Wind Turbine Mk II Instruction Manual
Wind_Turbine_MkII_Instruction_Manual
User Manual:
Open the PDF directly: View PDF 
.
Page Count: 16
| Download | |
| Open PDF In Browser | View PDF |
MKII 5 Watt 3dprintable Wind Turbine. Product Liability Waiver This agreement releases ‘3dp’ from all liability relating to injuries that may occur during the use of this Prototype Wind Turbine. By downloading the plans for this Prototype you agree to hold ‘3dp’ entirely free from any liability, including financial responsibility for injuries incurred. The user acknowledges the risk involved in operating a product of this type. These include but are not limited to the release of highenergy debris or electric shock. The buyer participates voluntarily, and accepts all risks. By downing these plans you understood and agree to the above terms. Introduction This document contains the Manufacturing, Assembly and Operational instructions for 3dp’s Wind Turbine. This fully functional wind turbine has been specifically design to be manufactured, assembled and operated at home with its unique 3d printable design. The wind turbine is optimized to produce a power output of 5 Watt (12volt ~4amps) at 5m/s wind speeds, perfect for battery charging applications. The wind turbine has been designed with a unique Passive Variable Pitch (PVP) design. The PVP maintains an optimum power output through control of the turbines rotational speed. Whilst optimizing power output the PVP also protects the Turbine from dangerous over speed conditions, limiting its maximum revolutions per minute in wind speeds greater than 5m/s. The main components of the turbine have been designed for Additive Layer Manufacturing (ALM) methods using PLA plastic. 95% of the ALM components require no post processing as these parts do not require ‘print supports’ reducing material usage whilst improving the overall finish of the part. MKII Design Improvements The MkII has three design improvements, the first is an all important tail fin to allow the turbine to turn into the wind and extract the maximum wind energy in changeable conditions, the second is a stiffer tower structure with bigger bearings and increased diameter locating pin to support the increased loads from the tail whilst allowing for the third improvement which is the inclusion of Split Ring Electronics. The Split Ring Electronics allows the turbine to spin around the tower axis without any limitations it brings the power electronics into the tower where there is more space and its easier to access. The MkII requires the following new parts: • • • • Structure Rear Structure Tower Header Nacelle Wind Turbine Test Data 800 19.00 18.00 17.00 Keep Out Zone 700 16.00 15.00 600 Revolutions per Minute (RPM) 4.1 m/s13.00 4.5 m/s 500 12.00 4.9 m/s 11.00 4.1 m/s Voltage Max (V) 10.00 4.5 m/s Voltage Max (V) 400 9.00 4.9 m/s Voltage Max (V) 8.00 300 7.00 6.00 5.00 200 4.00 3.00 100 2.00 1.00 0 0.00 0 10 20 30 40 50 60 70 80 Blade Pitch Angle (90 deg = design intent for max lift) 90 100 110 120 Voltage Output (14 Volts = design intent)) 14.00 8 7 6 5 4 3 1 Wind Turbine Assy Drawing F 5 8 1 Tower Assy 2 Structure Assy SEE ASSEMBLY DRAWING 1 3 Rotor Assy SEE ASSEMBLY DRAWING 1 4 Shaft Nut Y 1 5 Nacelle Y 1 6 M3 12mm 8 PART NUMBER QTY. 1 E 2 8 M6 300mm Threaded Rod M6 Nut 9 Tail Fin 7 3 9 F PRINTED SEE ASSEMBLY DRAWING ITEM NO. E 2 1 4 Y 1 7 D D 6 2 A A C C 1 4 B Pole Length is dependant on Installation type B 3dp_MKII SECTION A-A SCALE 1 : 2 A A 8 7 6 5 4 3 2 1 8 F 7 6 5 4 3 2 1 Rotor Assembly ITEM NO. E D PART NUMBER 1 2 3 4 5 6 7 8 9 10 Disc Crank Pitch Arm Piston Piston Cover Nose Cone Blade Shaft Shaft Shroud Nose Cone Tip 11 12 13 14 M3 Nut Pitch Bearing M5 40mm M3 12mm 15 16 17 18 19 20 M4 50mm M4 Nut M3 25mm M5 50mm M5 Nut Pitch Spring F PRINTED Y Y Y Y Y Y Y WITH ENBEDDED NUT Y Y Y QTY. 1 3 3 1 1 1 3 1 1 1 8 E 9 1 6 6 3 9 Self taping D 3 6 3 1 1 1 7 10 16 3dp_MKII C A 6 14 ITEM2+13 Interference Fit A 15 C 16 14 2 3 13 B 12 B 14 4 5 18 SECTION A-A SCALE 1 : 2 11 A 8 13 7 17 20 6 19 A 5 4 3 2 1 8 7 F 6 10 3 5 4 3 7 ITEM NO. 6 E 1 9 5 1 Structure assembly 2 D 2 PRINTED Y Y Y Y Y PART NUMBER 1 2 Structure Stepper Motor Bracket 3 Generator Cog Driven 4 Generator Cog Driving 5 6 7 8 9 10 Structure Rear Stepper Motor NEMA11 M3 12mm M3 25mm M4 25mm Main Location Bearing F QTY. 1 1 1 1 1 1 4 2 2 2 D 8 4 Both Cogs require a grub screw (part not shown) NEMA Stepper motor wiring routed here. A 2 B 3 C E C 1 4 B B A 5 8 SECTION A-A SCALE 1 : 1 7 3dp_MKII 6 5 4 A A B SECTION B-B SCALE 1 : 1 3 2 1 8 7 6 5 4 3 2 1 Tower Assy Drawing F ITEM NO. A 4 E 7 PART NUMBER PRINTED QTY. 1 Tower Footer Y 1 2 Tower Header Y 1 3 Tower Pole 4 5 6 Tower Shaft Main Tower Bearing Slip Ring Tower O-Ring Setting & Seal 7 F 1 Y 1 2 1 E 1 5 2 6 D D Slip Ring is an interference fit no screws should be required however holes have been included incase they are required C 3 C 64.50 3dp_MKII Tower Pole Standard home drain pipe B B 1 A 8 7 A SECTION A-A SCALE 1 : 1 A 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Blade Setting Instructions F Step A E D 3dp_MKII F Task Description 1 Depress the Piston to the stop 2 Hold the piston in the depressed position throughout the operation 3 Thread each blade onto the M5 bolt and tighten down 4 Align Blade Setting Facing face with Pitch Alignment Feature on the Disc 5 Use a spring washer, washer or rubber o-ring to ensure the blade is aligned and tight. This is likely to take a number of attemps. 6 Repeat the operation for all Three blades E D Alignment Plane Blade C C Pitch Alignment Feature on Disc B B Blade setting Face DETAIL A SCALE 1 : 1 A 8 7 6 Piston 5 A 4 3 2 1 8 7 6 5 4 3 2 Blade Drawing A F 1 F E E 3dp D MKII D USING SLICER SOFTWARE PLUG-IN. Pause the print at a height of 9.1mm insert M5 nut. Before resuming the print ensure the nut is below the print surface. 9.10 C B C B B A A 8 7 6 A DETAIL B SCALE 2 : 1 SECTION A-A SCALE 1 : 1 5 4 3 2 1 BILL OF MATERIAL Shell thickness Bottom/Top Thickness * Component requires an embedded nut, see blade drawing. Description Wind Turbine Assembly Tower Assy Structure Assy Item No. Part Name Printed QTY 1 2 3 4 5 6 7 8 9 1 2 4 3 5 6 7 1 2 3 4 5 6 7 8 9 10 1 2 3 Tower Assy Structure Assy Rotor Assy Shaft Nut Nacelle M3 12mm M6 300mm Threaded Rod M6 Nut Tail Fin Tower Footer Tower Header Tower Shaft Tower Pole Tower Location Bearing Slip Ring O-Ring Structure Stepper Motor Bracket Generator Cog Driven Generator Cog Driving Structure Rear Stepper Motor NEMA11 M3 12mm M3 25mm M4 25mm Main Location Bearing Disc Crank Pitch Arm NA NA NA Y Y N N N Y Y Y Y N N N N Y Y Y Y Y N N N N N Y Y Y 1 1 1 1 1 2 1 4 1 1 1 1 1 2 1 1 1 1 1 1 1 1 4 2 2 2 1 3 3 Layer Height (mm) 1.2mm 1.2mm Print Settings Fill Density Print Speed (%) (mm/s) Support type 0.1 0.1 100 30 20 50 None None 0.1 0.3 0.3 0.1 15 30 30 80 50 50 50 50 None None None None 0.1 0.1 0.1 0.1 0.1 50 100 100 100 50 50 50 20 20 50 None None None None None 0.1 0.1 0.1 70 100 100 50 20 20 None None None Rotor Assy 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Piston Piston Cover Nose Cone Blade Shaft Shaft Shroud Nose Cone Tip M3 Nut Pitch Bearing M5 40mm M3 12mm M4 50mm M4 Nut M3 25mm M5 50mm M5 Nut Pitch Spring Y Y Y Y* Y Y Y N N N N N N N N N N 1 1 1 3 1 1 1 6 6 3 9 3 6 3 1 1 1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 100 50 100 30 50 15 100 50 50 50 50 50 50 20 None None Touching Build Plate None None None Touching Build Plate MAIN LOCATION BEARING Brand: EU Budget Inside Diameter: 25mm Outside Diameter: 37mm Width: 7mm Seals / Shields: Rubber Sealed http://simplybearings.co.uk/shop/advanced_search_ result.php?search_in_description=1&keywords=F680 52RS PITCH BEARING Brand: EU Budget Inside Diameter: 9mm Outside Diameter: 17mm Width: 4mm Seals / Shields: Non http://simplybearings.co.uk/shop/advanced_search_ result.php?search_in_description=1&keywords=F689 PITCH SPRING RS Pro Steel Alloy Compression Spring, 80.5mm x 8.63mm, 0.17N/mm http://uk.rs-online.com SLIP RING file://localhost/link http/::www.dx.com:p:4-wires-15a-240v-d12-5mm-micro-capsule-slip-ring-for-cctvmonitoring-robot-black-388255 - .WDXzrHcTmRu Electrical The Turbine Power Circuit shown is used to convert Alternating Current from each of the twostepper motor coils to Direct Current, smooth the signal and regulate the output. Turbine Power Circuit M R - R + - C C - M R C Vr Stepper Motor Full Wave Rectifier Capacitor Voltage Regulator + Vr + NEMA11 Vishay VS-2KBP005, Bridge Rectifier, 2A 50V, 4-Pin D 44 Panasonic 4700?F 25 V dc Aluminium Electrolytic Capacitor, FC Radial Series 5000h Magnatec L78S12CV, Single Linear Voltage Regulator, 2A 12 V, 3-Pin TO-220 RS Components Stock Numbers Stock no.: 468-1603 Stock no.: 315-0669 Stock no.: 633-032
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf Linearized : No Page Count : 16 PDF Version : 1.4 Title : Microsoft Word - Wind Turbine Doc.docx Producer : Mac OS X 10.12.1 Quartz PDFContext Creator : Word Create Date : 2016:11:26 20:36:20Z Modify Date : 2016:11:26 20:36:20ZEXIF Metadata provided by EXIF.tools