Problem Statement:

Create CAD models of the design to further analyze the forces within the system, and to gain a better understanding of how the system operates. 

Problem Assumptions:

• The CAD model will not have the exact dimensions of the final product.
• Specific off-the-shelf components will be generic at this stage.
• There will be sufficient wind in the location of the turbine.
• Movement among the parts may need to be changed after analysis.

Decision Matrix:

Link: Decision MatrixLinks to an external site.

Multiple Solutions: 

Three solutions were designed to meet the functional requirements of a wind turbine that produces power, while operating on a small scale with minimal maintenance required an a low cost of entry. all three of these solutions use a similar design HAWT blade, with a 4 inch diameter, threaded (4.000 , 4) output shaft, that has a set screw to prevent backing out from occurring during rotation. These solutions go through a series of stress calculations and all use the same torque value, produced from the wind (calculations shown). 

Module 1 Gear: 

The first module uses a series of gears to transmit the torque produced from the wind, to a gear box and generator located near the base of the wind turbine. Two, 18 tooth, 8in diameter gears we used to transmit the torque 90 degrees, allowing the force to go to the bottom of the turbine. It was determined through calculations and the decision matrix, that this module was the most effective for transmitting the wind force. 

Module 2 Slip Pulley:

The second module uses a traditional, friction style slip pulley and a nylon belt. The inner diameter of the output pulley is 7.5 inches. The belt carries the calculated torque from the top of the turbine to the bottom where a gearbox steps up the RPM and a generator produces power. Through research it was found that this is not an effective way to transmit wind energy, and that due to the high forces within the gear box, belt slippage would occur. This module would be the least ideal, however in a situation where it sees less forces, it could work. 

Module 3 Pulley w Teeth:

The last module utilizes a bit of both. A pulley with teeth is used to transmit the torque from the turbine to a generator and gear box. This module prevents the slippage from occurring that happened in module two, however it is a bit more complicated than the one found in module 1. For our applications, the belt system will work fine, however if there were unusually high winds the belt could snap, leaving the turbine broken. 

M1 FRDPARRC: https://docs.google.com/spreadsheets/d/1j47iAiQX3mhpn3r0TBnA-qPdZRBlFUdNJDEo_9qSo4c/edit?usp=sharing

M1 FRDPARRC:

https://docs.google.com/spreadsheets/d/11E8ZARh0SQg2J3zjZpmA_ZSf2DFkpr2SMwyAk38nIuY/edit?usp=sharing

M3 FRDPARRC:

https://docs.google.com/spreadsheets/d/1Yr4tU5HZkxUt-cxgiNhy0RiveaDv_D1n6DFaVKyrno4/edit?usp=sharing

Lessons Learned:

Most of the designs I have made within CAD programs have been for parts with no movement. Accounting for the variables involved with moving parts was an interesting learning experience. It was also a learning experience to develop the cad for a 90 degree change in motion. The initial spinning of the wind turbine, has to be converted to be able to spin a shaft that is in a different orientation. One of the other lessons learned during this assignment was a better understanding of how to plan out parts, before actually going to create them in a CAD program.