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Tag Archives: AIDG Wind Turbine

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The case for tiny wind energy

Jeremy in the belly of the wind turbine, with Nili supervising

Jeremy in the belly of the wind turbine, with Nili supervising

Editor’s note:  This is the second blog in a series related to the testing of the wind turbine at the NASA-Ames wind tunnel in Mountain View, CA.  Check out the first blog in the series for some context!

Working squeezed/scrunched up in the belly of the Army Aeroflightdynamics Directorate 7’x10’ wind tunnel gives one lots of time to think about the world and our place within it, and how these “tiny” wind generators (the term “micro” has already been claimed for systems up to 5000 watts) can help contribute to an improved quality of life for some.  Remember the target market is people who either have zero access to electricity, or who perhaps depend on charging worn out car batteries in distant grid connected towns – you pay bus drivers to transport your battery back and forth – to get a trickle of power.  How people use that first few watt-hours of high quality energy they have access to fascinates me, since while we sometimes have an impression that everyone else wastes scarce resources too, in reality people with scarcity tend to know the value of conservation and wise use best – especially when their costs are high.

Extending their day by a few hours with an efficient light is usually the first use – most unconnected places seem to be close to the equator where the days are always short, and recurring costs for candle/kerosene lighting are cumbersome/prohibitive – allowing people to read, do homework, and maybe even earn extra income.  Charging batteries – for flashlights, the radios all campesinos carry to the fields, and cell phones – is another priority, hopefully reducing the number of discarded disposable ones that litter the ground.  Both of these applications require very little energy – for us it would be worth just pennies worth a day, but for people who all year around are used to calling 6 pm bedtime… priceless!  And yes, one of the first appliances to appear is the ubiquitous television, often for soap operas and soccer matches, but also news and education.

Charlie investigating Chinese instream picohydro generators (~30 watts) in a Vietnamese market

Charlie investigating Chinese instream picohydro generators (~30 watts) in a Vietnamese market

Just a hundred watt-hours a day will do all kinds of things when the appliances are efficient, and in a breezy location it shouldn’t take an expensive turbine to provide this.  As a slightly technical aside, it is best to remember that people use energy to do things while we have a tendency to express the output of wind generators (and photovoltaic panels, and microhydro installations, and nuclear power plants) in units of power (watts).  The wind tunnel tells us how many watts we might generate at a given wind speed, but winds fluctuate so we can’t count on getting that much all of the time.  Commercial turbines are almost invariably rated just in watts, and you always have to ask “At what wind speed?” – and you’ll quickly find that they choose to rate at some phenomenal (and usually unrealistic) value, like 25 miles/hour (~11 meters/sec).  Southwest Windpower has now started doing the right thing by helping you estimate how much energy (in watt-hours… each one of these helping to perform a useful task, such as a one watt LED lamp aiding a kid do homework for one hour) you might expect to generate from their products, after making some assumptions about your local wind speed distribution.

This brings us to the question “How do we extract power (and energy) from the wind – which comes originally from the sun?”  The maximum power available from the wind, per square meter of turbine swept area, can be easily calculated from the equation

Power = ½ rAV3

where r is the density of air, A is the swept area of the turbine, and we see that the power increases as the cube of the windspeed (doubling the windspeed gives 8 times as much power), so that while there is lots of power produced at high wind speeds there is almost none available at very low speeds.  Our Lenz blades sweep out an area of .75 m2 (the Savonius configuration we tested is .45 m2) and we know that we can only realistically have a fraction of the energy the wind contains – Albert Benz said that 59% is the maximum, but more like 30-40% is typical for small tubines like ours.  So the amount of power you can tap into depends on how much the wind blows, and with like so many other things (like per capita income) the averages provided to us by the government don’t always do us enough good – some days it doesn’t blow, some days it blows too much, and luckily some days it blows just enough for your turbine to fill up your batteries for the

Weibull distribution (wind speed vs. probability) for an average wind speed of  6.6 m/s and a shape factor of 2.

Weibull distribution (wind speed vs. probability) for an average wind speed of 6.6 m/s and a shape factor of 2.

coming week.  That’s the concept of the distribution (vs. and average), and luckily the wind speed variability tends to follow a Weibull distribution, a statistical function, where just two variables describe the distribution.  These are the average wind speed and a number related to the general amount of time with no or low winds (the shape parameter), and this site does a much better job of explaining it than I can here – and they allow you to type in your power vs. wind speed data (such as from wind tunnel testing), plug in a shape factor, and get the anticipated energy output (say in watt-hours/day) at your target location.  Now you can buy the right number of storage batteries to get you through the wind-less doldrums, and compare the cost of your tiny wind system with your other electricity alternatives – including continuing to charge your car battery for the equivalent of $3/kW-hr, and waiting a long time for the grid to arrive.

Maximum power vs. wind speed of the Lenz 2 turbine configuration

Maximum power vs. wind speed of the Lenz 2 turbine configuration

Taking the raw wind tunnel data Tyler showed (torque and power vs. RPM) we can determine the maximum amount of power a given blade set or configuration can extract from the wind at each speed and plot it – that upward curved shape is very important because it tells us that not much power is available to us at low wind speeds (say, <10 mph) and this is an unfortunate fact of life.  Our experimental method did not include a generator to turn the winds power into the electrical power we need to run appliances, and there will be losses in this conversion process – we expect it to be ~75% efficient – so we have to take this into account, giving us the ability to get about 25% of the energy embodied in the wind – not bad if the resource is free.

As mentioned, a single “power rating” for a turbine is not very useful (and only meaningful if the wind speed it was measured at is associated with it), but people are used to hearing just one number so we may need one.  Catapult Design will tend to rate these turbines (a set of blades plus the associated generator) at more realistic wind speed values, like 15 mph (7 m/sec), and then we’ll do our best to try and characterize the wind resource at a specific locale.  If we choose to rate at 15 mph, for example, then the real power output of the Lenz blades is ~30 watts, and the wind will need to blow at that particular speed for ~3.5 hours/day to provide 100 watt-hours of energy per day to a family or small business.  Blowing at half that speed for twice as many hours does not do us much good, since the blades of VAWTs often don’t start turning until 8 mph, and at 10 mph we might have to rate these tiny turbines at only a watt or 3.  For estimation purposes, Weibull wind speed distributions with very low shape parameter values would be an example where it blows very little, much of the time.

blog5Its unfortunate that life is never as simple as it needs to be – it seems like that if a family wanted to consider buying a tiny turbine at X dollars, to decide whether it is worth it they need that power performance curve for it, decent information on their local wind conditions, and some idea how much electricity is worth to them (for example based on how much they are presently using and the cost for charging that car battery, or how much more they want to use – say if their neighbors pay them for charging cell phones).  Now if we just knew the probable lifetime and annual maintenance costs we could start to understand the cost of each future watt-hour… what an exercise, and don’t forget that investing in all forms of renewable energy is tantamount to buying at one time all the electricity you will use for the rest of your life, which is not an easy decision to make.

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Testing Our Turbines in the NASA-Ames/AFDD Wind Tunnel

NASA-Ames 7x10 wind tunnel

The end of September saw a major milestone completed on the wind turbine project – we finished our wind tunnel testing at the NASA-Ames research center! The experience was fantastic and so far we have been blown away by the quality and quantity of data we collected. While it is still a bit too soon to publish our complete test results here (we still have a lot of analysis to do), I nevertheless wanted to get started by explaining our test set-up and posting a few photos from the tunnel.

Test Set-up

Since the beginning of this project we have focused on two vertical-axis turbine designs: Savonius and Lenz (see photos below). The major purpose behind our wind tunnel testing was to characterize the performance of these turbines, allowing us to select the most promising design and move forward with developing the alternator that will generate the electricity. In order to characterize the turbines, we needed to collect data on how they perform in different wind speeds while under different loads.

Savonius & Lenz Turbines

The end result of this testing will be a series of power curves (see chart below) describing the mechanical energy generated by the turbine as a function of wind speed and turbine speed (rpm). We also explored three different angles of attack for the turbine blades on both turbine designs to see how they impacted turbine performance.

Lenz Power Curve

The theory behind our turbine test is this simple equation:

Power = Torque x Rotational Speed

When the wind blows it hits the turbine, causing it to spin. In spinning, the turbine converts the energy contained in the wind into mechanical power. In order for us to figure out just how much wind energy is converted into mechanical power we needed to place the turbine in a flow of wind with a known speed and then apply a known torque load to the turbine while measuring the effect of the load on the turbine’s rotational speed. Referring to the equation above, we would supply a known torque and measure the rotational speed, thereby allowing us to calculate power.

The way we mechanically applied the torque load was relatively straightforward. We coupled a DC motor to the bottom of the turbine shaft and tried to turn the motor opposite the direction of the turbine rotation (see image below). Since the torque produced by a DC motor is a function of current, we could apply a known load to the turbine by applying a known current to the motor.

Wind Turbine Test Set-up

This test set-up, while elegant, nevertheless proved problematic as the motor we sized proved unable to resist the amount of torque the turbine was generating and we quickly overheated the motor. Another way of applying torque to the turbine was needed, fast. Thankfully, the NASA-Ames facility is full of advanced testing labs, many of them working on rotating equipment. The day after we identified our problem we had a torque cell in-hand and connected to the turbine shaft (see image below).

Torque Cell

This torque cell contained a strain gage mounted on a shaft that output a voltage based on how much stress was applied to the shaft. One end of the shaft was attached to the turbine and the other end had a mountain bike disc brake attached to it that could apply a drag load that would slow the turbine and provide the strain that the gage would measure. This set-up allowed us to apply our known torque load as desired and the testing went on as planned. The only downside was that we were unable to maintain a steady torque and were forced to take our readings dynamically as the torque applied and turbine speed varied. This scenario was less than ideal, but we still managed to collect a copious amount of data that should allow us to compensate for any dynamic and inertial effects.

Ultimately we collected all the data we wanted and, at first blush, the results look great! My next blog post will focus on that data and our resulting analysis. Many thanks to Malcolm Knapp, Jeremy Kimmel, Sarah Felix, and Charlie Sellers who all devoted many days to the wind tunnel testing. Other Engineers Without Borders volunteers that played an important role are Jerry Pugh, Matt McLean, and Ann Torres. Finally, none of this would have happened without the help of Jose Navarette, Nili Gold, and Farid (all of whom work at the NASA-Ames facility), the technicians running the tunnel, and the generous donation of the facility by the US Army Aeroflightdynamics Directorate (which leases the tunnel from NASA).

To see more images of our wind tunnel tests, check out our Wind Tunnel album and watch the video below:

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Wind Tunnel Preparations

US Army Aeroflightdynamic Directorate

Since our last post the wind turbine team has been single-mindedly focused on our wind tunnel tests at the NASA-Ames research center. This testing opportunity will be a godsend for us as we will finally be able to get some clean, quality data concerning the performance of the two turbine styles we are evaluating: Savonius and Lenz. Good bye chasing wind around San Francisco!

What we are most excited about is the controllable nature of the wind tunnel and the ability we will have to set our test parameters. As a result of this unprecedented level of control, we will finally be able to apply a degree of rigor to our tests that has previously been unattainable. This more scientific approach will allow us to accurately predict not only the performance characteristics of the turbines, but also determine the appropriate alternator specifications for maximum power extraction from the system.

7x10 FT WIND TUNNEL

The tunnel in which we will perform the tests is a 7’x10’ wind tunnel owned by NASA, but leased to, and operated by, the US Army – specifically the Aeroflightdynamics Directorate (AFDD). We are extremely grateful to both the US Army and the folks at the test facility for their generosity and assistance. Without this unique opportunity, we would be hard pressed to continue making substantive progress with our turbine design.

Over the past handful of weeks Jeremy Kimmel, our wind turbine intern, and Malcolm Knapp, an EWB/Catapult volunteer, have been diligently working out the bugs in our set-up. Malcolm has spent countless hours programming the Data Acquisition System (DAQ) and they have both made a number of trips down to the test facility in order to ensure that we’ll be ready once the wind tunnel is ready for our appearance. Speaking of which, we’ve been told that we will finally get into the tunnel on August 17th! There have been a number of delays, but it is finally going to happen.

Below is a photo from our data collection training session just prior to shipping the turbine down to the NASA-Ames facility. We are fortunate enough to have an entire two weeks of dedicated wind tunnel time! During that period, Jeremy, Sarah, and Charlie will be leading our testing efforts and maintaining a constant presence at the tunnel. A number of other volunteers will cycle through to lend a hand and participate in this major testing milestone. Stay tuned for a post about our wind tunnel experience…

Left to right: Sarah Felix, Malcolm Knapp, Charlie Sellers, and Jeremy Kimmel

Left to right: Sarah Felix, Malcolm Knapp, Charlie Sellers, and Jeremy Kimmel

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Catapult, EWB featured in GOOD video

good_twitter1Catapult and EWB’s Wind Turbine Project is the latest to be featured in GOOD Magazine’s on-line video collection as part of the Harmony series, a GOOD/3rd Generation Prius endeavour highlighting people and organizations seeking a balance between man and nature.   Catapult and EWB’s Wind Turbine is in partnership with AIDG in Guatemala and is heading to the NASA-Ames wind tunnels on August 17, 2009 for final prototype testing. Read more about the project here.

Watch the video on GOOD or on our Press page.

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What is electricity worth?

The “holy grail” as it were of developing world solar power proponents is $1/watt. This is often seen as the point at which local electricity generation becomes affordable for the majority of the world’s population that do not currently have regular, reliable access to a regional electrical grid. This then begs the question, “Should $1/watt be the target of any new, small-scale renewable energy project?” Furthermore, if that price point appears unattainable is it foolhardy to chase after a technology that is otherwise very appealing? The only way we can know for certain is by dealing directly with our end-user to establish what they can afford and how much they will be willing to pay.

wind_solar1That said, it is still informative to thoroughly evaluate a technology to see how it fits into the panoply of options. This is exactly what we are attempting to do with our wind turbine and the testing we intend to conduct at the NASA-Ames research center. Our goal is to establish just how much mechanical power one can reasonably attempt to collect from the wind with a small, family-sized, vertical-axis wind turbine using the most promising blade designs we’ve encountered. Using the data we collect we should be able to estimate just how much it will cost per watt to simply capture the energy before turning it into electricity (this is based on the costs associated with building the turbine: blades, bearing, shaft, etc.). From there we will be able to predict just how much money we can afford to spend on the generator and circuitry and still achieve the price point our partner, AIDG, will help us establish (is is truly $1/watt or a more achievable $10/watt?). The amount of money available for the generator and circuitry based upon this price point will directly inform just how feasible this product may be for rural Guatemalan villages.

It could well be that the raw materials alone for the alternator simply price the whole concept above our acceptable price target; it is, after all, notoriously difficult to scale wind generation down and keep it cost-effective. As a rule of thumb, the larger a turbine is the less the electricity it generates costs per watt. We hope our tests prove that small, vertical-axis turbines are a promising avenue for additional design research (we’re fans of wind energy, after all), but the numbers won’t lie and should allow us to provide AIDG with a realistic evaluation as to how good an investment their continued development appears to be.

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Vast empty space

wtunnel1Quick pics from our first trip to the wind tunnels at NASA-Ames in Mountain View, California.  The wind turbine project is testing prototypes in the wind tunnels in May ‘09 and heavy in preparation for the visit.  NASA-Ames has three wind tunnels — a 7′x10′ tunnel, a 40′x80′ tunnel and an 80′x120′ tunnel, the world’s largest.  The experience is quite eery.  The tunnels are sound dampened to the extent that being inside makes you feel like you’re ears are plugged.  All voices are muffled, and both ends of the tunnel are shrouded in vast darkness.  It’s how I imagine the tip of the Earth would look if it was flat — peering off the edge into deep space.  The tunnels are a prominent landmark as you drive along Hwy 101 in the Bay Area and attract companies (and philanthropic groups!) worldwide for their use. More photos, blogs, and testing results to come!

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Prepare for lift-off

It’s looking more and more like our proposed NASA testing will indeed happen. In fact, the testing schedule has been accelerated and we’ve been told to be ready to go by the end of April! Thankfully we’ve already been hard at work getting our new Lenz blades built and sprucing up our old Savonius blades for prime time. In the below photo you can see Charlie assembling the “spines” of the Lenz blades over which well will affix some light plastic sheet. These blades reportedly have some very exciting performance characteristics and we’re looking forward to seeing how they perform in the tunnel.

windIn addition to making certain the turbine is mechanically ready for the wind tunnel we have also been busy jumping through the hoops that NASA and the Army (which manages the the 7′x10′ wind tunnel we’ll be using) sets up for all prospective wind tunnel users. One of those hoops is a “failure analysis” of the turbine and its component parts to ensure that the turbine won’t fail during testing and harm the tunnel or its operators.

At the suggestion of the extremely helpful tunnel technicians we’ve been working with we decided to forgo the analytical approach to failure analysis and instead go with real-world “proof” testing. This involves showing the turbine can withstand substantially larger loads than it is expected to see in the tunnel by calculating the maximum load it is should see in the tunnel, multiplying that of a factor (say four), and then subjecting the turbine to that load outside the tunnel. If it survives it should pose no threat to the tunnel at the loads it will see.

In this photo we are applying a 40 lb load horizontal to the middle of the turbine to simulate approximately four times the 11 lb force the turbine is expected to see if we test it to our proposed maximum speed of 25mph. I think it’s going to be ok.

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Cracking open the mold

Resin-cast stator based on 200W design by Hugh Piggott.

Resin-cast stator based on 200W design by Hugh Piggott.

This last Sunday we cracked open the mold for our new stator based on a 200W design by Hugh Piggott, and this is what we found.  The eight coils seen inside were cast in resin and fiberglass the week before (the colors are from crayon we used to coat the inside of the mold). While we hope to generate only 10% of what this stator was designed for, we decided that building a small alternator on an existing design would not only prove to be educational from a fabrication standpoint, but would also give us a well-understood baseline from which to proceed.  At some point I hope to slap this baby on the bottom of our turbine just to see what it will do.  After all, a direct drive alternator would be superior to a smaller, chain driven alternator for a whole host of reasons…

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Battling Mother Earth for wind…

Heather tests the turbine on Twin Peaks

Heather tests the turbine on Twin Peaks

‘Tis the season of no wind. And while it’s freezing cold outside, the sky is clear and annoyingly calm. In a desperate attempt to put some mileage on the Wind Turbine testing unit, a few of us drive up to Twin Peaks and draw a small crowd while we assemble our girl for testing. No wind — as the internet predicted.

(On the plus side, we captured some beautiful shots of the turbine with an SF backdrop!)

The testing unit (pictured above) is three plywood disks with blue plastic blades sandwiched inbetween. This arrangement is solely to enable quick-and-easy profile changes. Our objective: to experiment with the blade spacing, curvature, and width. A DAQ is connected to an anemometer, a force guage, and a tachometer collecting wind speed, force, and turbine rpm, respectively. From this info, the DAQ plots torque vs wind speed for each blade arrangement.

It’s week six or so of absolutely zero wind. We’ve exhausted our contacts trying to find a wind tunnel at Stanford, Berkeley, NASA-Ames, SLAC, etc. Time to play God and create our own wind. To build a wind tunnel, or to build a car mount system? While the latter would make for some hilarious visuals, a wind tunnel would bring consistency to testing. How easy is it to build a wind tunnel? No idea. We’ll find out. I’m convinced it can’t be that difficult — in fact, according to Heather’s highly technical sketch all we need is a plywood box and some fairly enormous fans (hmm, McMaster-Carr?). Now… where to store a wind tunnel?