graded unit stage 2

Graded Unit 2 Stage 2

Dylan Fitzsimmons30050607

E3HNDMECENDV1235

1

ContentsIntroduction page5

Objectives page5

Schedule page5

Task page5

Aesthetics page6

Ergonomics page6

Health and Safety page6

Environment page7

Personal Skills/Knowledge page7

Software page8

Manufacturing Considerations page8

Labour Costs page8

Components list page8

Method of Manufacture page9

AutoCAD (Initial) page9

Optional Workshop Day Disclaimer page9

Workshop Week 1: Day 1 page10-- Turbine Base Procedure -- Marking Tool Procedure

-- Turbine Shaft Procedure page11-- Procedure Notes -- Improvisations

-- Alterations -- Summary

Workshop Week 1: Day 2 page12-- Blade Cover Procedure

-- Procedure Notes -- Summary page13

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Workshop Week 2: Day 1 page13-- Airfoil Profile Procedure

-- Aluminium Blade Procedure-- Procedure Notes page14

-- Mistakes-- Alterations-- Summary

Workshop Week 2: Day 2 page15-- Base Supports Procedure

-- Turbine Base Procedure page16-- Base Assembly

-- Procedure Notes-- Alterations-- Summary

Workshop Week 3: Day 1 page17-- Aluminium Blades Procedure

-- Blade Supports Procedure-- Shaft Support Procedure page18

-- Procedure Notes-- Improvisations

-- Alterations-- Summary

Workshop Week 3: Day 2 page19-- Blade Supports Procedure-- Shaft Support Procedure

-- Shaft Support Assembly page20-- Procedure Notes

-- Summary

Workshop Week 4: Day 1 page20-- Shaft Procedure

-- Blade Supports Procedure page21-- Procedure Notes-- Improvisations

-- Health and Safety-- Summary

Workshop Week 4: Day 2 page22-- Blades Procedure

--Improvisations--Summary

Workshop Week 5: Day 1 page23-- Blade Supports Procedure

-- Procedure Notes-- Improvisations

-- Summary

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Workshop Week 5: Day 2 page24-- Turbine Shaft Procedure

-- Blade Covers-- L-Brackets page25

-- Improvisations-- Summary

Workshop Week 6: Day 1 page26-- Bearing Attachment (Base) Procedure

-- Bearing Attachment (Blades and Shaft) Procedure page27-- Motor Vice Procedure

-- Turbine Assembly (Blades and Shaft)-- Upper Blade Cover Assembly

-- Procedure Notes page28-- Improvisations

-- Summary

Workshop Week 6: Day 2 page29-- Lower Blade Cover Assembly

-- Summary

Workshop Week 6: Day 3 page30-- Motor Shaft Procedure

-- Error of Judgement-- Replacement Motor

-- Summary page31

Workshop Week 7: Day 1 page31-- Motor Assembly

-- Procedure Notes page32-- Summary

Workshop Week 7: Day 2 page32-- Securing Motor

-- Summary page33

AutoCAD (Initial) page33

Verification Strategy page33

Reference page35

Photo Diary page36

Appendices page45

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IntroductionThe Gorlov Helical Wind Turbine did not surpass the research stage. Instead, another design was chosen in compliance with the Design Matrix, Calculations and personal opinion of each SKYE Ltd member: the Savonius. The model was agreed upon by all participants to be the most likely design to achieve the performance specifications under the given test conditions, as well as the pressures placed upon the group that may hinder the chance of success. The most appealing qualities of the Savonius are its ability to retain a favourable level of efficiency at low wind speeds, whilst maintaining its reputation in ease of manufacture. The SKYE Ltd team on average has a reasonably low skill set in terms of hands on work and craftsmanship, as for some members, this year was their first experience in using tools of any sort. Planning began on the 26/02/2016; construction begins on the 23/03/2016 and ends on the 19/05/2016 (operating on a budget of £150, with labour costs at £25 per hour).

Objectives Design a wind turbine capable of achieving the given specification. Purchase materials needed for components. Construct the wind turbine of the chosen design. Test the product. Analyse and evaluate its effectiveness. Learn new skills from the experience.

Savonius CalculationsEquation Result

Angular Velocity at 15mph (ω) 106.7 RPMTip Speed Ratio (λ) 1

Blade Area (A) 0.565mPower (Cp=0.25) 26.1W

The above table represents the expectations of what the final product will be able to attain under the given test conditions, if the design is true to the calculations.

ScheduleTo succeed, each aspect of the design and construction stage would be monitored throughout. Gantt charts are the standard procedure when preplanning tasks; using Microsoft Project, the Gantt charts allow the team keep on schedule. As well as software, it is necessary that the group maintains a consistent communication standard in meetings, whilst updating the log book at every step of the process. Additionally, a method of manufacture was produced before the construction began, which led to the creation of engineering drawings – essential for the build. All Gantt charts, minutes of meetings, log book transcript, method of manufacture and drawings are stored in the appendix section.

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TaskSKYE Ltd Member Job

Dylan Fitzsimmons Risk Assessments, Verification StrategyChris Walker CAD ModellingCharles Thomson Method of ManufactureKieran Johnstone Gantt Charts

Each task was allocated to an individual member, a tactic that not only promotes better team integration but increases the speed of the work – since SKYE Ltd operates within an inflexible timescale.

AestheticsSince the product is a prototype focusing solely on performance output, aesthetics was not an essential factor taken into consideration by the SKYE Ltd design team. However, a final design would incorporate such a valuable property which is important when the product is introduced into the marketplace. Of course, market research will be conducted prior to development to assure customer satisfaction in this area is guaranteed. For the majority of potential customers, the initial attraction towards the product is its visual representation; followed by price and performance.

ErgonomicsWith the aim of improving user welfare whilst retaining a high standard of performance, ergonomics is the science of thought that determines the interactions that take place between a person and a product. Using a mix of anthropometrics, cognitive psychology and engineering; the practice enhances the experience of the user. Ergonomic factors were taken into consideration when designing the SKYE Ltd Savonius, the most prominent of which was health and safety of the user. Furthermore, the turbine in its design was made to be easily operable.

Health and SafetyRisks to students and any other member of staff are taken seriously at City of Glasgow College, under the Health and Safety at Work etc. Act 1974. All personnel are required to wear PPE at all times which includes: overalls, steel toe cap boots, and safety glasses. Additionally, anyone visiting or working in the workshop has the option to wear ear protection; however, this is not mandatory. Other PPE that is available to students is the use of thick safety gloves whilst handling aluminium or other sharp metals, although they are not available at all times (students advised to purchase their own). All individuals have a responsibility to comply with college regulatory practices which can be found on the City of Glasgow College website. Risk assessments are necessary for tools, rooms and raw materials; and can be found in the appendix section.

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EnvironmentThroughout the process, environmental impacts and consequences were considered to help prevent waste. From the beginning of the build, materials were shared within the class as a means of preventing such a situation. Keen to promote its commitment to the environment, City of Glasgow College was awarded a bronze level certificate (which it hopes to improve upon) as a result of its work with Resource Efficient Scotland, a programme funded by the Scottish Government. The methods are visible in the workshop, as each room has 3 types of bins for waste material:

Green – general waste and plastic swarfBlack – metal swarfYellow – soiled rags

Personal Skills/KnowledgeAs a HND student who progressed through the HNC, I was capable of putting those subjects previously taught into the construction of this project:

Statics and Strength of Materials. Dynamics. Material Selection. Heat Transfer and Fluid Mechanics. Computer Aided Draughting for Engineers. Engineering Drawing. DC and AC Principles. Quality Management. Plant Systems. Business Awareness and Continuing Personal Development. Design for Manufacture. Energy Overview. Engineering Skills.

The project gave the opportunity for the group to use the skills previously learned within the college, and cluster them together into a real life situation that would prove useful in a working environment.

In addition to the skills taught at City of Glasgow College, I was able to build upon skills I learned whilst at school, which included:

Craft and Design (metal and woodwork). Graphic Design. Physics.

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SoftwareThroughout the design stage, a range of software packages were used to piece together the project:

Microsoft word Microsoft Excel Microsoft Project Report Graphs, tables Gantt charts

Autodesk Inventor 3D Smart Draw PreziEngineering Drawings Electric circuit diagram Presentation

Manufacturing ConsiderationsBefore the final list of components was agreed upon, other materials were considered for the construction of the turbine.

Component Material Justification

Blades Plastic barrelA COSHH report was necessary, and although this method would

have saved time, it would neglect SKYE Ltd of the valuable experience of cutting and shaping the aluminium.

Base MDF The material would produce unsafe levels of sawdust for a room with no ventilation. Plywood is stronger.

ShaftHollow steel

tube The material was found to be too expensive.

Labour CostsEmployee Workshop

HoursResearch and

ReportNI (13.8%) Total

Dylan 30 132 (approximate) -£558.90 £3491.10Chris 46 149 (approximate) -£672.75 £4202.25

Charles 42 120 (approximate) -£558.90 £3491.10Kieran 24 106 (approximate) -£448.50 £2801.50

- 142 507 (approximate) -£2239.05 £13985.95

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Savonius Raw Materials ListComponent Material Dimensions (mm) Cost Supplier

Base x2 Plywood 12x1220x2440 College Supplied N/ABlade Covers x2 Plywood 6x1220x2440 College Supplied N/A

Blades Aluminium 1x950x2400 College Supplied N/AShaft Nylon Ø50x1600 College Supplied N/A

4 Hole Flange Bearing Cast Iron Internal Ø50143x143x54.6 £25.20 RS

Components

2 Hole Flange Bearing Cast Iron Internal Ø50115x197x54.6 £25.20 RS

ComponentsMotor (16GA DC 12V

100RPM)Aluminium Ø25x64.2

2mm shaft £10 eBay

Base Supports x2Kiln Dried Soft

Wood 50x100x3600 College Supplied N/A

Blade Supports Steel Rod M8x2000 College Supplied N/ANuts/Bolts/Washers/

ScrewsSteel M12-M8 College Supplied N/A

Total - - £60.40 -

Method of Manufacture

3D AutoCAD Design (Initial)

Optional Workshop Day Disclaimer:Regrettably, I was not able to attend the entirety of the optional workshop days which were available to me due to family commitments and financial restrictions.

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Workshop Week 1: Day 1 (23/03/2016)Component Material Cut Dimensions

(mm)Tools PPE Completed

By

Turbine Base x2 Plywood 12x1220x1400

Measuring tape, jigsaw tool, pencil,

marker pen, G-clamps, engineers

square.

Overalls, safety glasses, steel toe cap

boots.

Dylan, Chris, Kieran, Charles.

Turbine Shaft Nylon Ø50x1165

Masking tape, measuring tape,

pencil, vice, semi-automatic heavy duty band saw.

Overalls, safety glasses, steel toe cap boots, gloves.

Kieran.

Marking Tool for Blade

CoversPlywood 30x500

G-clamps, jigsaw, pencil, hand saw, measuring tape, portable power

drill, vice.


boots.Dylan.

I arrived at workshop R.00.075 on Wednesday morning, where I joined group members Chris Walker and Kieran Johnstone. The members of SKYE Ltd were being briefed by course leader John Robertson on the arrival of materials, which were then allocated to each group and carried by ourselves to the work station R.00.072. The group was then joined by the final group member, Charles Thomson, and began by measuring the raw materials to check that the correct sizes were in our possession – to avoid any sudden shortages late into the project.

- Risk assessments required for these processes: 00110A, 008, 0012 and 005. Found in appendix.- Method of manufacture used: 001A and 004A. Found in appendix.- Engineering drawings used: 001.1A, 001.2A and 0042A. Found in appendix.- Pictured examples in purple; found in photo diary.

Turbine Base Procedure The 12mm thick plywood sheet was placed on top of a work bench to be prepared for cutting. Using a measuring tape and a pencil, the material was marked at 1400mm by 1220mm. A line was drawn across the material using the large engineers square and thick marker pen. The plywood was then cut using the jigsaw, taking the cut to the midpoint then resuming from

the opposite side. *(1) (1) The fresh cut material was used as a stencil onto the second sheet of plywood, and a line was

drawn using a marker pen. The second sheet was cut with the jigsaw using the same cutting method.

Marking Tool Procedure The 12mm thick plywood was measured to 500mm in length by 30mm in width using a

measuring tape and pencil.

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Securely held to the bench, the cut was made using the jigsaw. The material was placed into a vice, measured at 480mm, and a wedge was cut using the hand

saw. Measuring in 20mm from the opposing end, and using the portable power drill, an 8mm hole

was drilled into the material. An 8mm nut and bolt was placed into the hole. (2)

Turbine Shaft Procedure Initial size 1600mm, the shaft was cut down to 1165mm using the semi-automatic heavy duty

band saw. *(2) (3)

Procedure Notes *1) To operate the tool safely and controlling all hazards, precautions had to be taken when making

the cut. After a brief introduction on how to use the tool by John Robertson, Charles began the first cut along the measurement line with the other members of the group holding the wood steady on the work bench. Due to the length of the cut being 1220mm, when the jigsaw tool reached the midpoint the cut had to be stopped and restarted from the other side – to avoid strain on the users’ back muscles and to secure an accurate cut.

2) A brief introduction was given by the technician; the task was carried out by Kieran.

ImprovisationsAlthough the 6mm thick plywood sheets were available, work could not begin to measure the 920mm diameter circles that would be used as the blade covers: as no tools were available. The solution was an improvised marking tool made from recycled scrap plywood from a previous cut. A bolt would be placed through the stick and into the 6mm thick plywood which would then freely rotate in a circular motion, and by placing a pencil in the wedge at a distance of 460mm, the circle could be easily drawn for cutting.

AlterationsWidth of base – the team discovered that the thickness of the wood was 1220mm. To save time and to prevent any uneven cuts, the dimension on the base of the final product was changed; an addition of 20mm in width from the original 1200mm. since the change from 1200mm to 1220mm would have no negative effects on the performance of the turbine; the slight adjustment in design was a logical step to preserve the limited workshop time.

Length of shaft – on the original drawing the shaft was to be 1168mm; however, it was changed to 1165mm for ease of measurement. The reduction in overall height of the turbine as the shaft reached the highest point. In performance terms, the adjustment made neither a negative or positive change.

SummaryUltimately, in the group’s opinion, the first day in the workshop was well structured; well organised; and well executed (despite a series of unfortunate and unforeseen time delays). Under substantial pressure to succeed, the team created an atmosphere that encouraged creativity and communication, and no member felt left out or received unfair treatment from another.

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Workshop Week 1: Day 2 (Optional) (24/03/2016)Component Material Cut Dimensions


By

Blade Covers x2 Plywood Ø920x6

Improvised marking tool, jigsaw, G-clamps, pencil, portable power

drill, bolt/nut, measuring tape.

Overalls, safety

glasses, steel toe

cap boots.

Chris, Charles.

I was not present during this optional class and neither was Kieran Johnstone; however, group members Chris Walker and Charles Thomson were, and this is their account of what progress was made on that day. Before work could begin, the group was notified that the arrival of materials that they had planned on working on had not been delivered, so the team was left to persevere with limited tasks. All operations were completed in workshop R.00.072.

- Risk assessments required for these processes: 00110A, 008, and 005. Found in appendix.- Method of manufacture used: 005A. Found in appendix.- Engineering drawing used: 005A. Found in appendix.- Pictured examples in purple; found in photo diary.

Blade Cover Procedure A 1220mm by 2440mm 6mm thick plywood sheet was measured in half using a measuring tape

and a pencil. *(1) The material was then cut using the jigsaw. The centre of the circle was measured, and an 8mm hole was made using the portable power

drill. *(2) Using the 460mm measuring stick, a 920mm diameter circle was drawn onto the material with a

pencil. The circle was then held securely to the bench with G-clamps. Using the jigsaw, the circle was cut from the material. *(3) (4) The fresh cut circle was then used as a stencil, and a circle of the same size was drawn onto the

second half of the plywood. A 57mm hole was drilled out from the centre of the circle. (5)

Procedure Notes *1) 1 sheet was used for both blades covers to reduce waste.2) At first, a 5mm hole was drilled through the stick and into the material to accommodate the

bolt; however, it proved too small. Through a process of trial and error, 7mm was tested, until finally the 8mm hole was found to be the correct size.

3) Before the cut was made into the plywood, practice cuts were undertaken on scrap material as to adjust to the technique. To achieve an accurate cut, small pieces were taken off at a time, whilst stopping to rotate the plywood around the workbench.

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SummaryProgress was restricted due to the delay in arrival of materials. However, the day will be regarded as successful in relation to another aspect – the interpersonal development in classmate relationships and communication between two separate groups (an important characteristic required in a thriving working ambience). A member of another group, Haroon, was the only person of his team that was able to attend the optional workshop class and the members of SKYE Ltd were happy to help a friend out in a time of need since both tasks were of a similar nature.



By

Airfoil Profile Plywood Ø602x12

String, measuring tape, portable

power drill, wood screw, pencil,

steel rule.


boots.

Chris, Dylan.

Blades Aluminium 550x950

Engineers square, marker pen,

guillotine, taper tool.

Overalls, safety glasses, steel toe cap boots, safety

gloves.

Chris, Dylan, Kieran, Charles.

I arrived at workshop R.00.072 on Wednesday morning, where I met group member Chris Walker. We were later joined by other group members Kieran Johnstone and Charles Thomson.

Originally, the shaping of the aluminium blades was to be carried out by the Skye Ltd team using the pyramid rollers with the supervision of the course leader (John Robertson); however, due to unforeseen circumstances (the equipment was not suitable) technicians were drafted in to complete this task offsite throughout the Spring Break.

- Risk assessments required for these processes: 00110A, 007, 001, and 005. Found in appendix.- Method of manufacture used: 007A. Found in appendix.- Engineering drawing used: 0071A. Found in appendix.- Pictured examples in purple; found in photo diary.

Airfoil Profile Procedure Using the portable power drill, a wood screw was drilled into a section of 12mm plywood. *(1) The hole at the end of the steel rule was placed over the screw. *(2) With a pencil attached to the opposing end of the steel rule, the tool was rotated in a circular

motion to draw a semi-circle into the plywood measuring at 610mm in diameter. (6)

Aluminium Blade Procedure Using a measuring tape, large engineers square and a marker pen; the 550mm by 950mm

rectangle was marked onto the aluminium sheet. *(3) (7)

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The sheet was then placed into the guillotine, and cut. *(4)*(5) (8) The accurately cut piece was placed onto the remaining material and used as a stencil, drawing a

line with a marker pen. The aluminium sheet was then placed into the guillotine, and cut. *(6) Sharp edges were removed with the taper tool.

Procedure Notes *1) A member of another group helped with this task.2) The second method attempted. The first failed method, involved a piece of string with a pencil

tied at the other end at 300mm.3) Before the piece was cut it was measured again and found to be 600mm instead of 550mm, the

measurement was then corrected. 4) Practice cuts were made beforehand on scrap material to ensure accuracy on the final product.5) A torch had to be shone onto the guillotine as poor lighting in the workshop made it more

difficult to cut accurately. 6) The second sheet of aluminium was slightly over the measurement and skewed to one side – the

same material was cut again, this time to the correct dimensions. (9)

MistakesAn error occurred during the process of cutting the second aluminium sheet, a consequence of poor area lighting. The cut was made too short, as the line to which the blade of the guillotine meets the sheet metal was misjudged. However, a second attempt at aluminium sheet number 2 was a success.

AlterationsAirfoil Profile – after taking longer than it should to achieve the curve, the discovery that the length was slightly off by 10mm was not a substantial problem. It appeared to be an error, but not one that would harm the moulding of the blades as the length of the aluminium would not exceed it. So, due to time constraints, the measurement was left as it was.

Aluminium Blades – in the original drawings, the dimensions were 550mm by 942mm; however, these were adjusted as recommended by the Course Leader as a way of saving time and the reduction in waste material. Also, the decision would reduce the odds of making a poor cut, as the lighting in the area around the guillotine was not sufficient for a professional working environment. It is unknown whether the addition of extra material on each blade will affect the final performance of the turbine (more wind equates to greater energy capture, although in contrast, more material is the increase of overall weight which may increase friction). Its ambiguity can only be speculated until testing is complete.

SummaryWhat needed to be achieved on workshop week 2: day 1 was completed. It was of the utmost importance that both the blade profile and blades themselves were completed, as that was the final timetabled workshop day available before the Spring Break. The group also showed creativity, as when advised to leave a skewed cut as it was, we successfully corrected the mistake; confident in our own judgment. Although the group would have preferred the experience of curving the blades ourselves, and

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we feel like we have been neglected the development of this skill; the silver lining is that a time consuming task was reduced which would allow us to focus on other areas of the project.

Furthermore, due to college regulation that students cannot work unsupervised (health and safety), which is completely understandable; we could not proceed to continue our work on the other sections of our project as we had no lecturer in workshop R.00.072. As SKYE Ltd were first to use the guillotine, and every other group had to use it individually, John could not supervise us in R.01.040 and R.00.072 simultaneously – the workshop was regrettably cut short for our group.



By

Base Supports

Kiln soft wood 50x100x276

Wood saw, measuring tape,

pencil, vice, combination

square.


boots.

Chris, Charles.

Turbine Base Plywood Ø57

Portable power drill, measuring

tape, pencil, jigsaw tool.


boots.

Chris, Charles.

Base Assembly

Kiln soft wood,

plywood, wood screws

(24)

N/APortable power drill, measuring

tape, spirit level.


boots.

Chris, Charles.

I was not available for this optional class, along with Kieran Johnstone; however, group members Chris Walker and Charles Thomson were, and this is their account of what progress was made on that day. All operations were completed in workshop R.00.072.

- Risk assessments required for these processes: 00110A, 002A, 008, and 005. Found in appendix.- Method of manufacture used: 001A, 0012A. Found in appendix.- Engineering drawings used: 002A and 0011A. Found in appendix.- Pictured examples in purple; found in photo diary.

Base Supports Procedure The 50mm by 100m softwood plank was placed into a series of vices along the work bench. The softwood plank was measured into 8 equal 276mm sections using a measuring tape, pencil

and combination square to assure a straight line across the material. *(1) Using the wood saw, the equal cuts were made into the timber.

Turbine Base Procedure 2 slots were measured at the thickness of the wood (50mm by 100mm) into the 1220mm side of

the turbine base on the top section of plywood. *(2)

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The marked sections were then cut using the jigsaw whilst the plywood was securely held onto the bench. (10)

The centre was then marked out onto the top section of plywood using a measuring tape and pencil, which would later hold in place the nylon shaft.

A 57mm hole was then drilled into the material. *(3)

Base Assembly The lower section of plywood was then measured into the 6 sections where the softwood

supports would be attached, 4 at each corner, and 2 between the corners of the 1220mm sides. Using the portable power drill, 2 80mm by 4mm wood screws were drilled through the plywood

and into the first softwood block. This process was repeated for every other marked section (5 times). Once the process was complete, the top section of plywood was drilled onto the current product

at the time. Again, 2 screws into each block (24 screws in total). (11)

Procedure Notes *1) Later changed to 6.2) To accommodate the support arch into the new design.3) Completed by workshop technician.

AlterationsBase Supports – instead of the original plan of 8 blocks between the plywood base, the design was changed to 6 as recommended by the course leader. The supporting pillars that arch over the blades will now start from the bottom of the base on the lower piece of plywood. The change is an improvement in the design as it gives the structure greater stability whilst in operation, as the axial forces acting upon the blades during motion could potentially lead to failure of the product if the pillars were to separate from the upper section of plywood. However, the downside in changing design after the timber was cut is the waste of material; although, spares were available.

SummaryAll things considered, it is reasonable to conclude that important progress was made throughout the day. Out of the three main sections of the project (the base, the shaft/blades, upper supports), one is now complete, and awaits the others for final assembly. In relation to timescale, the group is already at a disadvantage; however, the construction is progressing at an adequate pace.



By

Blades Aluminium Ø8Hole punch,

hammer, centre Overalls, safety Chris, Dylan,

16

punch, masking tape, combination

square, pencil, rasp.

glasses, steel toe cap boots.

Kieran, Charles.

Blade Supports x4 Steel Ø8x750

Masking tape, pencil, hacksaw, vice, measuring

tape.

Overalls, safety glasses, steel

toe cap boots.

Chris, Dylan, Kieran.

Shaft Supports x3

Kiln soft wood

50x100x974 (2)50x100x1200 (1)

Measuring tape, pencil, vice, wood

saw.


toe cap boots.Kieran.

I arrived at workshop R.00.072 on Wednesday morning, where I met group members Chris Walker and Kieran Johnston who had just been briefed from our course leader (John) on the arrival of the aluminium blades that were completed externally throughout the Spring Break. We were then joined by group member Charles Thomson, and got to work.

- Risk assessments required for these processes: 001, 002A and 006A. Found in appendix.- Method of manufacture used: 007A, 006A and 008A. Found in appendix.- Engineering drawings used: 0071A, 008A, 0061A and 009A. Found in appendix.- Pictured examples in purple; found in photo diary.

Aluminium Blades Procedure 12 holes were marked in total on the aluminium blades, with accuracy, using the combination

square. *(1) The diameter of the hole punch was adjusted to 8mm. Using a centre punch, little indents were made onto the aluminium on the sections which were

previously measured, allowing the hole punch to effortlessly slot into position. 12 holes were then punched into the blades (6 each) whilst the material was held securely on

the bench. *(2) (12) Using the rasp tool, the diameter of each hole on the blades was slightly widened: enough to

accommodate the steel supports.

Blade Supports Procedure The steel bar was held securely in a series of vices, and was measured into 4 750mm sections

using a measuring tape, a pencil and masking tape. The steel bar was then cut using the hacksaw.

Shaft Support Procedure Held securely in a series of vices, the 50mm by 100mm timber was marked at a length of

974mm, and cut using a wood saw. (13) The process was repeated for the second piece. Finally, using the same method, the last section of the support was cut measuring at 1200mm.

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Procedure Notes *1) Each hole was labelled from 1 to 4 and corresponded with the same number on the opposing

blade. (14)2) Practice cuts were carried out beforehand on scrap material to ensure accuracy.

ImprovisationsThe holes in each blade were widened using a rasp file; the tolerances were not accounted for in planning.

AlterationsBlades – instead of the previous 16 holes, the design was adjusted to 12. The decision was based on the assumption that the additional material which would secure the blades to the shaft was unnecessary, and such, appeared to be over-engineered. The theory is that the drop in weight may lower the frictional forces acting longitudinally within the shaft, effectively improving efficiency in relation to the Betz’ Limit (59.3%). The supports would now pass through 4 points in the inside of each blade where it is closest to the shaft, for stability; whereas the outside of the blades will only be held at 2 points, to hold them in place.

Blade Supports – the design, in relation to the blades, was changed. Instead of the supports going from the end of one piece of aluminium to the other, it was found that 4 shorter steel bars would be sufficient; at 750mm.

Shaft Support – once the 974mm timber supports were cut and placed upon the base of the project for a visual inspection, they appeared at first glance to be too small (despite complying with the engineering drawing). A decision was then made by the group to change the height to 1200mm, which would give the blades more space between the enclosure. Although the decision was agreed upon this lesson, the changes were not completed as the available workshop time had come to an end.

SummaryWorkshop day 3 was a success in relation to time management, as a significant level of work was achieved by the group. Working fast and effectively under pressure, we were able to pinpoint a solution to each and every problem we came across; creating new ideas to improve on old methods. One such issue being that the hole punch was rather difficult to change, and with no instruction manual or help by someone with past experience, we were left with the challenging task of figuring out through a process of trial and error. By visual inspection, it appeared that the tool could be changed by unscrewing a piece of the tool; removing it; adjusting the lever enough to remove the smaller diameter tip; and replacing it with the 8mm alternative. A resolution was swifter than expected, thanks to the joint effort by Chris and myself.

Along with my other colleagues, I agree that communication and equality are important factors when navigating tricky situations; which can be seen in the quality of our work.

Workshop Week 3: Day 2 (Optional) (21/04/2016)Component Material Cut Tools PPE Completed

18

Dimensions (mm)

By

Blade Supports Steel bar Ø8x750

Threading tool, roebuck

lubricant, vice, steel rule, vice.


boots.Charles.

Shaft Supports x2 Kiln Softwood 50x100x1200

Wood saw, vice, measuring

tape, marker pen, steel rule.


boots.Chris.

Shaft Support Assembly

Kiln softwood, wood screws

(4)N/A Portable power

drill.


boots.

Chris.

Unfortunately I was not able to attend this class, and neither was Kieran Johnstone; however, group members Chris Walker and Charles Thomson were, and this is their account of what progress was made on that day. All operations were completed in workshop R.00.072.

- Risk assessments required for these processes: 006A, 002A, and 005. Found in appendix.- Method of manufacture used: 006A and 008A. Found in appendix.- Engineering drawings used: 0061A, 008.2A and 009.2A. Found in appendix.- Pictured examples in purple; found in photo diary.

Blade Supports Procedure With the steel bar held securely in the vice, the material was thread down to 70mm on each

side. (15) This process was continued throughout the lesson. *(1)

Shaft Support Procedure Complying with the previous day’s adjustments, the new 1200mm dimensions were measured

onto the timber with a measuring tape, a steel rule and a marker pen. Using the wood saw whilst the material was held safely in the vice, measurements were cut. This process was repeated once more as there are 2 pieces of 1200mm timber required for the

shaft support.

Shaft Support Assembly Using the portable power drill, the top piece of 1200mm timber was attached to both 1200mm

side sections using 4 wood screws (2 on each piece). *(2)

Procedure Notes *1) During the process, it was found to be highly difficult to achieve a thread that was completely

straight.2) A member of another group helped with this task.

19

SummaryAlthough I was not in attendance throughout this optional day, I was assured by my colleagues that progress was made; such as the shaft support assembly – the second of three major sections that is ready for the final piecing together of the entire project.



By

Shaft Nylon Ø8.5 holes

Milling machine, rasp, portable power drill,

measuring tape, marker pen,

combination square.


boots.

Chris, Dylan.

Blade Supports Steel bar Ø8x750

Threading tool, roebuck lubricant,

vice, steel rule, vice.


boots.

Charles, Kieran.

Arriving at workshop R.00.072 on Wednesday morning; I met group members Chris Walker, Kieran Johnstone and Charles Thomson. The group got to work right away, continuing tasks from previous lessons and progressing with the method of manufacture.

- Risk assessments required for these processes: 004 and 005. Found in appendix.- Method of manufacture used: 006A and 004A. Found in appendix.- Engineering drawings used: 0061A and 0042A. Found in appendix.- Pictured examples in purple; found in photo diary.

Shaft Procedure The nylon rod was placed into a serious of vices along the workbench. Using a measuring tape, a distance of 121mm was measured from the bottom of the material

and labelled with a marker pen. A measurement was taken 50mm up from the previous mark using the combination square. Measuring from the other end, a distance of 435mm was labelled with the marker pen. *(1) A fourth hole was then measured 50mm from the previous mark using the combination square. The material was the held securely in the milling machine vice. Using an 8mm diameter drill bit, the four holes were drilled through the nylon rod. (16) The holes were then widened using the rasp file. Finally, the holes were widened slightly more using the portable power drill with an 8.5mm drill

bit.

Blade Supports Procedure The 750mm steel bar was held securely in the bench. Using the threading tool, the material was thread down to 70mm on each side.

20

Procedure Notes*1) After completion, in an attempt to assemble the blades and the shaft using the 750mm steel

bars, a discovery was made that the distance between the holes on both components were not the same (480mm on the shaft, 454mm on the blades). As this realisation was not made clear until the end of the workshop day, the problem could not be resolved until the next lesson.

ImprovisationsAs the steel bar and the 8mm holes on the nylon shaft had the same diameter, the two materials would not merge together. To counter this problem, the solution at first was to widen the holes using the rasp file. Although this method was working, it was also time consuming. The solution found was to use the 8.5mm drill bit on the portable power drill whilst the material was held in the bench – as the holes were already removed on the milling machine, securing an accurately straight cut was not a difficult task.

Health and Safety Some safety concerns were expressed by the course leader, mainly based on overcrowding in the workplace. 5 groups of 4 students (20) were working side by side in a small area of the workshop, which presented a trip hazard for anyone who was walking around the room; worsening as the projects came together as they all had similar dimensions. Also, concerns were raised on the lack of supervision given to each group as only 1 lecturer was available throughout the entire workshop process. (17)

SummaryNot many tasks were completed on this workshop morning, the reason being that both jobs were time consuming. Setting up the milling machine takes a considerable amount of time, and although the cuts made into the material were perfectly straight, it was later discovered that the measurements were incorrect and would have to be repaired during the next lesson.



By

Blades Aluminium Ø8

Hole punch, combination

square, marker pen, steel rule.


toe cap boots.

Chris, Charles.

I was not able to attend this class, along with Kieran Johnstone; however, group members Chris Walker and Charles Thomson were, and this is their account of what progress was made on that day. All operations were completed in workshop R.00.072.

21

- Risk assessment required for this process: 001. Found in appendix.- Method of manufacture used: 007A. Found in appendix.- Engineering drawing used: 0072A. Found in appendix.- Pictured examples in purple; found in photo diary.

Blades Procedure Using a combination square and a marker pen, holes 3 and 4 on the blades were measured

again, an increase of 25mm above the previous holes. Using the hole punch, two 8mm diameter holes were removed from the material. (18)

ImprovisationsWhen marking the holes to be cut into the nylon shaft, an error was made and the result was that the lower holes in the shaft did not meet the lower holes in the blades. The solution was pragmatic – recut the holes in the blades as the shaft would take too much time on the milling machine; the outcome was successful.

SummaryAs the motor had not yet been delivered, work was restricted. Furthermore, there was an issue with the order on the bearing which had not been dealt with, as the reason behind the delay was unclear during this time. However, some work was completed which is important.



By

Blade Supports x4 Mild steel 50x50x120

thickness – 3

Hacksaw, steel rule, masking

tape, vice.


toe cap boots.

Chris, Dylan, Kieran, Charles.

I arrived at workshop R.00.072 on Wednesday morning, where I met group members Chris Walker, Kieran Johnstone and Charles Thomson. Progress was restricted this week, as our electric motor had not been delivered and the order on the bearings from RS Components was faulty; failing to process.

- Risk assessments required for these processes: 006A. Found in appendix.

22

- Method of manufacture used: none.- Engineering drawing used: 0012A. Found in appendix.- Pictured examples in purple; found in photo diary.

Blade Supports Procedure A long section of 50x50x120mm material was placed and held in a series of vices. Using a steel rule and masking tape, a section that measured 120mm was labelled onto the

material. *(1) The labelled section of the material was cut using a hacksaw. This process was repeated 3 more times. *(2)

Procedure Notes*1) One for each steel rod supporting the blades. (19)2) Chosen as that was found to be the optimal distance in terms of performance, in accordance

with the calculations.

ImprovisationsWhen piecing together the shaft, blades and blade supports; it was found that there was nothing between the shaft and the blades that would stop them from moving whilst the turbine was in motion. The solution to this problem was the idea of creating spacers that would slide over the steel bars, and fit between the inside of each blade and the shaft (essentially holding them in place).

SummaryIn a similar situation as the previous week, the motor was not available to us. Furthermore, the bearings had not arrived, soon realising that the order was not properly processed. However, to resolve this, I drove the group to RS Components on our lunch break to place the order in person; the package was available for collection the following morning.

Spending that amount of valuable workshop time looking for a solution to the Blade Supports was not the correct way to deal with the problem; the issue should have been dealt with before the lesson. However, the team was unaware of these issues previously, and it had to be resolved immediately – which the group handled well.



By

L-Brackets Steel 30x25x25

Vice, measuring tape, masking tape, hacksaw,

pillar drill.


toe cap boots.

Chris, Charles, Dylan.

Blade Covers Plywood 0051A

Jigsaw, G-clamps, marker pen, steel

rule.


toe cap boots. Chris.

Turbine Shaft

Nylon Ø1.8 down 290 Lathe Overalls, safety Technician

23

Ø1.8 down 150 glasses, steel toe cap boots. (Callum)

Arriving at workshop R.00.072 on Thursday morning, I was greeted by group members Chris Walker and Charles Thomson. Earlier that morning, Charles picked up the bearings from RS Components that was ordered in person the previous day.

- Risk assessments required for these processes: 00110A, 003, 009 and 006A. Found in appendix.- Method of manufacture used: 005A, 004A. Found in appendix.- Engineering drawings used: 0010A, 0043A and 0051A. Found in appendix- Pictured examples in purple; found in photo diary.

Turbine Shaft Procedure The 50mm diameter nylon rod was placed securely into the lathe for turning. (20) A diameter of 1.8mm was removed down a distance of 290mm from the bottom of the shaft. The nylon was removed from the lathe after completion, and place back into the machine, this

time to trim the diameter of the top. Again, 1.8mm was removed from the material, down a distance of 150mm.

Blade Covers Procedure The 920mm blade covers were marked using a pencil, covering the shape of the aluminium

blades in correspondence to the dimensions. The material was placed onto a bench and held securely with G-clamps. Using the jigsaw, the ‘propeller’ like shape was cut into the plywood, following the lines marked

out previously. (21) The cut sheet was then used as a stencil over the second blade cover. Using the same method, the second section of plywood was cut with the jigsaw.

L-Brackets Procedure Scrap metal of a width 30mm was placed into a vice, and measured to 50mm using a steel rule

and a marker pen. The material was then cut using the hacksaw. This process was repeated 16 times. The 50mm piece of metal was then bent in the vice by striking it with a hammer, into an ‘L’

shape of two equal 25mm halves. Again, this process was completed with all 16 pieces of metal. Once this was complete, two 5mm holes were drilled using the pillar drill into each side of the ‘L’

shaped material. Using the pillar drill again, this time with a countersink drill bit, each hole was countersunk to

accommodate the head of either a wood or a self-tapping screw. Again, this process was repeated for all pieces of metal. Once drilling was complete, all rough edges were removed using the bastard file as the brackets

were held securely in the vice.

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ImprovisationsL-Brackets were chosen to secure the shaft supports onto the plywood base, as it was found that the supports may pivot under stress without them. Expanding on that idea, the decision was made to use additional L-Brackets on the connection between the aluminium blades and the plywood covers – using self-tapping screws.

AlterationsTurbine Shaft – once the bearings were available, it was found that the shaft (in its then current condition) was not suitable: it would not fit. The solution, with the help of the workshop technician, was to scale down the diameter by 1.8mm on each side of the shaft using the lathe; 290mm from the top, 150mm from the bottom.

Blade Covers – the shape of the Blade Covers would be changed; reducing the unnecessary wind capture on areas of the turbine that would not enhance efficiency. The effect of the change could be positive, as the new design may reduce unwanted axial forces acting upon the shaft throughout rotation.

SummaryAlthough only small jobs were completed, the work done was important to the final triumphant stages of the project. The turning of the Nylon Shaft, along with the creation of 16 L-Brackets, were both physically demanding tasks; using almost all the available workshop time given. However, as a bonus, time was found to adjust an old idea into a potentially performance enhancing alteration (reshaping of the Blade Covers).

Workshop week 6: Day 1 (11/05/2016)Component Material Cut Dimensions


ByBearing

Attachment (Base)

Plywood Ø10 (4) Portable power drill, spanners.

Overalls, safety glasses, steel toe

cap boots.

Chris, Kieran.

Bearing Attachment

(Shaft Support)

Kiln softwood Ø57

Portable power drill, chisel,

mallet, spanners, measuring tape.


cap boots.

Charles, Kieran.

Motor ViceKiln soft

wood 50x100x65 (2)

Pillar drill, hand saw, vice, steel

rule, marker pen, spanners.


cap boots.Dylan.

Turbine Assembly

Aluminium, steel bar,

N/A Hammer, spanner, measuring tape.


Dylan, Chris.

25

(Blades and Shaft)

nylon. cap boots.

Upper Blade Cover

assemblyPlywood N/A

Portable power drill, duct-tape,

steel rule, marker pen, hacksaw.


cap boots.

Dylan, Chris.

I arrived at workshop R.00.072 on Wednesday morning, where I met group members Chris Walker, Kieran Johnstone and Charles Thomson. The group were working towards completion of the project, as the motor was now in our possession. We started the day with an itinerary to maximise time efficiency since the job list was lengthy; beginning each pre-planned task immediately.

- Risk assessments required for these processes: 00110A, 002A, 006A, 009, 001 and 005. Found in appendix.

- Method of manufacture used: 003A, 005A, 007A, 006A, and 004A. Found in appendix.- Engineering drawing used: 001.1A. Found in appendix- Pictured examples in purple; found in photo diary.

Bearing Attachment (Base) Procedure The bearing was placed over the 57mm diameter hole that was previously drilled into the base,

and using a pencil, was marked as to where the holes would be drilled. Using the portable power drill with a 10mm diameter drill bit, 4 holes were made. The bearing was then placed back into position, where it was secured using 4 M12 bolts, M12

washers, and M12 nuts. (22) The nuts and bolts were then tightened using a 19mm spanner. *(1)

Bearing Attachment (Shaft Support) Procedure Using a measuring tape, the centre was marked out on top of the Shaft Support. Using the 57mm diameter drill bit attached to the portable power drill; a hole was drilled

through the timber. Using the bearing as a stencil for alignment, 2 10mm holes were drilled into the timber that

would accommodate the M12 bolts. At the underside of the shaft support, the area around both 10mm holes were drilled into using

the hole drill at a depth of 35mm. The drilled wood was then removed using a mallet and chisel. *(2) The bearing was then placed back into position, where it was secured using 2 M12 bolts, M12

washers, and M12 nuts. (23) The nuts and bolts were then tightened using a 19mm spanner.

Motor Vice Procedure A section of 50mm by 100mm timber was placed and held securely in a vice. Using a steel rule and a marker pen, a length of 65mm was made onto the material. Then, using the hand saw, the cut was made into the wood.

26

The freshly cut piece was used as a stencil to measure a length of 65mm onto another piece of 50mm by 100mm timber.

Again, the material was cut in the vice using the wood saw. After this was completed, 2 measurements were marked onto each section of wood – 25mm

across and 32.5mm upwards. *(3) 2 12mm holes were then made into each section of the timber where the measurements were

made. An M12 bolt was then placed into each hole of the first section of timber, continuing on through

the second piece, both secured with an M12 washer and an M12 nut. The motor was then placed between the two pieces of wood and the nuts were tightened on

both bolts using a 19mm spanner: holding the small motor in place. *(4) (24)

Turbine Assembly (Blades and Shaft) Holding the aluminium in place, a steel bar was placed through hole 1 on the first blade; meeting

with hole 1 on the second blade; passing through the spacer; continuing through the shaft; and finishing by slotting into hole 1 on the opposite end of the first blade. *(5)

The steel support bar was then secured in place using an M8 nut and washer. This process was repeated for all 4 support bars that made their way through the blades and into

the shaft. *(6) (25)

Upper Blade Cover Assembly With a steel rule and marker pen, 3 equal sections were marked onto each blade that would

accommodate an L-Bracket; distance of 200mm apart. Using the portable power drill, a self-tapping screw was drilled through one section of an L-

Bracket until it pierced the aluminium blade. (26) This process was repeated 5 more times. Using the hacksaw, the sharp edges of the self-tapping screws that were protruding from the

aluminium were removed. The Blade Cover was then placed over the shaft and onto the aluminium, and using the portable

power drill and self-tapping screws, each L-Bracket was drilled through the plywood. Duct-tape was then place around the sharp edges of the self-tapping screws that were

protruding from the plywood. *(7)

Procedure Notes*1) One spanner placed on the nut and one placed upon the bolt head to secure a tight lock.2) The bolts alone were not large enough to extend all the way through the 50mm timber.3) The optimal position through the material that would equally share the load when under tension

(to prevent failure).4) Hence the term ‘Motor Vice’, the component in theory should hold the motor in place and still

whilst the Shaft is in spinning motion.5) Hole number 4 was poorly measured and was not in line with the shaft. Offset by 10mm, the

steel bar had to be hammered through the nylon shaft.

27

6) Duct-taped as the workshop time came to an end, although this method is also an acceptable safety standard.

ImprovisationsIf the motor’s shaft was expected to turn, the body of the motor had to be held securely in place whilst the nylon shaft was in motion. Measuring 64.2mm in height and 25mm in diameter, there were no tools available that would have held the object in place. The solution was a wooden vice. The vice used two M12 bolts, with an inside clearance of roughly 50mm, which could have held any small object in place; the motor in this circumstance.

SummaryThe most well-structured and productive day of the workshop to date, the team worked highly efficiently and performed great under pressure. Individual members of the group began to feel the strain of each delay, piled on top with anxiety – the effects of an approaching deadline. However, these concerns would only hinder the advancement of creativity, so were pushed to one side as we continued toward completion.

Workshop Week 6: Day 2 (Optional) (12/05/2016)

Components Materials Cut Dimensions (mm)

Tools PPE Completed By

Lower Blade Cover

(Assembly)Plywood N/A

Portable power drill, duct-tape,

steel rule, marker pen, hacksaw.


toe cap boots.

Chris, Dylan, Charles.

I arrived at workshop R.00.072 on Thursday morning, where I was joined by group members Chris Walker and Charles Thomson. We prepared to progress onto the final stage of the project – connecting the power source.

- Risk assessments required for these processes: 00110A and 005. Found in appendix.- Method of manufacture used: 005A. Found in appendix.- Engineering drawings used: none.- Pictured examples in purple; found in photo diary.

Lower Blade Cover Assembly With a steel rule and marker pen, 3 equal sections were marked onto each blade that would

accommodate an L-Bracket; distance of 200mm apart.

28

Using the portable power drill, a self-tapping screw was drilled through one section of an L-Bracket until it pierced the aluminium blade.

This process was repeated 5 more times. Using the hacksaw, the sharp edges of the self-tapping screws that were protruding from the

aluminium were removed. The Blade Cover was then placed over the shaft and onto the aluminium, and using the portable

power drill and self-tapping screws, each L-Bracket was drilled through the plywood. Duct-tape was then place around the sharp edges of the self-tapping screws that were

protruding from the plywood. (27)

SummaryWith the motor in our possession and still not connected, things were not looking good by this point. After the assembly of the lower blade cover, which was only a brief task, the rest of the lesson was spent debating on which method was best suited to attach the motor to the shaft. Charles had the idea that a similar method to my ‘Motor Vice’ was necessary for the tiny 2mm diameter shaft protruding the motor, however, Chris also came up with a method of connecting it to the nylon that he felt was superior. All variables considered, I felt that the idea Chris presented was best suited as it put less force upon the motor which was fragile in its contemporaneous state. Despite the decision, before the team had time to begin the task, the lesson was coming to an end – leaving it to another day.




Motor Shaft Vice Steel 30x50 (2)

Vice, hacksaw, steel rule, marker

pen, pillar drill, centre punch,

hammer.


boots.

Chris, Charles.

Unavailable to attend this day due to another commitment, group members Chris Walker and Charles Thomson set about the task of connecting the motor. Kieran Johnstone was also not in attendance as he had other commitments.

- Risk assessments required for these processes: 006A and 009. Found in appendix.- Method of manufacture used: none.- Engineering drawing used: none.- Pictured examples in purple; found in photo diary.

Motor Shaft Vice Procedure A long piece of flat 30mm width steel bar was placed into a vice and measured at 50mm in

length, using a steel rule and a marker pen. The material was then cut using the hacksaw.

29

This process was repeated once more. Then using the centre punch and a hammer, 2 holes were made on both ends of each piece of

metal, 12mm down and roughly 15mm apart. The metal was then placed in a vice, and bent in half using the hammer. Using the pillar drill, each mark made with the centre punch was drilled using the 5mm drill bit. 2 M5 bolts were places through both sections, each clasped together with an M5 washer and

nut. The ‘vice’ was then tightened around the shaft protruding the motor. (28)

Error of JudgementWhilst the ‘Motor Shaft Vice’ appeared to be successful in terms of tightly gripping the small 2mm diameter shaft, it failed when the device was placed under tension. The forces acting upon the small object were too great, and the inside of the motor sheared; breaking the component.

Replacement MotorLuckily, a group from another class had already conducted tests on their turbine, and as a goodwill gesture allowed SKYE Ltd to borrow the component for test purposes; as it was too late in the process to purchase another motor. The new motor was attached to a horizontal-axis wind turbine, which was stripped down and ready for assembly onto our Savonius. The signed agreement can be seen in the appendix section.

SummaryA disappointing result, as our motor failed despite high hopes previously expressed by the team. Realistically, the chances were slim due to the component’s size; however, we gave it the best attempt. Although I would have preferred to use the method that Chris proposed instead of the method Charles decided upon, I was not available to express my concerns. The positive point is the loan of a functioning, reasonably sized, and easy to connect motor. The team are thankful for the act of generosity.

Workshop Week 7: Day 1 (18/05/2016)

Components MaterialsCut Dimensions

(mm) Tools PPECompleted

By

Motor Assembly

N/A Ø4.2 holes (3)Ø15 hole

Pillar drill, portable power drill, allen key,

steel rule.


cap boots.

Dylan, Chris, Kieran, Charles.

All members of the team gathered at workshop R.00.072 on Wednesday morning, the final timetabled workshop day available for the assembly of the project.

- Risk assessments required for these processes: 005 and 009. Found in appendix.- Method of manufacture used: none.- Engineering drawing used: none.- Pictured examples in purple; found in photo diary.

30

Motor Assembly Procedure Using the pillar drill, 3 4.2mm diameter holes were drilled into the mounting hub of the motor.

*(1) The top section of the shaft support was removed, and the turbine was flipped: to reduce the

amount of nylon material protruding the lower section of the base. *(2) The base of the turbine was then turned onto its side, and using the portable power drill, the

bottom section of plywood was removed to allow access to the shaft. Using the portable power drill with a 12mm drill bit, a hole was drilled into the centre of the

shaft, swirling around in a circular motion to achieve a 15mm diameter hole. *(3) (29) Once the hole was correctly drilled into the shaft, 3 3mm holes were drilled into the shaft using

the mounting hub as a stencil. *(4) Then, the mounting hub was secured to the bottom of the shaft; holding it in place with 3 4mm

by 30mm screws. The motor was then placed into the mounting hub, where it was tightened using an allen key. The bottom section of plywood was then placed back into position, and drilled back into place

using the portable power drill. (30) Likewise, the top section of the shaft support was reattached back into position. *(5)

Procedure notes*1) The diameter of the mounting hub was too large for our shaft, so 3 new holes had to be drilled

through the material to be fit for purpose.2) Essential to make room for the new motor as it did not fit in its then-current state.3) Poor error of judgment resulted in the hole being drilled out from the centre point, which had to

be corrected.4) The screws alone would not penetrate the nylon, so pilot holes had to be made into the

material.5) As the team were in a rush to finish before the end of the lesson, the bottom section of plywood

was screwed into the shaft support pillar at a skewed angle: resulting in the turbine being slightly off centre.

SummaryAs the team only had 2 available hours on this workshop morning, time was of the essence. A team member made a crucial error when drilling the hole into the shaft: the hole was off centre. The results of this would have been catastrophic; the motor would have spun with the shaft on its axis and would be prone to failure. Thankfully the hole drilled had a 12mm diameter, so I was able to repair the mistake made by that member by rotating the drill around the hole in a semi-circular motion: changing its position to the centre. The motor was connected; all that remained was to test the product.




Securing Motor

Kiln softwood, duct-tape 100x100x278 Portable

power drill.Overalls, safety

glasses, steel toe Dylan, Kieran.

31

cap boots.

Arriving at workshop R.00.072, I was met by Kieran Johnstone; soon joined by Chris Walker and Charles Thomson, and set about the task of securing the motor so that it didn’t spin with the nylon shaft during testing.

- Risk assessments required for these processes: 005. Found in appendix.- Method of manufacture used: none.- Engineering drawing used: none.- Pictured examples in purple; found in photo diary.

Securing Motor Procedure Between the 2 sheets of plywood, two blocks of spare timber were placed into position; side by

side with the motor. Using the portable power drill, 2 4mm by 50mm screws were drilled from the top section of

plywood into each piece of timber below, securing them into position. Finally, the motor was held securely in place with duct-tape: wrapping it around the motor and

the timber; unable to rotate. (31)

SummaryAs this was the last available time allocated to test the turbine, work had to be completed fast. The task was completed in around 20 minutes, enabling the team to focus on the test.

3D AutoCAD Design (Final)

Verification StrategyInspection – a final inspection of the product was carried out after completion to ensure that the turbine complied with the build specification, as well as adhering to the college safety regulations. Firstly, a visual inspection was implemented to check the product was fit for purpose. Furthermore, each component was measured to confirm its accuracy in relation to the Engineering Drawings. Next, through

32

a process of physical manipulation, the blades were rotated; paying attention to any irregularities such as an uneven spin, or any concerning sounds given off by any component. It was important that the shaft supports were secured, so as to avoid any chance of danger to any personnel during the event of failure. Finally, all nuts and bolts were tightened and held in position. These techniques were applied to find any unwanted characteristics, best achieved through observation.

Analysis – the group analysed the final product with evidence gathered through a brainstorming process, which included such techniques as logical thinking and the theoretical calculation of function probability. Each scenario was full evaluated in relation to conformance with the original operation expectations.

Similarity – checks conducted to retain assurance that the final design of the product is not replicated from former or similar models. Evidence was gathered by comparison of comparable Savonius designs, through feedback and research.

Demonstration – a set of tests conducted in conditions similar to the environment which the product will be operational. Used as a method of verifying that the turbine is fit for purpose; the results were measured against the correlation to its predetermined outcome.

Test – conducted upon the product under controlled conditions to authenticate its position in terms of its competence to performance expectations and machine functionality. Data was taken using test equipment that measures wind speed and voltage output.

Sampling – a quality control technique which is used throughout the process of selecting a means of verifying that the product is attuned to the technical specification in relation to tolerances and additional machine characteristics.

Date Component Changes/Comments23/03/2016 Base Width adjustment: 1200mm to 1220mm.

No effects/changes on specification. Poses no risk.23/03/2016 Shaft Length adjustment: 1168mm to 1165mm.

No effects/changes on specification. Poses no risk.30/03/2016 Blades Width adjustment: 942mm to 950mm.

No effects/changes on specification. Poses no risk.31/03/2016 Base Supports No. of supports: 6 instead of 8.

No effects/changes on specification. Poses no risk.20/04/2016 Blade Supports Length adjustment: 900mm to 750mm.

No effects/changes on specification. Poses no risk.21/04/2016 Shaft Supports Length adjustment: 974mm to 1200mm.

No effects/changes on specification. Poses no risk.05/05/ 2016 Blade Covers Reshape (see appendix).

No effects/changes on specification. Poses no risk.

By the end of the procedure, 7 components were altered for reasons that may have improved quality or that were a means of saving time and reducing waste. Despite these changes, the final product was still

33

in compliance with the build specification (max height: 1500mm; max blade diameter: 1000mm). The adjustments were able to be made due to the vague specification in terms of size. However, in relation to performance specification (12v, 20W); the changes were seen at the time as methods of enhancing output.

ReferencesCity of Glasgow College. (2016). Student Health and Safety Handbook. [online] Available at: https://www.cityofglasgowcollege.ac.uk/sites/default/files/health-safety-students.pdf [Accessed 26 Mar. 2016].

Chartered Institute of Ergonomics & Human Factors. (n.d.). Manufacturing - Chartered Institute of Ergonomics & Human Factors. [online] Available at: http://www.ergonomics.org.uk/manufacturing/ [Accessed 22 Apr. 2016].

City of Glasgow College. (2016). City of Glasgow College demonstrates green credentials. [online] Available at: https://www.cityofglasgowcollege.ac.uk/news-events/news/city-glasgow-college-demonstrates-green-credentials [Accessed 18 Apr. 2016].

Encyclopaedia Britannica. (2010). aesthetics | philosophy. [online] Available at: http://www.britannica.com/topic/aesthetics [Accessed 11 Mar. 2016].

Steeltubedirect.co.uk. (n.d.). Steel Tube Direct - Select Your Steel Tube. [online] Available at: http://www.steeltubedirect.co.uk/product_selector.aspx?category=100002&shape=150 [Accessed 6 Mar. 2016].

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Photo Diary

Picture 1 Picture 2

Picture 3 Picture 4

35

Picture 5 Picture 6

Picture 7 Picture 8

36

Picture 9 Picture 10

Picture 11

37



38

Picture 16

Picture 17

39



Picture 22

40

Picture 23

Picture 24

41


Picture 27

42



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Appendices

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graded unit stage 2

Documents