October 14, 2010

Iowa State University: Department of Electrical and Computer Engineering

Members:Andrew NigroShonda Butler

Chad HandLuke RupiperRyan Semler

Advisor:Dr. Venkataramana Ajjarapu

Wind Turbine Design and Implementation Phase III

Project Plan

Project: SDMAY11-01

DISCLAIMER: This document was developed as a part of the requirements of an Electrical and Computer engineering course at Iowa State University, Ames, Iowa. This document does not constitute a professional engineering design or a professional land surveying document. Although the information is intended to be accurate, the associated students, faculty, and Iowa State University make no claims, promises, or guarantees about the accuracy, completeness, quality, or adequacy of the information. The user of this document shall ensure that any such use does not violate any laws with regard to professional licensing and certification requirements. This use includes any work resulting from this student-prepared document that is required to be under the responsible charge of a licensed engineer or surveyor. This document is copyrighted by the students who produced this document and the associated faculty advisors. No part may be reproduced without the written permission of the Senior Design course coordinator.

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Table of Contents:

I. List of Figures and Tables 3

II. Executive Summary 4

III. Acknowledgement 4

IV. Problem Statement 4-5

V. Operating Environment 5

VI. Intended User(s) and Use(s) 5

VII. Assumptions and Limitations 6

VIII. Expected End Product & Deliverables 6-7

IX. Proposed Approach 7-9

X. Statement of Work 9-11

XI. Estimated Resources 11-12

XII. Schedules 13-14

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XIII. Project Team Information 15

XIV. Closing Summary 16

XV. Appendices 17

I. List of Tables and Figures:

Figure 1: Estimated Individual Team Member Effort Page: 11

Figure 2: Required Resources Page: 11-12

Figure 3: Project Schedule Page: 13

Figure 4: Project Timeline Page: 14

Figure 5: Project Team Information Page: 15

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II. Executive Summary:

Over the last century electrical needs have been steadily increasing due to population growth and technological and industrial expansion. Growing environmental concerns and the depletion of fossil fuels have influenced the increased production of electricity from renewable resources. Iowa is one of the leading producers of wind generated electricity in the United States, and Iowa State University has been taking strong steps to implement new ideas to decrease its environmental impact and increase self -sustainability.

Our senior design team plans to expand and fine tune a previous wind energy project led by Dr. Ajjarapu. The project consists of a wind turbine coupled to a motor that is controlled by an external power source. The goal of the project is to accurately simulate wind conditions to the turbine in a controlled environment and monitor voltage, current, power, and speed. As a team, we need to first understand what was designed and built by the previous group. We need to clearly understand how the system is controlled and document all of our progress.

The end product will resemble a small scale renewable electrical network. We will simulate wind conditions to our turbine through data we will receive from wind sensors placed outside provided by another senior design group. The power generated from the turbine will charge a bank of batteries. The direct current (DC) will be converted to alternating current (AC) through an inverter. From the inverter, a load consisting of four light bulbs will be powered.

III. Acknowledgement:

Professor Ajjarapu – Faculty Advisor – Provides us with advice on project management as well as technical and financial support.

Coover Parts Department – Provides us with hardware support. NI forums – Provide us with hardware support. Brandon Janssen – Worked on previous project team. Brought us up to speed on the current

system. Senior Design Team DEC10-05: Provide us with wind speed data.

IV. Problem Statement:

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This project is a continuation of two previous senior design groups. The final implementation of this project is to design a wind turbine electrical generation system and integrate the power generated into the power grid. A wind turbine will be installed on the exterior of Coover Hall.

This semester’s implementation of the project is to simulate the outdoor wind speed with a motor connected to the turbine. We will also be gathering data and displaying current power output, current wind speed, and other necessary data. The project will require us to update the GUI, and add sensors to the current design. We will be rebuilding the load test-bed, and generator/motor housing. Our group will be adding documentation to the project to help future groups get started on their implementation quickly.

V. Operating Environment:

Ideally the wind turbine would be mounted to the roof of a building, such as Coover Hall, and integrated into the power grid at Iowa State. Although this is ideal, it will not be achieved with our senior design group due to budget constraints. Our system will not be intended for outdoor use; instead we are simulating wind conditions in a controlled environment inside a power lab in Coover Hall. However, our system will be able to handle all environmental conditions such as dust, extreme temperatures, rain and other weather elements should future innovations include outdoor implementation. Wind simulation will be achieved using a three-phase AC motor along with sensors to read current and voltage levels as well as rpm measurements. Data will also be provided via wireless signals from wind sensors mounted outside, which will be used to simulate changing wind speeds for pitch control. An interactive graphical user interface (GUI) in LabVIEW will be used during simulations to display readings and measurements sent from the various sensors.

VI. Intended Use(s) and User(s):

Intended Users:

The simulation environment is intended to be used by students of the Iowa State University Electrical and Computer Engineering department. These students will have at least a high school education and an interest in using wind as a renewable source of energy. Primary users will consist of Dr. Ajjarapu and future senior design projects for its expansion. Secondary users will consist of students viewing the simulation as a display.

Intended Uses:

This environment will be used to simulate wind energy generation. This simulation is intended to be an educational tool used to study power generation from small wind turbines. Where the turbine will be rotated by a motor at the current wind speed and charge its battery bank and power a load according to its current generation level. The

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load is not intended to provide a primary light source for a room and the battery bank is not intended to power any devices other than the simulation environment.

VII. Assumptions and Limitations:

Assumptions:

The previous group has all equipment in working condition. For example, the wind turbine has not been damaged in testing.

The LabVIEW interface has been developed and tested to be accurate in displaying voltage, current, power and speed.

The senior design group working on designing the wind sensor will complete their objectives and will activity communicate any issues in receiving data.

The end product will be comparable to a regular connection to a classroom on the I.S.U. grid (120 V AC at 60 Hz).

Limitations:

The budget of $400 leaves little room for any equipment malfunctions so our group must be completely knowledgeable of the system and its mechanical limitations.

The budget does not allow proper funding for field testing the equipment in its intended environment, mounted to the top of Coover Hall.

There is a lack of documentation (schematics, wiring diagrams, and system manual) of the previous group’s work.

VIII. Expected End Product:

Control Interface:

We will be expanding on the previous groups control interface to include motor control that will accurately simulate wind speed. This interface will be programmed in LabView and will be used to control and monitor the entire system.

Variable Load:

We will be creating a variable load to connect to our power generation system in order to simulate the system being connected to a real grid. This grid will have voltage and

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current sensors so it can report back to our interface the amount of power being used and the power output can be adjusted accordingly.

Wind Turbine Mount:

A new mounting system will be designed in order to stabilize the system and avoid damage to the turbine and the motor. This will involve a thicker base that will solve the problem of the previous group having the base bow down making the system unbalanced. It will also include a stabilization plate that will decrease the vibrations that the turbine receives from the motor increasing efficiency and avoiding damage to the system.

User Manual:

We will be creating a user manual that will help future groups and other users become acquainted with the setup more quickly. This will save others time and hopefully avoid future mistakes.

IX. Proposed Approach:

Functional Requirements:

FR01 The turbine will generate a 24V DC output. FR02 The turbine will generate a 400W peak output. FR03 The test-bed connection will serve to simulate the load. FR04 The motor will simulate outdoor wind speed in real-time with our external

sensor. FR05 The wind turbine will supply a load after charging the batteries to full. FR06 The user interface will display accurate measurements of relevant data.

Constraints Considerations:

We are limited by what the previous group had done, and our understanding of what they were attempting. We will also be limited by other senior design groups implementing portions of our project necessities. We will not be able to replace the expensive components of the project, so some expansion limitations exist.

Technology Considerations:

We must all be comfortable with our LabvVIEW environment. All group members need to have a thorough understanding of the LabVIEW code and diagrams. We do not know the output of our outdoor wind speed sensor, so when we need it we may need to do conversion to get it working with our system.

Technology Approach Considerations:

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We will be doing any technical approach decisions internally.

Testing Requirements Considerations:

Testing will be required in every step of our project because we have multiple systems that will not work outside of small tolerances. We will be designing several tests to check individual components and the system as a whole.

Wind Turbine Testing - We will use the wind turbine manual to verify all the functionality the manufacturer recommends.

Battery Charge Testing - We will be verifying the battery bank can be fully charged, and the batteries properly charge and discharge.

Inverter Functionality Testing - We will be verifying the inverter turns on at the recommended voltage in the factory manual, and also checking the voltage points at which the inverter will give warnings for out of range voltages. We will also be checking the inverter is supplying enough voltage to power the load we are using.

LabVIEW Motor Control Testing - The wind turbing will be powered by a motor. This motor output will be controlled by LabVIEW and automated through sensor data. We must first verify that LabVIEW can control the motors power supply and adjust motor speed in small increments

Sensor Data Testing - The automation of our system relies on various sensor inputs in LabVIEW. We will need to check all sensors are reporting reliable data over the entire range of outputs we can have in our simulations.

Security Considerations:

The security concern for our project is the location. Our project is in a lab that will be frequently used by other students, and tampering is very harmful to our projects reliability, and reproducibility.

Safety Considerations:

There are many safety issues we need to address. The turbine will need to be better secured with safety switches to cutoff power.

Intellectual Property Considerations:

All intellectual property is shared with the team/university/advisor.

Commercialization Considerations:

This project will not be commercialized it is an academic research project.

Possible Risks and Risk Management:

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Working with high voltage there is always the risk of shock. There is also the risk of high speed moving parts becoming unstable. We will be designing systems to cut power and stop the spinning machines quickly and safely.

Project Proposed Milestones and Evaluation Criteria:

Our project will have weekly reports to our Faculty Advisor who will be addressing concerns he has in our project. We will be evaluated by our Faculty Advisor and the goals he has for the project.

Project Tracking Procedures:

We will be tracking our individual efforts, as well as our team goals based on our scheduling. We have determined points at which we will work in two smaller teams to speed up decision making and fabrication when having a large group would be inefficient. We will also be tracked by our advisor on a weekly schedule to ensure we are at appropriate points in the project.

X. Statement of Work:

Task 1 - Familiarize with Project Subtask 1a - Meet with previous senior design group and Dr. Ajjarapu. Task Objective: Become familiar with current setup and how it should operate. Task Approach: Meet with Brandon Janssen to view current setup. Analyze the wiring to

understand how everything is hooked up. Introduced to GUI. Task Expected Results: Group is familiar with current setup and any issues we must

initially address.

Task 2 - Initial System Testing Task Objective: Test current setup to find any issues we must address. Task Approach: Attempt to operate the current setup and view the GUI to familiarize

ourselves with how everything should work. Apply load once the battery bank is charged.

Task Expected Results: System works as intended with no initial issues to address.

Task 3 - Draft Project Plan Task Objective: Create a draft project plan in PowerPoint for class presentation. Task Approach: Group meeting to address all requirements for draft project plan. Once

requirements are decided each section will be typed and added to PowerPoint for presentation.

Task Expected Results: Draft project plan complete and presented in class.

Task 4 - Project Plan

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Task Objective: Create project plan document with all requirements addressed. Task Approach: Group meeting to setup Google document allowing all group members

to work on project plan. Once Google document is created a final document will be created in Microsoft Word

Task Expected Results: Final project plan document will be completed with all requirements addressed.

Task 5 - Website Building Task Objective: Create a project website that can be updated throughout semester. Task Approach: Use premade template and link to our network space. Link files to

hyperlinks. Include weekly reports, final project plan, etc. Task Expected Results: Website created allowing easy updating when needed and

access to information about project.

Task 6 - Familiarize with GUI Task Objective: Understand LabVIEW and the programming behind the GUI. Task Approach: View forums on National Instruments website. Play around with

tutorials in LabVIEW. Direct contact with engineers from National Instruments. Review book on LabVIEW.

Task Expected Results: Fully understand current GUI as well as improvements needed.

Task 7 - Procure Equipment Task Objective: Obtain materials needed to construct new test bench. Task Approach: Upon department approval, obtain materials for new test bench.

Materials will be gathered from ECpE department as well as local businesses such as Lowes.

Task Expected Results: All new materials will be procured allowing new design of test bench.

Task 8 - Constructing New Test Bench Task Objective: New test bench is constructed using materials procured. Task Approach: Once materials obtained new test bench is built according to new

design. Run new system testing to test reliability of new setup. Task Expected Results: New test bench is constructed allowing more reliable system

testing.

Task 9 - Final Design Document Task Objective: Create final design document for final presentation. Task Approach: Adding on to final project plan with new additions addressing final

requirements of project. Task Expected Results: Final design document created and turned in to senior design

board at end of the second semester.

Task 10 - Load Improvement Task Objective: Rebuild current load setup while adding an emergency load. Task Approach: Pulling apart previous load and creating a system that can account for

multiple adjustments.

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Task Expected Results: More efficient reliable load while also adding an emergency load.

Task 11 - Wind Sensor Implementation Task Objective: Simulate wind conditions outside using wind sensors. Task Approach: Receive data via wireless signal to LabVIEW. Use data to simulate pitch

control for changing wind speeds. Task Expected Results: Turbine adjusts properly for changing wind speeds to prevent

damage to turbine.

Task 12 - Technical Manual Task Objective: Create technical manual for future senior design groups continuing this

project. Task Approach: Work with English 314 class in constructing a technically sound

document. Setup meetings with group from 314 to ensure proper steps are accounted for.

Task Expected Results: Technically sound manual created for future senior design groups continuing this project.

XI. Estimated Resources:

Estimated Individual Team Member Effort (hours)

Task: 1 2 3 4 5 6 7 8 9 10 11 12Team Member: TotalsAndrew Nigro 7 7 3 5 2 2 2 8 5 8 2 4 55Chad Hand 6 2 3 5 10 2 8 5 3 2 2 48Luke Rupiper 7 5 3 5 2 6 8 5 3 2 4 50Ryan Semler 6 5 3 5 4 2 2 12 5 3 2 2 51Shonda Butler 16 3 6 5 2 2 8 5 3 10 2 62Totals 42 22 18 25 6 18 14 44 25 20 18 14 266

Figure 1. Estimated Individual Team Member Effort

Required Resources

Parts and Materials:Team Hours

Other Hours

Cost without Labor

Cost with Labor ($20/hr)

Purchased by Phase I:

Turbine- Air X 400 current price $700 $700

Inverter-Outback GTFX2524 $1,400 $1,400

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Battery Bank guess $100 $100

NI USB-6008 current price $170 $170

Purchased by Phase II:Coupling $112 $112Current Transducer $21 $21Stop Switch $16 $16Kikusui Power Supply Borrowed $03-phase AC Motor Borrowed $0

Phase III Estimates:Mounting Platform: 44 $880

Sturdy Building Material $40Brackets and Mounting Material $20Wire Encasing Material $20

Load Platform 20 $20 $420Wire 5 $10 $110RPM Sensor 40 $10 $810Printing Costs $15

Services:Wind Sensor- Other Senior Design Group (Dec 10-05) 2 $40Technical Manual- Engl 314 Group 20 $400Knowledge of Project- Dr. Ajjarapu 30 $600Knowledge of Project-Previous Senior Design Team member 2 $40Turbine Expertise- National Instruments Forums 1 $0Totals: 109 55 2654 5819

Figure 2. Required Resources

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XII. Schedules:

Our project schedule includes specific tasks and deadlines that designate how we manage time throughout the duration of the project. Each task has a specific task leader whose purpose is to understand each item, designate roles, and verify the scope of the task has been fulfilled. A Gantts chart helps compare our anticipated progress to the actual progress being made on each task item.

Project Schedule

TEAM NAME: SDMAY1101PROJECT MEMBERS: Andrew Nigro , Shonda Butler, Ryan Semler, Chad Hand, Luke RupiperPROJECT TITLE: Wind Turbine Design and Simulation

ANTICIPATED TASK DEADLINES, WORK LOAD, TASK LEADER, AND TASK DESCRIPTIONS

TASK START TASK DEADLINE TASK # WORK LOAD TASK LEADER TASK DESCRIPTION9/9/2010 9/23/2010 1 Shonda/Andrew Familiarize with project

9/15/2010 10/14/2010 2 Ryan Initial system testing9/21/2010 9/28/2010 3 Luke/Shonda Draft Project Plan9/21/2010 10/14/2010 4 ALL Project Plan9/28/2010 10/8/2010 5 Ryan Website Building9/15/2010 12/13/2010 6 Chad Familiarize with GUI10/7/2010 12/13/2010 7 Andrew Procure Equipment

10/14/2010 11/14/2010 8 Ryan Constructing new test bench10/14/2010 12/3/2010 9 ALL Final Design Document

1/10/2011 3/11/2010 10 Andrew Load improvement1/10/2011 3/11/2010 11 Shonda Wind sensor implementation

9/9/2010 3/11/2010 12 Chad Technical Manual

Figure 3. Project Schedule

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Figure 4: Project Timeline

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XIII. Project Team Information:

Client:

Iowa State University : Department of Electrical and Computer Engineering

Faculty Advisor: Dr. Venkataramana Ajjarapu

1122 Coover Hall Ames, IA 50011-3060 Phone #: (515) 294-7687 vajjarp@iastate.edu

http://www.ece.iastate.edu/who-we-are/faculty-and-staff/faculty-new/index/detail/abc/289.html

Student Team:

Andrew NigroElectrical Engineering2129 Sunset DrAmes, IA 50014-7074Cell: (402) 917-4753Email: anigro@iastate.edu

Chad HandElectrical Engineering3114 Woodland StreetAmes, IA 50014-7074Cell: (563) 210-6631Email: chand@iastate.edu

Luke RupiperElectrical Engineering2506 Lincoln Way Unit 22Ames, IA 50014Cell: (612) 840-4465Email: lrupiper@iastate.edu

Ryan SemlerElectrical Engineering1005 Pinon Dr Unit 3Ames, IA 50014-7944Cell: (515) 451-9336Email: rsemler@iastate.edu

Shonda ButlerElectrical Engineering1317 Roosevelt AveAmes, IA 50010Cell: (210) 834-6114Email: sbutler@iastate.edu

Figure 5: Project Team Information

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XIV. Closing Summary:

The United States continues to increase its electrical consumption and recently has stressed the need for solutions from renewable resources. Our project focuses on the electrical needs of Iowa State University and aims at taking advantage of an abundance of wind energy in the Iowa area. By creating a simulated environment, we can work in a controlled laboratory to test load control with a wind turbine. Our goal is to improve the previous system by using real-time wind data to control our turbine. If we can accurately monitor the output of turbine and control its ability to feed a load, future groups will be able to easily use our system and interface to design other wind turbine systems for campus buildings.

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XV. Appendices:

A-1:

Wind Turbine Manual: http://www.windenergy.com/documents/manuals/3-CMLT-1004_REV_E_AIR_X_OWNERS_MANUAL.pdf

Wind Turbine Specification Sheet: http://www.windenergy.com/documents/spec_sheets/3-CMLT-1339-01_Air_X_Spec.pdf

Wind Turbine Wire Sizing: http://www.windenergy.com/documents/misc/AirX_wire_sizing.pdf

A-2:

Inverter Manual: http://www.outbackpower.com/pdf/manuals/gtfx_gvfx.pdf

A-3:

Labview USB-6008 DAC:http://www.ni.com/pdf/manuals/371303l.pdf

A-4:

Labview Manual: http://www.ni.com/pdf/manuals/320999e.pdf

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