Wind Energy

Wind Energy 2

Table of Contents:

Description ……………………………………………………………………………. 3
Importance ........................................................................................................... 4
Design Process ..................................................................................................... 5
Research ............................................................................................................... 6
Calculations ......................................................................................................... 8
Project Analysis ................................................................................................... 9
Group Member Roles ......................................................................................... 10
Budget ................................................................................................................ 11
Timeline ............................................................................................................. 12
 Wind Energy 3

Description

Our group, made up of Samantha Springer, Austin Odell, Scott

Stockdale, and Kramer Babilla, spent the second trimester researching and
building an energy producing windmill. We spent many of the weeks doing
research on what type of motor, what material to make the blades from, how
tall to make the windmill, and where could we get the best price from. Our
final product is made from wood with PVC blades and a DC motor. The
motor produces variable output, dependent on the wind speed, but if spun by
hand, it produces ~3V. The Windmill stands on four stake-like legs so that it
can be put into the ground and not move around.
 Wind Energy 4

Importance

With all of the advancements in technology, it is absurd that we still

rely on fossil fuels in our everyday lives. This is the reason why our group
has focused on creating a clean energy solution. Not only is our project clean
energy, but semi-portable energy. The portability of our windmill could give
it the possibility of becoming a common household item. For example, if you
wanted to have an outdoor party where there was not an outlet near by, you
could set the windmill up and power your party.
 Wind Energy 5

Design Process

We began by creating many sketches of possible windmill setups. We

created drawings of both three-leg and four-leg structures. After we decided
to pursue a four-leg structure made of wood, we made a small scale K’Nex
model of what we wanted to build. However, that, still, was not accurate as it
had a horizontal axis. At that time, we did not know we would build a
vertical axis. From that model, we began building the frame of the windmill.
When we were almost finished with the frame, we altered the K’Nex model to
show a vertical axis. We then attached the blades, mount, and motor.
 Wind Energy 6

Research

The group researched the following topics: how to build a windmill,

types of motors, efficiency of motors, construction materials, blade materials,
mounting materials, construction techniques and blueprints, and how to
make a windmill portable.
Over Christmas break Samantha went to talk to Ken Meline, a
mechanical and electrical engineer, from DFW Consulting. He gave us a lot
of information on the electrical materials needed to make an effective
windmill.
From our research, a DC motor would be the most efficient and give us
the highest output for a low speed wind. Our DC motor was brushless, which
eliminates the problems of connecting current to the current armature. We
were lucky to find a brushless DC motor for a decent price.
In the best circumstances we would have used more durable material
for our base, like metal for the leg supports and the top platform. Since our
budget did not allow this we had to use the next best thing, wood. We found
that wood would be the next durable material because of its use in building
structures today. Also all the other materials we considered were too
expensive or were not durable enough. Another material we used was metal
brackets. These metal brackets were put in to help support the platform and
keep the structure together.
When we began our research on the type of blades and how we were
going to mount them. When we first tried to find ways to make windmill
blades the outcome ranged from carbon fiber to PVC pipe. We chose PVC
because it was easiest for us to obtain and to work with. Once we bought our
PVC pipe we needed to research how to mount them. Our original plan was to
mount them on a horizontal axis mainly because that is how many people
 Wind Energy 7

envision a windmill. After much more research we found that a vertical axis
would be more reliable and easier for us to mount them using a vertical axis.
When we began our project we wanted it to be a portable windmill. After
much research we found that we needed to find out how to build a stable
windmill before we could build a portable one. We then had to come to the
conclusion that with our budget and timeline that we would have to make a
prototype instead of our intended product.
 Wind Energy 8

Calculations

Some calculations we made were concerning picking out our motor.

When we were picking out our motor we had to find what rpm we need to the
motor to have. Our calculations told us it needed to be in 1100 to 1800 rpm
range. It was difficult for us to find it because many motors run on much
higher rpm.
There were many calculations that needed to be done in building the base of
the windmill. The first calculation that needed to be made was the angle the
legs would be when they connected to platform. We originally were thinking
of using a twenty degree angle but after we saw how wide it would be at the
bottom we decided to decrease it to ten degrees. Next we used basic
trigonometry to find the length of the legs and the height to put the middle
support beams between each leg.
Our calculations played a huge role in the building of the product
because of how exact the physical materials needed to be so it would be able
to stand up straight and spin the motors shaft fast enough to produce enough
energy to collect energy.
 Wind Energy 9

Project Analysis

The members of our group did an exceptional job by working together

and lending a hand whenever help was needed. Our final product (prototype)
is an 8 ½’, wooden windmill. Our blades are made from the halves of a 4”
PVC pipe that has been split in half. When the blades spin, they turn a
brushless DC motor which generates electricity from the power of the wind
alone. The biggest problem we had with the final product is that the blades
weren’t balanced as well as they could have been. The prototype was made in
a very short amount of time, thus, it does need many improvements. In our
future endeavors, we plan on focusing more on the portability aspect of the
windmill and incorporating stronger building materials such as carbon fiber
and alloys such as aluminum or titanium. Even though the windmill isn’t
perfect, the fact that it was made using materials acquired for around $100 is
an incredible feat that we were able to achieve.
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Group Member Roles

Samantha Springer:
• Group Manager
• Design Leader
• Research Assistant
• Construction Assistant
Austin Odell:
• Webmaster
• Research Leader
• Construction Assistant
Scott Stockdale:
• Construction Leader
• Design Assistant
Kramer Babilla:
• Construction Assistant
• Design Assistant
 Wind Energy 11

Budget
Our budget does not exceed the allotted $200 budget. We found most of our
materials at Lowe’s, but our big ticket item, the DC motor, was found online.
We searched for the cheapest motor of the classifications we needed, finding
many for over $100. However, because of our persistence, we saved a great
deal of money.

Item Estimated Dollar Amount

Permanent Magnet TENV Motor $50.65
2 2x4x8 Planks of Wood $5.94
23/32”x4x8 Square of Wood $19.97
Drywall Screw Case $11.94
2 2x4x12 Planks of Wood $9.94
4”x5’ PVC Pipe $7.90
Total $106.34
 Wind Energy 12

Timeline
Week 1: November 29 – December 3

• Discuss Possible Projects

• Agree on a Project
• Build a Website
• Research what Items are Needed for Project
• Start Preparing a Project Proposal by Creating a Timeline and Budget

Week 2: December 6 – December 10

• Finalize Project Proposal and Present
• Create Budget

Week 3: December 13 – December 16

• Start Blueprinting a Design
• Search for Cost Efficient Materials

Week 4: January 4 – January 7

• Research Blade Designs

• Research Motors/Generators

Week 5: January 10 – January 14

• Creat 3D-Solidworks Design
• Create a K’Nex Prototype

Week 6: January 18 – January 21

• Went Shopping for Materials at Lowe’s

• Researched Motors/Generators

Week 7: January 24 – January 28

• Started Construction of the Frame
• Bought a DC Motor
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Week 8: January 31 – February 4

• Snow Week (No Work Done)

Week 9: February 7 – February 11

• Cut the PVC into Blades
• Continued Construction of the Frame

Week 10: February 14 – February 18

• Continued Construction of the Frame
• Received Motor and Began Exploring its Features

Week 11: February 22 – February 24

• Final Presentation
• Continued Construction of the Frame

Week 12: February 28 – March 4

• Finished Construction of the Frame
• Attached Motor
• Verified Successfully Creating Electrical Output
• Create Final Report