use Standard Products Where possible

• Consumer Electric Space Heaters for Power Dump• Battery Voltage Input Inverters (either Solar Oriented or

Consumer (RV))

– Microprocessor Control– Oversize Electronics. Non-Optimized.– Ability to Explore Different Configurations

• Battery charger• Inverter input• Space heating.

WPU Region of Operation

• Following Figure is for Illustration and Discussion Only—not Real Data.

• STALL Region– RPM below Max Efficiency Point. – Unstable Operation, but Tolerant of Wind Gusts

• STABLE Region– RPM above max efficiency.– Stable Operation, but high rpm, more energy dump

required to slow down.

WPU Control

Figure 1: Available Power vs Rpm

-500

0

500

1000

1500

2000

2500

3000

3500

0- 50 100 150 200 250 300 350 400 450

rpm

Watt

s

8 m/s

10 m/s

12.5 m/s

14.5 m/s

16.5

Stall Region

Max Efficiency

Stable Region

Power Dump

Keep out

WPU Operation Philosophy

• Low Winds—Seek Max Efficiency Point• Medium Winds—Slow down into Stall Region.

– Maintain Power Dump Margin for sustained gusts.

– Limit cycle operation. Long time constant—minutes.

• High Winds– Operate Deeply in Stall Region.

WPU Operating Philosophy

• Maintain WPU RPM at desired point by– First Transfer Power to Battery/Inverter.– Second, Transfer Power to Power Dump.– Switch between two based on monitoring of

output voltage—too high, transfer to Power Dump.

• No inverter or battery—control circuit becomes a space heater driver.

Simplified Block Diagram

Power Dump

WPU400VDC to 12/24/48 VDC

Buck/Battery Charger Inverter

Battery

Microprocessor Control

110/220VAC50/60 Hz

Simplified Block Diagram

• Power Dump is two (one per phase) space heaters. Triac Controlled.

• Inverter can be – Sunny Boy or Xantrex for grid connection– Multiple (Cobra, others) for non-grid

connected. Much Cheaper.

Simplified Block Diagram

• Buck Circuit (300-400VDC to 12/24/48VDC) is programmed by microprocessor.– Battery Charge State is determined by voltage and

temperature.

– Battery Capacity chosen to accommodate max capacity of WPU (Battery ampere-hours> max output current/5).

– Buck Circuit uses one large International Rectifier IGBT Half Bridge (600V; 200A) and a big inductor.

Simplified Block Diagram

• Leave out the Battery and Inverter– Power transfers only to Heaters, or other

resistive load– Buck circuit can be left out. Microprocessor

and Triacs do the control• Micro is probably <$10.