1

Second Wind System Design and Project Plan

Josh Dowler

Caleb Meeks

John Snyder

2

Table of Contents

System Design…………………………………………………………………………………..3

Background………………………………………………………………………………4

System Overview…………………………………………………………………..…4

Block Diagram………………………………………………………………………....5

Functional Description of Blocks……………………………………………...6

Project Plan………………………………………………………………………………..…….7

Organization and Management………………………………………………..8

Work Breakdown Structure – Fall 2009…………………………………….9

Work Breakdown Structure – Spring 2010……………………………..10

Budget……………………………………………………………………………………11

Gantt Chart – Fall 2009…………………………………………………………..12

Gantt Chart – Spring 2010………………………………………………………13

Network Diagram – Fall 2009…………………………………………………14

Network Diagram – Spring 2010…………………………………………….15

Appendices…………………………………………………………………………………….16

Requirements Specification..…………………………………………….17-18

3-D Model……………………………………………………………………………..19

3

System Design

4

Background : Alternative power sources address a need produced by the depletion of traditional energy sources. Wind is one of the most abundant energy resources that can be harnessed to generate power and our project aims to harness that power in an innovative and more effective way than traditional wind turbines. Kite wind generation is more effective than conventional turbines in gathering the energy from the wind for two reasons. First, the kite can reach much higher altitudes than turbines, where the wind is more reliable and strong. Second, kites can cover more area in the sky and therefore use more of the energy than a stationary turbine can. Our kite generator aims to produce clean sustainable energy in a world where green power generation needs a second wind.

System Overview: Our team will design and prototype a kite wind generator. The generator will produce electrical power from the drag force applied to the kite by wind. The kite will be autonomously guided by a microprocessor to perform the gliding maneuvers necessary to produce power. When being deployed the kite string reel will dispense kite line, thus allowing the kite to gain altitude. The kite wind generation unit will produce power based on the drag force produced by the kite in flight and the amount of line pulled, which will be connected to a generator. When being retracted the kite orientation will be changed to reduce its drag coefficient, and the kite will be reeled in using much less power than is generated from the pull up. The kite will run autonomously in winds of 10 to 45 kilometers per hour. When the wind speeds are too high the kite will be retracted to prevent damage to the system. If the wind speeds are too low the kite will be retracted. The system will also have a user interface that displays the length of line released, and power generation. The user will also have options for three different modes of operation for the kite; deploy, sustain, and retract.

Unregulated Voltage

5

Power Supply

Micro-Processor

Power Control Circuit

Kite Dynamics

+9VDC

MotorController

Kite Controls

±12VDC

Line Length/Tension Reading

+5VDC &12VDC

String Movement

Tension:Min: 10 N

Max: 250 N

Charge Controller

User Interface

Generator90V / 10A

Power Reading

Line LengthTension+5VDC

User Input

UnregulatedVoltage

900W

String Movement

Tension:Min: 10 N

Max: 250 N

Block Diagram

6

Functional Description of Blocks:

Power Supply: The power supply will be a single 12 V DC lead acid battery, which will provide unregulated voltage to the power control circuit. It will also supply an unregulated voltage signal to the charge controller and receive the power produced by the generator from the charge controller.

Power Control Circuit: The power control circuit will regulate the voltage delivered to the microprocessor, motor control circuit, and charge controller. It will take unregulated voltage from the power supply and output +9VDC to the microprocessor and +5VDC to the motor control circuit and charge control circuit. It will also output a +12VDC signal to the motor control circuit to provide power to the motors.

Microprocessor: The microprocessor will receive power from the power control circuit. The microprocessor will send data and voltage (+5VDC) to the user interface and receive user inputs from the user interface. The data sent will be on/off signals, via a three-way switch, for the retract and ascend modes and a digital signal to the LCD containing the length of string dispersed. The signals recieved by the user interface will be on/off signals from the retract/sustain/ascend switch triggered by the user. The microprocessor will receive analog data signals from the tension sensor and line length indicator switch. The kite control signals. The tension sensor signals will enable the microprocessor to verify if too much or too little force is on the kite strings so it can react accordingly with an interrupt. The microprocessor will also send control signals to the motor controller. The motor control signals will be digital logic signals with a direction bit for the left and right motors of the kite.

Motor Controller: The motor controller will receive power from the power control circuit as well as receive control signals from the microprocessor. The signals recieved from the microprocessor will tell the motors to turn on or off and in which direction to spin. The motor controller will then output power (±12VDC) to the kite control motors.

User Interface: The user interface will consist of an LCD screen, an array of LEDs, and switches. The LCD screen will display the length of line released, the array of LEDs will display the voltage on the battery, and the switches will allow the user to enable deploy, sustain, and retract modes. It will receive power and data from the microprocessor and charge controller and will send the user inputs back to the microprocessor.

Kite Controls: The kite controls will receive power from the motor controller and send analog tension sensor and line length sensor signals to the microprocessor. The kite controls will control the tension in the lines through software, sensors, and electromechanical means. Part of the kite controls will also mechanically retract the kite using a spring system in each cycle of the kite. The kite controls will then use the manipulation of the tension to control the kite behavior.

Kite Behavior: The kite behavior is controlled by the tension output of the kite controls. The kite behavior will then fly in a pattern that will increase the tension on the lines and send that tension to the generator.

Generator: The generator will produce power from the tension and pull of the kite lines from the kite behavior. The power that is generated will then be sent to a charge controller unit.

Charge Controller: The charge controller will receive power from the generator and provide overcharge and surge protection for the power supply. It will feature a breaker that can switch in case of surges and circuits featuring diodes to prevent overcharging. It will send the power it receives back to charge the power supply. The charge controller also reads the voltage over the power supply and sends that information directly to the user

interface.

7

Project Plan

8

Organization and Management

John Snyder – John is a senior computer engineering student, with a 50/50 electrical and engineering and computer science split. He will be working with programming the microprocessor to get it to work with the motor controller, kite controls system, and the user interface. He will also be working on the charge controller to prevent it from overcharging and surge protection for the power supply. He will also be working with different sensors to provide information for the system.

Josh Dowler – Josh is a senior mechanical engineering student, and is the project leader. He will be in charge of converting the tension provided by the kite behavior and turning it into electric power. He will be working with the generator motor and a freewheel mechanism to allow the kite to retract without affecting the generator and selecting gear ratios as necessary. As project leader, he will be in charge of managing the budget, overseeing all project happenings, and reviewing documentation.

Caleb Meeks – Caleb is a senior mechanical engineering student. He will be in charge of working with the controls system and kite behavior. He will construct and work closely with John on the electrical and mechanical aspects of the controls system. The controls system will also link with the power generation processes, and therefore Caleb and Josh will be working to integrate their systems.

All team members will contribute equally to any documentation that will be presented, including reports and oral presentations. Each team member will be in charge of maintaining their notebooks and doing research on their respective parts outside of group meeting times. Team members are required to attend team meetings unless they notify the other team members about their absence.

Work Breakdown Structure fall 2009Task Activity Description Deliverables / Checkpoints Duration

(weeks)

People Resources

F1.0 Requirements

Specification

Detailed overview of the project

and its application

Written report including project

ideas

3 ALL PC

F2.0 System Overview Detailed overall design of the

project

Written documentation and

oral presentation

4 ALL PC

F3.0 Controls Design Overall kite control mechanism Overall schematics 7 Caleb PC, Video

CameraF3.1 Mechanically

Governed System

Design

Aspect of kite control controlled

solely by mechanics

Schematics 3 Caleb PC

F3.2 Electronically

Assisted Design

Aspect of kite control featuring

electronic aid

Schematics 3 John/

Caleb

PC

F3.3 Kite Retraction

System Design

Mechanical system releasing

and retracting the kite

Schematics and calculations 3 Caleb PC

F3.4 Brake System

Design

Mechanical system used to

brake/retract the kite

Schematics 1.5 Caleb PC

F4.0 Generator Design Overall mechanical power

generation system

Overall schematics 6 Josh PC

F4.1 Freewheel and

Return Design

Mechanical system allowing one

way mechanical power

transmission

Schematics and calculations 4 Josh PC

F4.2 Gearing Ratio

Design

Mechanical system to increase

the torque applied to the

generation motor

Schematics and calculations 2 Josh PC

F4.3 Generator Motor

Selection

Discovery of an appropriate

motor for kite powered

generation

Selected motor and spec. sheet 2 Josh PC

F5.0 Charge Controller

Design

Circuit regulating the generated

power

Circuit design and MulitSim

analysis

2 John PC

F6.0 Motor Controller

Design

Circuit used to control all the

motors

Circuit design and MulitSim

analysis

3 John PC

F7.0 Microprocessor

Interface Design

Microprocessor used to control

electrically driven parts of the

system

Circuit design 3 John PC

F8.0 User Interface

Configuration

Design

Configuration of user display

and user input modes

Circuit design 2 John PC

F9.0 System Frame

Design

Frame holding the entire system

together

Schematics and calculations 1 Josh/

Caleb

PC

F10.0 Parts Selection Decisions reguarding selection

of all parts in the system

Part selection, order, and

documentation

6.5 ALL PC

F11.0 System Analysis Design analysis to test for

cohesivness

Test documentation 1.8 ALL PC,

MultiSim,

SolidworksF12.0 System Design /

Project Plan

Decomposition of system design

and work schedule breakdown

for the year

System documentation,

models, report, presentation

1.4 ALL PC

F13.0 Final Design Final design of all aspects of the

system

System documentation,

models, report, presentation

2 ALL PC

A1.0 Documentation Demonstration of continuous

work and research done for the

project

Engineering Notebooks, A3

Reports

15 ALL PC,

Engineering

Notebook

A2.0 Project

Management

Supervise the completion of

project goals on time and within

budget

Project is on schedule and

within budget

15 Josh PC

9

Work Breakdown Structure spring 2010

Task Activity Description Deliverables /

Checkpoints

Duration

(weeks)

People Resources

S1.0 Parts Assembly /

Testing

Assembly of parts and verification of

proper functionality

Functional sub-systems,

test data

9 ALL PC, Work

ShopS1.1 Mechanical

Control System

Build/ Test the kite controls controlled

solely by mechanics

Functional kite flying

controls, test data

4 Caleb Work Shop

S1.2 Electrical Control

System

Build/ Test the kite controls featuring

electronic aid

Functional kite flying

controls, test data

3 Caleb Work Shop

S1.3 Kite Reel System Build/ Test the mechanical system that

releases and retracts the kite

Functional kite reel

mechanism, test data

3 Caleb Work Shop

S1.4 Brake System Build/ Test the mechanical system

used to brake/retract the kite

Functional kite braking

mechanism, test data

2 Caleb Work Shop

S1.5 Freewheel and

Return

Mechanism

Build/ Test the mechanical system that

allows one way mechanical power

transmission

Functional freewheeel

and return mechanism,

test data

2 Josh Work Shop

S1.6 Gearing Ratio Build/ Test the mechanical system that

increases the torque applied to the

generation motor

Functional torque

increasing system, test

data

2 Josh Work Shop

S1.7 Generator Motor Test the motor to verify correct

operation

Power generation, test

data

3 Josh PC, Power

SupplyS1.8 Boarding Etching Design and order and/or etch circuit

boards

Finished circuit boards

and at least one

professional board

4 John PC, Work

Shop

S1.9 Charge Controller Build/ Test the circuit regulating the

generated power

Power regulating circuit

board, test data

3 John UI

S1.10 Motor Controller Build/ Test the circuit used to control

all the motors

Motor controlling circuit

board, test data

3 John PC, EVB

S1.11 Microprocessor

Interface Setup

Verify operation and connect/test

inputs and outputs of microprocessor.

Functional

inputs/outputs, test data

3 John PC, EVB

S1.12 User Interface

Configuration

Build and configure user display and

user input modes

Functional user controls,

screen output, test data

2 John PC

S2.0 System Frame

Assembly

Build/ Test the frame that holds the

entire system together

Constructed system

frame, test data

2 ALL Work Shop

S3.0 Programming Write code for microprocessor which

controls the system

Operational code, test

data

6 John PC

S4.0 Project Status Written/Oral presentation on our

project's status

Written report, models 2 ALL PC

S5.0 System

Integation

Bring all sub systems together to form

the complete system

Assembled system, test

data

3 ALL PC, Work

ShopS6.0 System Testing Verification of proper funtionality of

the system as a whole

Test data 2 ALL PC,

Multimeter

S7.0 Finalize

Prototype

Final troubleshooting and proof of

functionality

Finished prototype 2 ALL Work Shop

S8.0 Final Project Written/Oral presentation of finalized

prototype

Reports, models,

prototype

2 ALL PC, Work

ShopA1.0 Documentation Demonstration of continuous work

and research done for the project

Engineering Notebooks,

A3 Reports

14.2 ALL PC,

Engineering

NotebookA2.0 Project

Management

Supervise the completion of project

goals on time and within budget

Project is on schedule and

within budget

14.2 Josh PC

10

Product Quantity Quantity Needed Cost per Unit Estimated Cost

Kite 1 1 $132.00 $132.00

Tension Sensor 2 2 $24.40 $61.00

Microprocessor 3 1 $5.00 $25.00

Batteries 1 1 $45.00 $50.00

Wood (2"x4") 15 10 $1.50 $25.00

Nuts/Bolts $50.00

Axles 4m 3m $25.00

Bike Parts 2 n/a $0.00 $0.00

Kite String 50m 50m $30.00 $40.00

Circuit Boards 5 4 $50.00

Motors $190.00

Electical Components $25.00

Miscellaneous $177.00

TOTAL $850.00

Budget

11

Gantt Chart - Fall 2009Second Wind

Josh Dowler, Caleb Meeks, John Snyder

8 15 22 29 6 13 20 27 3 10 17 24 1 8

F1.0 Requirements Specifications 9/8/2009 9/29/2009 3

F2.0 System Overview 9/8/2009 10/13/2009 4

F3.0 Controls Design 9/29/2009 11/17/2009 7

F3.1 Mechanically Governed System Design 9/29/2009 10/20/2009 3

F3.2 Electronically Assissted Design 10/27/2009 11/17/2009 3

F3.3 Kite Retraction System Design 10/13/2009 10/27/2009 2

F3.4 Brake System Design 10/20/2009 10/31/2009 1.5

F4.0 Generator Design 9/29/2009 11/10/2009 5

F4.1 Freewheel and Return Design 10/20/2009 11/10/2009 3

F4.2 Gearing Ratio Design 10/13/2009 10/27/2009 2

F4.3 Generator Motor Selection 9/29/2009 10/20/2009 3

F5.0 Charge Controller Design 9/29/2009 10/13/2009 2

F6.0 Motor Controller Design 10/6/2009 10/27/2009 3

F7.0 Microprocessor Interface Design 10/13/2009 11/3/2009 3

F8.0 User Interface Configuration Design 11/3/2009 11/14/2009 1.7

F9.0 System Frame Design 11/3/2009 11/10/2009 1

F10.0 Parts Selection 9/26/2009 11/10/2009 6.5

F11.0 System Analysis 11/17/2009 12/7/2009 1.7

F12.0 System Design / Project Plan 10/1/2009 10/13/2009 1.4 ◊F13.0 Final Design 11/17/2009 12/8/2009 1.8 ◊A1.0 Documentation 9/8/2009 12/10/2009 12.5A2.0 Project Management 9/8/2009 12/10/2009 12.5

Duration

(Weeks)Finish DateStart DateTask NameID

12

Sep. 2009 Oct. 2009 Nov. 2009 Dec. 2009

Than

ksgiving B

reak

Gantt Chart - Spring 2010Second Wind

Josh Dowler, Caleb Meeks, John Snyder

11 19 26 2 9 16 23 2 9 16 23 30 6 13 20 27

S1.0 Parts Assembly / Testing 1/11/2010 3/4/2010 7.7

S1.1 Mechanical Control System 1/11/2010 2/9/2010 4.1

S1.2 Electrical Control System 1/26/2010 2/16/2010 3

S1.3 Kite Reel System 2/9/2010 3/2/2010 3

S1.4 Brake System 2/23/2010 3/4/2010 1.6

S1.5 Freewheel and Return Mechanism 2/16/2010 3/4/2010 2.6

S1.6 Gearing Ratio 2/2/2010 2/16/2010 2

S1.7 Generator Motor 1/11/2010 2/2/2010 3.1

S1.8 Boarding Etching 1/11/2010 1/21/2010 1.3

S1.9 Charge Controller 1/26/2010 2/16/2010 3

S1.10 Motor Controller 1/19/2010 2/9/2010 3

S1.11 Microprocessor Interface Setup 2/2/2010 2/23/2010 3

S1.12 User Interface Configuration 2/23/2010 3/4/2010 1.6

S2.0 System Frame Assembly 3/15/2010 4/6/2010 2

S3.0 Programming 1/19/2010 3/4/2010 6.6

S4.0 Project Status 2/16/2010 3/2/2010 2 ◊S5.0 System Integration 3/15/2010 4/6/2010 3

S6.0 System Testing 4/6/2010 4/26/2010 2.9

S7.0 Finalize Prototype 4/13/2010 4/26/2010 1.9

S8.0 Final Project 4/13/2010 4/27/2010 2 ◊A1.0 Documentation 1/11/2010 4/29/2010 15.3A2.0 Project Management 1/11/2010 4/29/2010 15.3

Jan. 2010

13

Feb. 2010 Mar. 2010 Apr. 2010

Sprin

g Bre

ak

Duration

(Weeks)Finish DateStart DateTask NameID

Network Diagram: Fall 2009

Second WindJosh Dowler, Caleb Meeks, John Snyder

14

Network Diagram: Spring 2010

Second WindJosh Dowler, John Snyder, Caleb Meeks

15

16

Appendices

Kite Wind GeneratorRequirements Specification

Overview:Our team will design and prototype a kite wind generator. The generator will produce electrical power

from the drag force applied to the kite by wind. The kite will be autonomously guided by a microprocessor toperform the gliding maneuvers necessary to produce power. A kite wind generator would be useful forgenerating power on large scale agricultural farms, in remote locations for disaster relief or military, or as a partof a larger wind farm.

Problem Statement:Due to pollution and depletion of traditional energy sources there is a need to generate power from

renewable energy sources. Wind is the second most abundant energy resource, next to solar energy, that can beharnessed to generate power. Kite wind generation is more effective than conventional turbines in gathering theenergy from the wind for two reasons. First, the kite can reach much higher altitudes than turbines, where thewind is more reliable and strong. Second, kites can cover more area in the sky and therefore use more of theenergy than a stationary turbine can. This technology could allow individuals to become energy self-sufficientand it could also be used in large scale projects as wind farms that produce high power.

Operational Description:The kite wind generation unit will produce power based on the drag force produced by the kite in flight

and the amount of line pulled, which will be connected to a generator, over time. When the kite has reached itsmaximum height the kite orientation will be changed to reduce its drag coefficient, and the kite will be retractedusing much less power than is generated from the pull up. The kite will run autonomously in winds of 10 to 45kilometers per hour. When the wind speeds are too high the kite will be retracted to prevent damage to thesystem. If the wind speeds are too low the kite will be retracted. The system will also have a user interface thatdisplays the length of line released, and power generation. The user will also have options for three differentmodes of operation for the kite; deploy, sustain, and retract.

Technical Requirements:• System will initially supply its own power to initiate energy generation and then store excess generated power• If power generation is not sufficient to generate excess power the kite will be retracted and the user interface will run off

of stored power• System will generate at least 500 Watts DC within one day and be able to store that much energy• Kite system will be able to generate power in winds from 10 - 45 kilometers per hour• Setup, including kite deployment, should take no more than 30 minutes• Power generation should occur within five minutes of kite deployment• System must have deploy, sustain, and retract modes of operation• Autonomous control of each mode (deploy, sustain, retract)• User interface to enable user to specify modes of operation (deploy, sustain, retract) and show user length of line

released within one meter and power generated within 20 watts• Must be able to sense length of line released within one meter and power generation within 20 watts• System will be able to fit through a standard door frame, with width of one meter and height of two meters

17

Design Deliverables:• User manual• Drawings and schematics with analyses• Kite generator unit• User interface• Parts list with associated costs• Test report• Final technical report

System Test Plan1. Kite stays aloft in winds of 10 - 45 kilometers per hour2. 10 minutes of autonomous flight and power generation in winds of 10 - 45 kilometers per hour3. Generation of 500 watts DC within one day4. The electrical system will have a fail safe mechanism that will enable in case of a power surge5. Kite retraction of less than 10 minutes in winds of 10 - 45 kilometers per hour6. Shows accurate value for length of line released by comparing it with a tape measure within one meter7. Shows accurate value for power generation within 20 watts by using current and voltage measurements using a

multimeter

Implementation Consideration:Follow FAA regulations part 101, subparts A and B: no flight between sunset and sunrise, a letter of

intent to fly the kite above 150 feet sent to the nearest FAA ATC facility, a 100m radius of land withoutobstruction around base, set in an area five miles away from an airport, land must have ground visibility greaterthan 3 miles, and the kite line must have streamers at 50 foot intervals above 150 feet that are visible for onemile. The leads for the generator and battery will be covered to prevent shock. Gears and chains may be part ofthe design and could propose some safety issues.

18

3‐D Model

19