tag:blogger.com,1999:blog-15484350102729609212024-03-07T01:02:23.764+05:00GREEN ENERGY ADVENTURE BY MECHANICAL ENGINEERKhalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.comBlogger43125tag:blogger.com,1999:blog-1548435010272960921.post-66948321158064203972013-02-13T13:36:00.001+05:002017-07-29T07:40:14.154+05:00WindMill Assembled<div dir="ltr" style="text-align: left;" trbidi="on">
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WindMill was assembled and with a minor wind got it rotation at No load. Still needs wiring and improvement in other things..<br />
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Let me show you a scary picture;)..My 4.5 year son standing near the windmill ..The windmill is not that fast but my camera can't capture the running object as stand still..<br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com13tag:blogger.com,1999:blog-1548435010272960921.post-41065233994502576372013-02-10T16:50:00.002+05:002017-07-29T07:40:14.058+05:00Back to The WindMill<div dir="ltr" style="text-align: left;" trbidi="on">
I am currently playing with three projects:<br />
1- WindMill (90% completed)<br />
2- Solar Concentrator (95% completed)<br />
3- Dual Axes Solar Tracking System (99% completed)<br />
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WindMill project needs more attention for long time. Yesterday did
some more work. The Generator was assembled on the structure. today made
Steel plate for holding the blades. As the blades are made out of 10mm
thick PVC pipe. To attach the blade on the plate i need to add a wooden
fixture between the blade and steel plate. This wooden structure should
have flat at bottom and profiled at top. The Flat bottom shall rest on
the steel plate whereas the blade will fixed on profile of wooden
fixture.<br />
I scanned a portion of PVC blade to get the profile vector of it and then made the 3D model for CNC machining. <br />
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You can see a piece of PVC blade perfectly fit on the CNC machined fixture.<br />
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I hope in few days i will start wiring of the windmill.<br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com5tag:blogger.com,1999:blog-1548435010272960921.post-14854761404617436242013-02-01T20:04:00.000+05:002017-07-29T07:40:13.997+05:00Can Concentrated Solar Power generate MW of electricity?<div dir="ltr" style="text-align: left;" trbidi="on">
<b>Concentrated solar power</b> (also called <b>concentrating solar power</b>, <b>concentrated solar thermal</b>, and <b>CSP</b>) systems use mirrors or lenses to concentrate a large area of sunlight, or solar thermal energy, onto a small area. Electrical power is produced when the concentrated light is converted to heat, which drives a heat engine (usually a steam turbine) connected to an electrical power generator.<br />
<br />
CSP is being widely commercialized and the CSP market has seen about 740 MW
of generating capacity added between 2007 and the end of 2010. More
than half of this (about 478 MW) was installed during 2010, bringing the
global total to 1095 MW. Spain added 400 MW in 2010, taking the global
lead with a total of 632 MW, while the US ended the year with 509 MW
after adding 78 MW, including two fossil–CSP hybrid plants.<sup class="reference" id="cite_ref-saw2011_1-0"></sup><br />
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CSP growth is expected to continue at a fast pace. As of April 2011,
another 946 MW of capacity was under construction in Spain with total
new capacity of 1,789 MW expected to be in operation by the end of 2013.
A further <b>1.5 GW of parabolic-trough and power-tower plants were under
construction in the US, and contracts signed for at least another 6.2
GW.</b> Interest is also notable in North Africa and the Middle East, as
well as India and China. The global market has been dominated by
parabolic-trough plants, which account for 90 percent of CSP plants.<br />
<sup class="reference" id="cite_ref-saw2011_1-1"></sup><br />
Concentrating technologies exist in four common forms, namely parabolic trough, dish Stirling, concentrating linear Fresnel reflector, and solar power tower.<br />
<br />
I am thinking of making small scale steam turbine from the plans:<br />
<a href="http://www.greensteamengine.com/products.htm">http://www.greensteamengine.com/products.htm</a> </div>
Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com8tag:blogger.com,1999:blog-1548435010272960921.post-1239258914029613702013-02-01T19:57:00.006+05:002017-07-29T07:40:13.991+05:00My approach to Parabolic Solar Concentrator<div dir="ltr" style="text-align: left;" trbidi="on">
Recently purchased a small satellite dish for making a parabolic solar concentrator. The idea was to take a feel of the heat it will generate.<br />
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I pasted 1 inch square mirror pieces with resin on the dish. It took more than 03 hours to mount hundreds of them. In the morning i just brought it into sun and viola in 03 seconds it started smoldering wood and other plastic things. It was a good start:<br />
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Some more experiment and temperature monitoring yet to be done. I shall check the maximum temperature attain on the focal point and will expand this topic here.<br />
<br />
The initial results are very promising so far. I am surprised the abundant heat generation with this method. I am seriously thinking of using this heat.<br />
<br />
I have an idea to make a bigger custom parabolic structure and mount flat mirrors on it.Installation of two axes sun-tracking and mounting a small boiler at the focal point. <b>Use the generated steam to run small turbine to generate electricity.</b><br />
<br />
Oh really.. should i have to design the steam turbine and fabricate it? How much steam it shall require to generate atleast 500watts of electricity from the generator? How big the parabolic concentrator to give me continuous steam for running turbine?<br />
<br />
Can i avoid generating electricity by using steam turbine? any other way to make electricity ?<br />
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<br />
May be we able to make some simple system to harness this heat.. <b>Thermodynamics is all about the temperature difference ;) </b><br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com3tag:blogger.com,1999:blog-1548435010272960921.post-46002538032583019242012-12-27T20:26:00.000+05:002017-07-29T07:40:14.081+05:00Dual Axes SunTracker with Advanced Options<div dir="ltr" style="text-align: left;" trbidi="on">
<br />
Finally i came up with the new efficient algorithm for the dual axes sun tracking system. The tracker is menu based , parameters can be set with 6-keys keypad with following functionalities:<br />
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<br />
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">1-
Single Axis or Dual Axis control settings</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">2-
12VDC / 24V DC motor (windshield car motors etc) or Linear Actuator (Peak Current 10Amp)</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">3- PWM
based motor controller. The PWM value is selectable from Menu.(0~100% duty
cycle)</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">4-
Return East Options (a- On Limit Switch stoppage based or -b- Time based)</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">5- User
Selectable Tracking Delay</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">6- Load
Sequencing management</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">7- Dark
return Time setting</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">8-
Twilight Time settings (after the twilight Dark return Time started)</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">9- RJ45
connectors for sensors</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">10-
Sensors sensitivity settings</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">11-
Highly efficient tracking Algorithm</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">12-Drive
Off sun position setting</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">13-Easy
menu driven parameters settings</span></span></div>
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<span style="font-size: small;"><span style="font-family: inherit;">14-
Saving Parameters values in EEPROM</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">15-Compact
and easy to install</span></span></div>
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<span style="font-size: small;"><span style="font-family: inherit;">16-Northern/Southern
Hemisphere Compatible</span></span></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBRv0RsENGOJ0E5ldcPWk00BHRd4n8-VanwOAdve2ANFODDjhEgL-aJa7WfCypnwP3tyjyVlDNjaHGU7NVKcBVhdHKPMg5ZH1EIy3yQ8wa0QZvUs2ptgoshJ-UQoU-GQD6xZGkujxLiQ/s1600/dua+axis+sun+tracker.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="190" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBRv0RsENGOJ0E5ldcPWk00BHRd4n8-VanwOAdve2ANFODDjhEgL-aJa7WfCypnwP3tyjyVlDNjaHGU7NVKcBVhdHKPMg5ZH1EIy3yQ8wa0QZvUs2ptgoshJ-UQoU-GQD6xZGkujxLiQ/s400/dua+axis+sun+tracker.png" width="400" /></a></div>
LCD, Keypad and sensor:<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0juyceQNML3tFymkXlGbddGxUP0Xi7HxJeLJeVGbES3ge_MP_J_b7FbMn4H29rlUccJeBqfNla9Yjb3NWpHa-CAn9Pdnz-U2SPQ6DfHxn66mIRGKgTGbHq8v1el84mMAscwoYBtc9iQ/s1600/Sensor+lcd+keypad.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="270" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0juyceQNML3tFymkXlGbddGxUP0Xi7HxJeLJeVGbES3ge_MP_J_b7FbMn4H29rlUccJeBqfNla9Yjb3NWpHa-CAn9Pdnz-U2SPQ6DfHxn66mIRGKgTGbHq8v1el84mMAscwoYBtc9iQ/s320/Sensor+lcd+keypad.jpg" width="320" /></a></div>
<br />
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<br />
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">I am
still adding much more features as it is micro-controller driven..</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<b><span style="font-size: small;"><span style="font-family: inherit;"><span style="font-size: small;">M</span>odular
type:</span></span></b></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">1- Main
Controller (Price Range 30~45 US dollar)</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">2- PWM
DC Motor Controller (10 ~15 US dollar)</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">3- Sun
Tracking sensors (single axis or dual axis) (5~10 US dollar)</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">4- 20x4
backlight LCD with control circuit ( 12~15 US dollar)</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">5- six
Key keypad (2 US dollar)</span></span></div>
<div class="MsoNormal" style="line-height: normal; margin-bottom: 0.0001pt;">
<span style="font-size: small;"><span style="font-family: inherit;">6-
Optional controller to sensor wiring</span></span></div>
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com7tag:blogger.com,1999:blog-1548435010272960921.post-38690992772363511402012-10-02T20:20:00.003+05:002017-07-29T07:40:14.047+05:00Mistakes... I think i am learning new things...<div dir="ltr" style="text-align: left;" trbidi="on">
One more addition of foolish blunder in my life<img alt="" border="0" class="inlineimg" src="http://www.talkshopbot.com/forum/images/smilies/biggrin.gif" title="Big Grin" /> below i posted a CAD drawing snap of the magnetic plate and stator...
Something is very wrong in it.. 12 magnets and 12 coils... Its not
possible<img alt="" border="0" class="inlineimg" src="http://www.talkshopbot.com/forum/images/smilies/biggrin.gif" title="Big Grin" /><br />
<br />
After casting and painting the magnetic plates and making 9 coils when i
assembled the coils around the magnets i feel that i have wide gaps
between the coils...
Then i consulted the drawing i made earlier, their were 12 coils.. what a nonsense... no way... This should be 9 coils...not more not less...<img alt="" border="0" class="inlineimg" src="http://www.talkshopbot.com/forum/images/smilies/rolleyes.gif" title="Roll Eyes (Sarcastic)" /><br />
<br />
So i have to destroy the magnetic plates for salvaging the magnets... Now i am going to make new magnetic plates with small diameters...This is a good thing..but why this happen, its still needs to be figured out.. this regularly happens in my life and reminds me i am a human and not a genius.<img alt="" border="0" class="inlineimg" src="http://www.talkshopbot.com/forum/images/smilies/rolleyes.gif" title="Roll Eyes (Sarcastic)" /><br />
<br />
Back to the drawing board, corrected the entire things... I am posting the improved coil winder picture that made my life easy.
It took 40minutes to make 9 coils, each 110turn with 1.5mm dia laminated
wire (SWG17)<img alt="" border="0" class="inlineimg" src="http://www.talkshopbot.com/forum/images/smilies/smile.gif" title="Smile" /><br />
<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTvj4_GpgRtohbJFGmWaai9-4WoZCHDARnzgw9JpliPBN5uDRGBzJF58ne4-MUkigRZTg5FkJuEoFXo5IZHMKRMkwDHc1oiJ9ge3fhSvwGHuyifuCNwuthTo9eaf2ZmzSUQ3nHqWhrNQ/s1600/coil+winder.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTvj4_GpgRtohbJFGmWaai9-4WoZCHDARnzgw9JpliPBN5uDRGBzJF58ne4-MUkigRZTg5FkJuEoFXo5IZHMKRMkwDHc1oiJ9ge3fhSvwGHuyifuCNwuthTo9eaf2ZmzSUQ3nHqWhrNQ/s320/coil+winder.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGfBS6IiCRSSeOYypIV6eCAhQvagfjs-omnTpfSW8gqNJtrLOGePsrkDDBYCybcWUWvVp5yuYpTSDKvbbg5rgDarmRhSD_t0omUAOk1Q1tbEd2_ByqKrJ8kNJ65-HFK-uDe9YQ3zLwlg/s1600/coils.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><br /></a></div>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivJXK4xu_QPR2CBlCSi-QLLRg5MBypjaVFYQM3nATB126vjRgW421hNDZtU0m2UyFbgYcQg5uxriqfcvMB7Q0qyytnP9PbmPM4eDfYm99vPsHHAvU7-Zq_5AqxrH2FoIvAyrn7ro8kJw/s1600/stator+new1.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"></a>
You can see i am arranging the coil for resin casting. I am using
electrical glass tape for high temperature. i know some time the
temperature of the coil will be high during high winds and not want to
make another blunder by using the simple tape.<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGfBS6IiCRSSeOYypIV6eCAhQvagfjs-omnTpfSW8gqNJtrLOGePsrkDDBYCybcWUWvVp5yuYpTSDKvbbg5rgDarmRhSD_t0omUAOk1Q1tbEd2_ByqKrJ8kNJ65-HFK-uDe9YQ3zLwlg/s1600/coils.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGfBS6IiCRSSeOYypIV6eCAhQvagfjs-omnTpfSW8gqNJtrLOGePsrkDDBYCybcWUWvVp5yuYpTSDKvbbg5rgDarmRhSD_t0omUAOk1Q1tbEd2_ByqKrJ8kNJ65-HFK-uDe9YQ3zLwlg/s400/coils.jpg" width="400" /></a><br />
In the drawing you can see rectangle magnets, its 3 phase , so if you
see closely the purple coils are at the center of magnets. It means they
are providing the full voltage at this condition. the other coils are
in the middle of high voltage range when the purple coils are at high
peak voltage.<br />
<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivJXK4xu_QPR2CBlCSi-QLLRg5MBypjaVFYQM3nATB126vjRgW421hNDZtU0m2UyFbgYcQg5uxriqfcvMB7Q0qyytnP9PbmPM4eDfYm99vPsHHAvU7-Zq_5AqxrH2FoIvAyrn7ro8kJw/s1600/stator+new1.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="197" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivJXK4xu_QPR2CBlCSi-QLLRg5MBypjaVFYQM3nATB126vjRgW421hNDZtU0m2UyFbgYcQg5uxriqfcvMB7Q0qyytnP9PbmPM4eDfYm99vPsHHAvU7-Zq_5AqxrH2FoIvAyrn7ro8kJw/s400/stator+new1.jpg" width="400" /></a></div>
<br />
<br />
<br />
PS:<br />
i have made the coils first, then measured the dimensions and reverse
engineer the magnetic plates. i think this is the easy way to go.<br />
<br />
<br />
<span style="font-family: Times,"Times New Roman",serif;"><span style="font-size: large;"><span class="huge">"Sometimes when you innovate, you make mistakes. It is
best to admit them quickly, and get on with improving your other
innovations.</span> "</span></span></div>
Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com3tag:blogger.com,1999:blog-1548435010272960921.post-74538288112216569432012-09-23T21:03:00.003+05:002017-07-29T07:40:14.177+05:00Test Coil, Country flag and Turbine blades<div dir="ltr" style="text-align: left;" trbidi="on">
<br />
I made a test coil winder earlier and today i made one coil with 37
turns. I didn't add any varnish coat but the coil is difficult to remove
from the fixture <img alt="" border="0" class="inlineimg" src="http://www.talkshopbot.com/forum/images/smilies/wink.gif" title="Wink" /> ... I shall make another simple jig tomorrow that will ease up removing the coil without destroying it.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGuWVbTBCxJOXDzqfp1hTH9AwsIbhF_U4w63_RKYwZr5UTvOE3puWfTb_oTWTeKRHNN1m1RHHwtoMO5m6JVts_Gh_TLI6G9NPJcdO8mVBmNQ-_EPJ3GTWflUR1p-KczVZMYb4VUPcT6g/s1600/coil.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="282" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGuWVbTBCxJOXDzqfp1hTH9AwsIbhF_U4w63_RKYwZr5UTvOE3puWfTb_oTWTeKRHNN1m1RHHwtoMO5m6JVts_Gh_TLI6G9NPJcdO8mVBmNQ-_EPJ3GTWflUR1p-KczVZMYb4VUPcT6g/s400/coil.jpg" width="400" /></a></div>
<br />
<br />
"<b><span style="color: red;">Roman</span></b>" at cnczone posted a helping post
in my thread about Coil winding , following are his words for
everybody who need to wind the coils:<br />
<br />
<span style="color: purple;"><i>"About your coil winding jig, I have done many coils and even
worked in an electrical motor shop that had a few commercial coil
winders.<br />
<br />
Suggestion 1; Put the jig on the end of a portable electric drill (with a
speed control) and then it can wind automatically. A lathe is also
good if it has a low speed. <br />
<br />
Suggestion 2; You can paint the coil with varnish or nail polish every
layer as you wind it, which will then be a reliable solid coil when
done. However this will stick badly to your coil former. If you made the
coil former from polyethelene (like food chopping board) the glue will
not stick and you can make solid coils then pop them off the former.
You might need a small taper on the middle round part, to slide out of
the coil. <br />
<br />
The magnetic forces on the windings will be high, so somehow they need
to be set in resin or varnish. Otherwise if there is any air in the coil
the windings will flex and rub because of the magnetic field and soon
wear through the insulation and fail. <br />
<br />
If putting a dry winding in resin we would put in a vacuum chamber to
make sure the resin goes through the coil and no air is present. It is
easier to varnish the coil as you wind it, every layer, so I would go
for the polyethelene former and do that. Varnish type is not that
important, quick dry nail polish is an acrylic and will be strong and
bond well later when you set the hard coil into the former with resin." </i></span><br />
<br />
I hand rotated the magnetic plates and got 1.5Volts (don't know about
the RPM) with single test coil. Tomorrow i shall borrow a stroboscope
and will plot a graph between RPM and Voltages. following is the formula
to get estimated cut in voltages.<br />
<span style="font-family: "Trebuchet MS",sans-serif;"><b><br /><span style="color: blue;"><span style="font-size: x-small;">Required Cut in Voltages= VAC(of test coil at cut-in speed) x No. of
coils/phase x1.732(multiplication factor for 3 phase)x1.414 (DC
conversion factor) - 1.4V (diode drop)</span></span></b>
</span><br />
<br />
The cut-in speed i shall keep around 150~200RPM. You can see pictures of
furling flapper that is turned into flag of my country.<br />
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<br />
Three PVC
blades 6feet each worked out by my brother one year back . The blades
are big you can see pen kept on the center blade for comparison.<br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com1tag:blogger.com,1999:blog-1548435010272960921.post-8836271823981423802012-09-21T13:48:00.001+05:002017-07-29T07:40:14.232+05:00Wind Mill Charge Controller arrived<div dir="ltr" style="text-align: left;" trbidi="on">
At last i received the wind mill charge controller. It took about 15 days to reach at my door step from Hong Kong port :).. It seems very solid and i have also recieved the software CD to monitor various parameters of the wind turbine.<br />
I also completed the furling tail flapper. <br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com0tag:blogger.com,1999:blog-1548435010272960921.post-6692867209724475562012-09-14T21:19:00.000+05:002017-07-29T07:40:14.148+05:00Birthday of My son<div dir="ltr" style="text-align: left;" trbidi="on">
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com1tag:blogger.com,1999:blog-1548435010272960921.post-92052650367503968492012-09-14T16:05:00.001+05:002017-07-29T07:40:14.240+05:00Coil Winder Jig completed<div dir="ltr" style="text-align: left;" trbidi="on">
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I have completed the coil winding jig. Meanwhile, i purchased the copper laminated wires SWG 17 number for making coil. The price of laminated wire per Kg is 11US dollar. I purchased 5.5Kg of laminated wire. <br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com1tag:blogger.com,1999:blog-1548435010272960921.post-12311840003459132562012-09-10T21:15:00.001+05:002017-07-29T07:40:13.977+05:00Fiber Glass Resin Casting of magnetic Plates<div dir="ltr" style="text-align: left;" trbidi="on">
Yesterday, after two failed attempts of fiberglass resin casting of magnetic plates i at last succeeded. <br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com0tag:blogger.com,1999:blog-1548435010272960921.post-26359532090989213612012-09-07T21:10:00.003+05:002017-07-29T07:40:14.023+05:00Alternator mount Frame and Furling completed<div dir="ltr" style="text-align: left;" trbidi="on">
Today i have completed the Alternator mount frame and furling design. I cut the 55 degree triangular jig which make the whole assembling process very easy and timely.<br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com0tag:blogger.com,1999:blog-1548435010272960921.post-17057054056088612072012-09-06T17:49:00.000+05:002017-07-29T07:40:14.005+05:00Beware of Advertisements- Chinese Wind Turbines <div dir="ltr" style="text-align: left;" trbidi="on">
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Recently I spent some time going over ads for micro turbines, and there's
lots of interesting claims out there. So before anybody parts with their hard
earned cash some wind math is in order. <br />
<br />
A case in point is an ad for a micro turbine:<br />
"<i>We build these wind turbines to provide 1200watts of power. They are
suitable for charging 12/24/48 volt battery systems....in winds over 4-5mph
(6.4-8kph or 1.7-2.2ms)...Brand new 24” (.61m) blades."</i><br />
<br />
Wow, 1.2kW from a 48" (1.22m) diameter blade. Unless you live in a wind
tunnel you'll never see that kind of an output.<br />
<br />
The most energy you can extract is 59.3% of the total kinetic energy contained
in the wind. Most small scale turbines operate much lower then that, while
industrial turbines approach it, but still can't get there.<br />
<br />
According to the Bertz co-efficient you would need a sustained wind of 27mph
(43kph or 11.9ms) to get 1200w from a 48" (1.2m) or 4ft blade (Wind turbine diameter=8ft). To come to this
number we need to use some wind math;<br />
---------------------------------------------------------------------------------------------------------<br />
First we need the swept area of the rotor; <br />
Area = π x (blade diameter x blade diameter) / 4 <br />
Using the above ad - 3.1416 x (1.22 x 1.22) / 4 = 3.1416 x 1.4884 / 4 = 1.17m2<br />
---------------------------------------------------------------------------------------------------------<br />
Power in watts = .5 x air density x swept area x wind velocity<sup>3</sup><br />
Where - air density (@ sea level) = 1.23kg/m3<br />
- swept
area in m2<br />
-
velocity in meters per second<br />
So.......... .5 x 1.23 x 1.17 x 5.5ms3 (5.5ms is my areas average wind speed)<br />
.5
x 1.23 x 1.17 x 166.37 = 117.91 watts<br />
--------------------------------------------------------------------------------------------------------------------------<br />
Now lets try doubling the blade area;<br />
.5 x 1.23 x 2.34 x 5.5m/s3 = .5 x 1.23 x 2.34 x 166.37 = 239.42 watts<br />
*Doubling the blade diameter roughly doubles the power output.<br />
--------------------------------------------------------------------------------------------------------------------------<br />
Now lets use the original swept area and double the wind speed;<br />
.5 x 1.23 x 1.17 x 11m/s3 = .5 x 1.23 x 1.17 x 1331 = 957.72 watts<br />
*Doubling the wind speed roughly increases 8x the original power output. Yet
we're still not at the 1200watts from the original ad.<br />
--------------------------------------------------------------------------------------------------------------------------<br />
Using 43kph wind speeds;<br />
.5 x 1.23 x 1.17 x 11.95m/s3 = .5 x 1.23 x 1.17 x 1706.49 = 1227.9 watts<br />
Wind speeds like this happen very rarely in most areas of the world. <br />
<br />
<br />
Below is a spreadsheet showing output at different wind speeds using the above 3meter (9ft) diameter wind mill.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimaENzm51QGzQJoUb01Bq7SqZCXwuOn6a6xOCW0yUxivLvn_o0zNggnEnWFqsi9A4FkWayy8vqkPGYvEnoW0TEp3ZgQZ6JK3spETeh5_9Vo5hFNrwCR4SxreoH85VywkoL3X1PMhR45g/s1600/blade+dia+with+changing+wind+speed.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="185" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimaENzm51QGzQJoUb01Bq7SqZCXwuOn6a6xOCW0yUxivLvn_o0zNggnEnWFqsi9A4FkWayy8vqkPGYvEnoW0TEp3ZgQZ6JK3spETeh5_9Vo5hFNrwCR4SxreoH85VywkoL3X1PMhR45g/s400/blade+dia+with+changing+wind+speed.jpg" width="400" /></a></div>
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com1tag:blogger.com,1999:blog-1548435010272960921.post-77112636001724995412012-09-05T21:11:00.000+05:002017-07-29T07:40:14.183+05:00More CNC and Metal work<div dir="ltr" style="text-align: left;" trbidi="on">
Today i machined the template for marking the position of Stator Holes on the structural frame. This template shall also be used for Resin casting. Moreover, the metallic structure for mounting the wheel hub and magnetic plate is also fabricated. Some snap shots of today's work.<br />
<br />
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The picture shows an Antique drill machine in local workshop where the structure being fabricated.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCEcJ_sEXRJ5kFpOolzwm22MgormNUbjIpYHTFMzweEGBxOFtkJRzoH3tfVZDz-zEnDwIzF38ituyv0ZhEydMM0gOdhCTLveNMQBmcmnEA6Pf4MjP4Py1NPAqZ-TmGWsFAvMLDCwlpYA/s1600/Antique+drill.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCEcJ_sEXRJ5kFpOolzwm22MgormNUbjIpYHTFMzweEGBxOFtkJRzoH3tfVZDz-zEnDwIzF38ituyv0ZhEydMM0gOdhCTLveNMQBmcmnEA6Pf4MjP4Py1NPAqZ-TmGWsFAvMLDCwlpYA/s400/Antique+drill.jpg" width="400" /></a></div>
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com1tag:blogger.com,1999:blog-1548435010272960921.post-19615671129394667712012-09-04T20:30:00.001+05:002017-07-29T07:40:14.013+05:00Precision Parts and Progress Updates<div dir="ltr" style="text-align: left;" trbidi="on">
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As the drawing development in progress so the parts coming out from my home made CNC machine.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8pauGE5Y95pzaiD2U_E-03TPvFj2LS7c064Te8LY7CdnEQC8ua1K1YouldgGSa3eD3ZhhYyFPIE68xaIngHxbuWNWuHPrSc3jBNtqjeDDX6Rqs3Z5EH_MHvquIqy4cWEYHtGZv3HG_Q/s1600/wind+mill+drawing+progress.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="207" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8pauGE5Y95pzaiD2U_E-03TPvFj2LS7c064Te8LY7CdnEQC8ua1K1YouldgGSa3eD3ZhhYyFPIE68xaIngHxbuWNWuHPrSc3jBNtqjeDDX6Rqs3Z5EH_MHvquIqy4cWEYHtGZv3HG_Q/s320/wind+mill+drawing+progress.png" width="320" /></a></div>
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Some MDF template along-with actual metallic parts.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtbKpFnhWhDSfMWDVve5plOjXmsht7gPnUSW5w01QKFZiKRa2Ey6GqCd4CqcizlwrH7uuLiEVYmHFqcEH39_K7uIELv9MTBR8wpv29vT9BjFODpA29KbnCZ_vXjsrfA0ITdbytvOjgOA/s1600/wind+mill+parts.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtbKpFnhWhDSfMWDVve5plOjXmsht7gPnUSW5w01QKFZiKRa2Ey6GqCd4CqcizlwrH7uuLiEVYmHFqcEH39_K7uIELv9MTBR8wpv29vT9BjFODpA29KbnCZ_vXjsrfA0ITdbytvOjgOA/s320/wind+mill+parts.jpg" width="320" /></a></div>
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You can see how accurate the MDF part produced with my home made CNC router compared to a metallic part produced with a precision industrial CNC machine.<br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com2tag:blogger.com,1999:blog-1548435010272960921.post-67585256765707475222012-09-01T18:43:00.004+05:002017-07-29T07:40:14.159+05:00CNC Machining of Coil winder<div dir="ltr" style="text-align: left;" trbidi="on">
Today completed the coil winder on my CNC machine.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6dU0o2UyhNnk15fk-745QzkCYS8ZD11IwuUwovxSvTiqSM_xoixzQoO475sId80yyxQVB4H9ieBfSgBA_swujRtueRZyJwMmCxsIvvKxZWLMGwtChbVdmfpd8iC-n-Am74s8GBWQcRw/s1600/coil+winder.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="183" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6dU0o2UyhNnk15fk-745QzkCYS8ZD11IwuUwovxSvTiqSM_xoixzQoO475sId80yyxQVB4H9ieBfSgBA_swujRtueRZyJwMmCxsIvvKxZWLMGwtChbVdmfpd8iC-n-Am74s8GBWQcRw/s320/coil+winder.png" width="320" /></a></div>
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the CNC machining process.<br />
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Checked the fitup of the coil winding mockup on the magnets and its perfect.<br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com8tag:blogger.com,1999:blog-1548435010272960921.post-21596177866904795812012-09-01T17:23:00.000+05:002017-07-29T07:40:14.018+05:00Wind-Solar Hybrid Charge Controller on its way<div dir="ltr" style="text-align: left;" trbidi="on">
Today i purchased the Wind Solar hybrid charge controller with following parameters:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqRPSadPigvTpMwKpx285UUD-NXWc_F_-Nb21Tm2IOa8S9qMpmgQQp_mF5u5kkHip8GBj8dsK44q1c93ds3XV0H91PzeSF-h_5H6nqzhzPODNOraj20HNbtna3u_2iZmdeBUoZpuPNtQ/s1600/wind+charge+controller.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="147" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqRPSadPigvTpMwKpx285UUD-NXWc_F_-Nb21Tm2IOa8S9qMpmgQQp_mF5u5kkHip8GBj8dsK44q1c93ds3XV0H91PzeSF-h_5H6nqzhzPODNOraj20HNbtna3u_2iZmdeBUoZpuPNtQ/s320/wind+charge+controller.jpg" width="320" /></a></div>
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<table align="left" border="1" cellpadding="0" cellspacing="0"><tbody>
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Rated Battery Voltage</div>
</td><td><div align="center">
24V</div>
</td></tr>
<tr><td><div align="left">
Rated Wind Turbine Power</div>
</td><td><div align="center">
600W</div>
</td></tr>
<tr><td><div align="left">
Wind Turbine Maximum Input Current</div>
</td><td><div align="center">
40A</div>
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Wind Turbine Maximum Input Power</div>
</td><td><div align="center">
1000W</div>
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Unload Voltage(factory default)</div>
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28V</div>
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Unload Current(factory default)</div>
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25A</div>
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Rated Solar Power</div>
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300W</div>
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Battery Over Discharge Voltage Shutoff</div>
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22V</div>
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Battery Over Discharge Recovery</div>
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24V</div>
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Output Protection Voltage</div>
</td><td><div align="center">
32V</div>
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Display Mode</div>
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LCD</div>
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Display Parameters</div>
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Wind Turbine Power, Wind Turbine Voltage, Wind Turbine Current, PV Voltage, PV Charge Current, PV Power, Battery Voltage,</div>
<div align="center">
Over Voltage, Under Voltage, Over Load, Short Circuit, Night. Etc</div>
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com1tag:blogger.com,1999:blog-1548435010272960921.post-5939045280052485722012-08-31T18:54:00.001+05:002017-07-29T07:40:14.136+05:00CNC Mold Machining for magnetic plates Resin Casting<div dir="ltr" style="text-align: left;" trbidi="on">
Today i CNC machined the molds out of 12mm thick MDF for resin casting of magnetic plates.The tool used was 8mm end mill at 70inch/minute using 3mm per pass depth of cut. The mold machining took 35minutes on the CNC router. The cast resin will help bounding the magnet with the CS plates so that the magnets stay at high RPM.<br />
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Hole drilling started on my home made CNC machine.<br />
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and the rest of the pictures are below.<br />
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and the magnetic plate fitted exactly in the MDF mold as desired.<br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com2tag:blogger.com,1999:blog-1548435010272960921.post-58758551159367737212012-08-30T10:16:00.000+05:002017-07-29T07:40:14.128+05:00Wind Mill Fabrication Started<div dir="ltr" style="text-align: left;" trbidi="on">
I have been collecting components for few years for fabrication of 1KW horizontal axis wind turbine diameter 12 foot. Last year i purchased 24 Magnets Rs.500Ea, a Car wheel hub for making the axial flux generator for the turbine.<br />
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Recently did some activities for making this wind turbine functional till the end of September 2012. Structure being fabricated in local market. I have made the CAD model of Wind turbine blades using NACA 2412 profile.<br />
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Here is the Magnetic plates of the Axial flux wind turbine.<br />
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Here is the average wind speed data and other parameters for Karachi.<br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com0tag:blogger.com,1999:blog-1548435010272960921.post-83835620583853125872012-08-29T23:27:00.000+05:002017-07-29T07:40:14.202+05:00Wind Mill (max 1kWatt) Started<div dir="ltr" style="text-align: left;" trbidi="on">
Today i got the time to start wind mill project. Last year i collected some of the parts for the win mill including the 24 powerful magnets and car wheel hub.<br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com1tag:blogger.com,1999:blog-1548435010272960921.post-39412674377395125362012-08-23T20:57:00.002+05:002017-07-29T07:40:14.053+05:00More advanced and Compact All New Sun Tracker<div dir="ltr" style="text-align: left;" trbidi="on">
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After loosing all the data from crashed hard drive, I started drawing the electronic circuit from scratch.This is all new sun tracker with multiple features. LCD Menu driven and more advanced and compact as compared to previous one.<br />
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Some complex programming yet to be carried out:)</div>
Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com1tag:blogger.com,1999:blog-1548435010272960921.post-37013216618195225272012-07-22T14:23:00.000+05:002017-07-29T07:40:14.034+05:00Improved Wiring<div dir="ltr" style="text-align: left;" trbidi="on">
Here is the improved wiring of solar panel setup. One of the picture shows 300 watts output from solar panels being fed into the batteries.<br />
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<br /></div>Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com0tag:blogger.com,1999:blog-1548435010272960921.post-9105367522441896862012-07-12T21:22:00.001+05:002017-07-29T07:40:14.236+05:00End of Episode-1<div dir="ltr" style="text-align: left;" trbidi="on">
Truly speaking there is nothing in the world like a<b> joy</b> of accomplishment...The adventure i started almost a year ago ended up quite nicely... The target achieved was well-worth of experience with a steep learning curve... This endeavor encompasses many failures but i think their is no gain without learning from failures...<br />
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Yesterday i installed the solar system at my Karachi home and got the results as desired. Today when i sleep getting cool breeze of Air-conditioner i can feel a bit of relief while thinking of my family at Karachi.<br />
In near future i shall install six more panels on the same structure. This structure can withstand easily 12 solar panels total wattage up-to 1200Watts..<br />
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The racks are under fabrication for holding the batteries and UPS stuff...<br />
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Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com1tag:blogger.com,1999:blog-1548435010272960921.post-52819744163333219742012-06-27T21:03:00.002+05:002017-07-29T07:40:14.103+05:00Today was a Sad Day :(<div dir="ltr" style="text-align: left;" trbidi="on">
Yes a sad and awful day indeed... In a couple of month lot of set backs happens in my life... In this month some of my sweet dreams turned into scary nightmares...some of my hopes and wishes washed away... and today was another sad day...<br />
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Alas, my laptop hard disk crashed without any signature... It showed no indication of failure.... All the family photos, my 1 year of research and lot of programming applications, my circuits and all good stuff went into holy grave :(..<br />
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Yes.. Today is very sad day ...</div>Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com0tag:blogger.com,1999:blog-1548435010272960921.post-57801281633505257802012-06-22T21:50:00.002+05:002017-07-29T07:40:14.123+05:00Solar Panel Sizing Basis<div dir="ltr" style="text-align: left;" trbidi="on">
As i earlier mentioned that i shall install 1260 watt solar panels. Now its the time to show what were the basis of calculations. I have used a smart on-line solar panel system sizing calculator. The link is at the end of this post. Click on the photos to make them bigger.<br />
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Here is the stepwise sequence of load calculation activities:<br />
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<b>STEP-1: MONTHLY POWER CONSUMPTION CALCULATION</b></div>
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<b>STEP-2: SOLAR PANEL SIZING</b></div>
In this step we shall calculate the number of solar panels required based on the energy consumed by the electrical appliances in Step-1.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEiU4a7vwOKVSbGPcDUuG_XaKEnMw1QXY3TcxaXh0A4jEILoiWHgE6px6VBcGGNRhMxZWBJ-bJPdqEfDR3g09ariVfIjPnbjtckrcjSS_iBe-w8wZctF9fSCu3ZXBb2O_oA8o2gloNWA/s1600/Solar+Array+sizing.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="261" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEiU4a7vwOKVSbGPcDUuG_XaKEnMw1QXY3TcxaXh0A4jEILoiWHgE6px6VBcGGNRhMxZWBJ-bJPdqEfDR3g09ariVfIjPnbjtckrcjSS_iBe-w8wZctF9fSCu3ZXBb2O_oA8o2gloNWA/s400/Solar+Array+sizing.jpg" width="400" /></a></div>
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<b>STEP-3: MPPT SOLAR CHARGER SIZING</b></div>
I have already purchased 150DC, 45Amp charge controller.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdLZqIV9nwHLH7v6xRXEVoM448AYFwBgv3jMrC5ipHeMhPAW6N8Eam5NULSfqtO7RLAHHfYKgIbqBewdEJCLPc-fsYsCncuACK9Ovxl9i3f6ndhFbKZ9zYGAiBTPpyOQkmYqCwcQErMQ/s1600/MPPT+sizing.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="251" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdLZqIV9nwHLH7v6xRXEVoM448AYFwBgv3jMrC5ipHeMhPAW6N8Eam5NULSfqtO7RLAHHfYKgIbqBewdEJCLPc-fsYsCncuACK9Ovxl9i3f6ndhFbKZ9zYGAiBTPpyOQkmYqCwcQErMQ/s400/MPPT+sizing.jpg" width="400" /></a></div>
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<b>STEP-4: BATTERY BANK SIZING</b></div>
I have already purchased two batteries 12VDC 220AH.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvy0FcgqiTOhBLDwVw-T69vOFdIQa-JNBzmN9zL0bagzWVOFYjWcLxnahafHb36rZ5qC0jZvHqIXTCOHtMei_8ceGTZYpMK2A01sOHBHfalQSMlxCs9GVDUz6fsdAdAfrbzeN7aALFVw/s1600/Battery+Bank+calculator.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvy0FcgqiTOhBLDwVw-T69vOFdIQa-JNBzmN9zL0bagzWVOFYjWcLxnahafHb36rZ5qC0jZvHqIXTCOHtMei_8ceGTZYpMK2A01sOHBHfalQSMlxCs9GVDUz6fsdAdAfrbzeN7aALFVw/s400/Battery+Bank+calculator.jpg" width="375" /></a></div>
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Here is the link of online calculator:<br />
<a href="http://www.sunsoglobal.com/calculator.html#">http://www.sunsoglobal.com/calculator.html#</a><br />
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<br /></div>Khalid Khattakhttp://www.blogger.com/profile/11895580638865703379noreply@blogger.com5