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Senior Design Final Presentation

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This presentation outlines the development of a prototype that harnesses wave energy to generate electrical power from a buoy, guided by Dr. Kishore Pochiraju and Group 10 comprising Biruk Assefa, Lazaro Cosma, Josh Ottinger, and Yukinori Sato. The project aims to design, develop, and test a self-sustaining power generator capable of producing hundreds of watts. Key components include mathematical modeling, device assembly, and energy conversion systems. The project addresses critical design constraints and focuses on optimizing efficiency while minimizing losses throughout various system components.

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Senior Design Final Presentation

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  1. Stevens Institute of Technology Mechanical Engineering Dept. Senior Design 2005~06 Wave Energy Power Generator Senior Design Final Presentation Date: December 14th, 2005 Advisor: Dr. Kishore Pochiraju Group 10: Biruk Assefa, Lazaro Cosma, Josh Ottinger, Yukinori Sato

  2. Agenda • Project Objective • Progress Feedback • Mathematical Model • Device Assembly • Component Designs • Cost & Weight Budget • Conclusion

  3. Selected Conceptual Design Project Objective • Project Description • Design, develop, prototype and test a device that harnesses wave energy to generate electrical power on a buoy • Off-shore location requires buoy to be self-sustaining • Power output in the 100’s of Watts range • Objectives • Functional wave power generator which meet initial requirements

  4. Progress Feedback • Identify losses in system • Mechanical Components  Mechanical Losses • Need for low number of components • Necessity of proper lubrication • Gearbox issues • Using gearbox to increase speed affects inertia by the ratio squared • As will be seen, ↑ Ratio: • Increases torque losses • Reach a point where the system is unable to overcome inertia • Impact of Model on the Design • Aid in sizing of several parameters: Buoy diameter, Reel radius, spring constant, gear ratio • How each variable affects overall system • Sensitivity of each variable

  5. Mathematical Model • Systems Approach to Mathematical Model • Divided overall simulation into 6 subsystems • Identified by system components • Within each subsystem includes detailed modeling of the governing equations • Simulation is solved by the simultaneous computation of each equation • To simplify the analysis the “engaged” case was analyzed

  6. Device Assembly

  7. Device Assembly

  8. Buoy Design • Buoyant force is the main driving force • Other forces: resistance from other components, weight, & damping force • Damping force is a function of buoy velocity • Buoy height (yellow) vs. Wave height (pink)

  9. Buoy Mold Buoy Design • Diameter of 6 feet • Height of 25 inches • Buoy Fabrication • Commercially unavailable / Expensive • Using low density urethane foam • Laminated with fiber class for added strength • Mold Options: • Manufactured at machine shop / sheet metal • Purchase kiddy pool

  10. Spring Operated Reel Function: Convert linear buoy motion into rotational shaft motion Design Aim: Maximize angular velocity of input shaft

  11. Spring Operated Reel

  12. Spring Housing Side plate Shaft connection Cable Guide Stand Cable Spring Operated Reel Design Variables used Wave Amplitude: 6 inches Wave Period: 7 seconds Reel Diameter: 3 inches Spring Constant: 10 inch pounds Preload length: 60 inches Buoy Diameter: 6 feet Reel Torque Reel shaft angular velocity

  13. Shaft Design • Maximum torque located at reel output • Worst case scenario • Full submersion • Locked shaft • Torque on the shaft can be expressed as • Factor of safety: 1.2

  14. Mechanical Rectifier • Design constraints • 1:1 ratio for CW & CCW rotation • Center distance relationship for gears: • Keeping effective inertia low • Design Issues • Engaged vs. Disengaged • Model simulation focuses on Engaged state • Testing will focus on Disengaged state

  15. Mechanical Rectifier

  16. Gear Box • Function: Speed up rotational shaft motion • Design Aim: Minimize gear ratio

  17. Input Shaft Output Shaft Gear Box Angular velocity of Reel vs. Gear Box Design Variables used Reel Diameter: 3 inches Spring Constant: 10 inch pounds Preload length: 60 inches Buoy Diameter: 6 feet Gear Ratio: 10 Gearbox Torque

  18. Flywheel Function: Maintain high RPM for Alternator Design Approach: • Size the flywheel by iteratively testing the prototype with flywheels with various moment of inertia

  19. Alternator Function: Produce electrical power Design Approach: • Low inertia, high efficiency at low RPM, and variable torque preferred • Test for Torque vs. RPM and Efficiency vs. RPM curves

  20. Alternator • Permanent Magnet Alternator • Wind industry • High efficiency at low RPM (~300RPM) • Variable EMF Alternator is chosen • Car Alternator will be used for prototype testing: • Inexpensive • Low efficiency at low RPM

  21. Typical alternator regulator Encoder setup at Flywheel Method of Control • Purpose: To maintain high power output by maintaining high RPM • Microcontroller – provides programmable, digital control • Monitor two inputs (voltage and RPM) • Use PWM to adjust effective rotor EMF • Use encoder to monitor RPM • Will be limited to basic control (such as P-control) in this project

  22. Battery Subsystem • Car battery: provide large amount of current for a short period • Deep cycle battery: provide steady current over a long period • Frequent charging and discharging capable • Optimal for the case of renewable energy generation • Regulate charging voltage • Utilize regulator placed between alternator & battery • Keep charging at consistent rate during the wave profile

  23. Predicted Power Output Power Output • The Mathematical Model was run with determined design variables • Efficiency of alternator assumed to be 50% • Higher average power expected with Flywheel

  24. Cost & Weight Budget

  25. Conclusion • What we learned from ME 423: • Necessity for Project Management • Importance of detailed design • ME 423 & E 421: • Connect Product design, marketing, & sales • Basic understanding of intellectual property • Initial plan to purchase COTS • Need to custom make several components • Focus in ME 424: • Purchasing / Fabrication • Final Assembly • Testing Phase

  26. Questions and Comments? ? THANK YOU FOR LISTENING! SEE YOU NEXT SEMESTER

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