PowerJet Wind Turbine Project

PROJECT OBJECTIVE The PowerJet wind turbine overcomes problems characteristic of the small wind turbines that are on the market today by providing reliable output at a wide range of wind speeds, durability, silent operation at all wind speeds, and bird-safe operation. Prime Energy’s objective for this project was to design and integrate a generator with an electrical controller and mechanical controls to maximize the generation of electricity by its wind turbine. The scope of this project was to design, construct and test a mechanical back plate to control rotational speed in high winds, and an electronic controller to maximize power output and to assist the base plate in controlling rotational speed in high winds. The test model will continue to operate beyond the time frame of the project, with the ultimate goal of manufacturing and marketing the PowerJet worldwide. Increased Understanding of Electronic & Mechanical Controls Integrated With Electricity Generator The PowerJet back plate begins to open as wind speed exceeds 13.5 mps. The pressure inside the turbine and the turbine rotational speed are held constant. Once the back plate has fully opened at approximately 29 mps, the controller begins pulsing back to the generator to limit the rotational speed of the turbine. At a wind speed in excess of 29 mps, the controller shorts the generator and brings the turbine to a complete stop. As the wind speed subsides, the controller releases the turbine and it resumes producing electricity. Data collection and instrumentation problems prevented identification of the exact speeds at which these events occur. However, the turbine, controller and generator survived winds in excess of 36 mps, confirming that the two over-speed controls accomplished their purpose. Technical Effectiveness & Economic Feasibility Maximum Electrical Output The output of electricity is maximized by the integration of an electronic controller and mechanical over-speed controls designed and tested during the course of this project. The output exceeds that of the PowerJet’s 3-bladed counterparts (see Appendix). Durability All components of the PowerJet turbine assembly—including the electronic and mechanical controls designed, manufactured and field tested during the course of this project—proved to be durable through severe weather conditions, with constant operation and no interruption in energy production. Low Cost Materials for the turbine, generator, tower, charge controllers and ancillary parts are available at reasonable prices. Fabrication of these parts is also readily available worldwide. The cost of assembling and installing the turbine is reduced because it has fewer parts and requires less labor to manufacture and assemble, making it competitively priced compared with turbines of similar output manufactured in the U.S. and Europe. The electronic controller is the unique part to be included in the turbine package. The controllers can be manufactured in reasonably-sized production runs to keep the cost below $250 each. The data logger and 24 sensors are for research only and will be unnecessary for the commercial product. Benefit To Public The PowerJet wind-electric system is designed for distributed wind generation in 3 and 4 class winds. This wind turbine meets DOE’s requirements for a quiet, durable, bird-safe turbine that eventually can be deployed as a grid-connected generator in urban and suburban settings. Results As described more fully below and illustrated in the Appendices, the goals and objectives outlined in 2060 SOPO were fully met. Electronic and mechanical controls were successfully designed, manufactured and integrated with the generator. The turbine, tower, controllers and generators operated without incident throughout the test period, surviving severe winter and summer weather conditions such as extreme temperatures, ice and sustained high winds. The electronic controls were contained in weather-proof electrical boxes and the electrical wires were fully contained inside the control arm, which prevented water damage to the electrical system during heavy rains. The wind conditions exceeded the Class 2 average for the test site, and there were episodes of high winds, including 3 10-minute periods of winds that exceeded 35 mps (80 mph). Electricity generation was constant throughout. There were no technology transfer activities during the project period, and there are no patents or property certifications pending as a result of this project. Field testing and data collection are continuing