Stage 2 final format v3

[Gmu2 Stages 2&3] Team engineers: Robert McLean, Scott McPherson, Mark Mortimer. Client: John Robertson

2016BeSpoke solutions

Patrick O'Donnell

May 26, 2016 [Gmu2 Stages 2&3]

ContentsIntroduction.................................................................................................................................................3

Team Skills...............................................................................................................................................3

Existing Skills........................................................................................................................................3

Planning.......................................................................................................................................................5

Material Selection...................................................................................................................................7

Vertical Shaft...........................................................................................................................................7

Horizontal Shaft.......................................................................................................................................8

Components selection.............................................................................................................................8

Electric motor..........................................................................................................................................8

Voltage Regulator....................................................................................................................................8

Additional Information................................................................................................................................8

Specification............................................................................................................................................8

Software used..............................................................................................................................................9

Components List..........................................................................................................................................9

Verification Strategy..................................................................................................................................10

Inspection..............................................................................................................................................10

Analysis..................................................................................................................................................10

Demonstration......................................................................................................................................10

Testing...................................................................................................................................................10

Logging Results......................................................................................................................................11

Non-conformance..................................................................................................................................11

Sampling................................................................................................................................................11

Method Statement of Works to be carried out:........................................................................................12

The Build....................................................................................................................................................31

Problems encountered..........................................................................................................................31

Vertical Tubing...................................................................................................................................31

Drive shaft Plate................................................................................................................................31

Regulator...........................................................................................................................................32

Team......................................................................................................................................................33

Environment..........................................................................................................................................33

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Facilities.....................................................................................................................................................33

Unforeseen circumstances........................................................................................................................33

Weather.................................................................................................................................................33

Blades....................................................................................................................................................33

Testing and commissioning.......................................................................................................................33

Set up....................................................................................................................................................33

Checks...................................................................................................................................................34

Test........................................................................................................................................................34

Tables of checks and results......................................................................................................................34

Final project thoughts...............................................................................................................................35

What I learned from the project:...........................................................................................................35

Changes if it were done again................................................................................................................35

Conclusion.................................................................................................................................................35

Appendix 1 Please find Gantt chart attached........................................................................................36

Appendix 2 Please find Minutes of meeting attached...........................................................................37

Appendix 3 please see attached drawings list and drawings.................................................................38

Appendix 4 Costs for labour..................................................................................................................39

Appendix 5 Verification Flow charts......................................................................................................40

Appendix 6 Electrical Method statement..............................................................................................41

Appendix 7 Please find Risk assessments attached...............................................................................44

Appendix 8 Please find permits attached..............................................................................................45

Appendix 9 Please find manufacture processes attached.....................................................................46

Appendix 10 Please find attached inside results....................................................................................47

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IntroductionStage 2 of the report will allow each team member to bring new skills to the table. The concept that best met the client’s requirements will be brought forward to the manufacture stage. This will allow the team to work on legal documents to support their build.

Working within the college work shop will allow a good understanding of health and safety at work along with a good knowledge of working as a functional team with a new project manager each week.

Team SkillsThe new skills that the team will obtain will help the team members develop a good understanding of how a work place comes together allowing good communication, project management and time management.

Existing SkillsI myself have had 16 years’ experience as a working member of a team, this has allowed me to take a leading role in the development of the project documents that were required before manufacturing took place whilst also working to tight schedules. I hope that throughout this stage not only will I gain a better knowledge of project management, time management and communication skills, but that I can pass on new skills to the other group members and allow an all-round development of skills.

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Team member Role Responsibility

Patrick Project Manager Turbine Designer Project/Electrical Engineer

Organise activity within workshop Assist manufacture within

workshop/provided electrical expertise

Compile verification strategy/ flow charts

Compile method statements/ Manufacture processes

Scott Assistant Project Manager Project Engineer

Design a computerised model of a HAWT.

Assist PM by recording activity, creating schedules and minutes of meeting

Assist manufacture within workshop

Robert Health and Safety Operative Assistant Project Manager Project Engineer

Develop health and safety procedure and appropriate documentation

Create schedule and conduct meetings

Assist manufacture within workshop

Mark Project Engineer Assist manufacture within workshop

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PlanningPlanning took place as a team with meetings held regularly to update other group members of their progress and also to plan our work shop classes to allow for efficient use of time. Gantt charts also helped to structure and follow progress throughout this project.

(See Appendices 1&2 for Gantt chart and MOM)

The design of the turbine was based upon a strong frame to allow it to withstand the high winds needed for testing, this will allow the turbine to stand alone without team members supporting it by hand. Using two different diameters of pipe allowed for a hinge to be developed which resulted in more wind energy harnessed for better efficiency. The angle iron used for the main shaft will allow a secure fit with little to no play this will stop any movement within the horizontal shaft while also providing good support for the nylon bar.

A breaking system was required for testing this consisted of a metal rod that could be slipped through a gap between the motor and the jubilee clips. This would be pushed through and catch on the hub as not to damage the pvc blades.

(For Detailed Drawings Please See Appendices 3)

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Material SelectionLabour costs & Facilities for workshop (See appendices 4)

When ordering materials for the project some were changed as to allow readily available materials to be used up with in the work shop.

PVC 150mm pipe changed to 75mm guttering

Guttering pipe was bought as it came already halved and reduced the use of dangerous equipment by students.

Materials were selected specifications and budget, numerous hardware stores and material suppliers were used with in our selection for best price only 2 of these were used to illustrate such a price gap for the same material.

The base was designed to be high off the ground, dimensions 1m by 1m square to offer turbine stability, the material of timber was selected for the base as this is easy to shape and fix due to time constraints in manufacture of the turbine.

Vertical ShaftThe vertical shaft is made up of 2 components the main shaft and also a point for the horizontal shaft to turn on its axis. The materials chosen for these components are angle iron and nylon bar, the angle iron allowed a good strong foundation for support whilst the nylon bar was connected by industrial sized jubilee clips and machined to the diameter required for a metal tube to slip over allowing a turning point.

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Horizontal ShaftThe horizontal shaft will consist of 5 parts, the tail fin that will be shaped out of marine ply as it is easy to manufacture. The shaft itself will be made from angle iron as to allow other components to be attached easily by M8 bolts. The vertical tube will be made from 48mm diameter metal tubing this will be connected to the horizontal angle iron by jubilee clips. The inside diameter of the tube is 43mm when the nylon bar is machined to 42mm they will make a simple but effective way for the turbine to rotate.The hub will be made from marine ply as this is a light and easy to shape material which will attach to the motor with a metal plate that has grub screws to hold it firm on the shaft of the motor.The blades will have formed from 75mm diameter PVC guttering pipe the selection was based on its already formed curve that will allow the wind to produce a high pressure on its face and rotate in a clock wise direction.

Components selectionElectric motorThe motor that was purchased from Ebay was selected for this project as it is capable of producing 220-240 volts this is by turning at a rate of 2650 rpm; this will allow 12volts to be produced by turning at a rate of 135.65 rpm.

Voltage RegulatorA voltage regulator will be fitted to the circuit between the motor and the bulb this will allow the voltage to be regulated to 12volts if the voltage exceeds the client’s requirements before turning on the bulb to produce light.

Additional InformationSpecificationElectrics

The electrical health and safety act shall be followed Electrical connections will be secure and easy to access Proper tools and equipment will be used to secure fittings Each component will be checked before use for defections

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Software usedThroughout this process the group has used computer software to complete this report and the design of the turbine itself. Without this technology the accuracy of this projects would not be the same.

Microsoft WordHas allowed the formation of a report in great detail with the ability to add pictures from our project with in the work shop.ExcelThis allows the creation of tables of data that can calculate formulas if entered in the right format, this information can then be brought forward and used in the main report.Microsoft ProjectMicrosoft project allowed the team to plan both the report and build from start to finish with the ability to keep track of who performed tasks along with time keeping.Auto Cad & Solid worksThe 2 software packages allowed the creation of detailed drawings of all the components and a finished 3D model on paper that allowed us to visualise the finished product.PublisherPublisher allowed us to create mind maps and flow charts that helped us follow direction in which to go.

Components List Voltage regulator Motor Hub Blades Platform Vertical Shaft Horizontal shaft Nylon bar Vertical tube Tailfin Legs Braces Platforms

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Verification StrategyThe verification strategy is the use of multiple procedures and documents such as method statements, process plans and risk assessments thus allowing a complete quality management system such as ISO 9000 & 9001.

InspectionThroughout the building of the wind turbine in the work shop, techniques will be used to inspect the quality of the build this will be done by continuous measurements of dimensions and visual checks of the structure. The checks will always consist of non-destructive methods to avoid injury the most commonly used are the human sense’s these will be sight, touch and listening. Other methods for a more in-depth inspection will be Physical manipulation of the structure, voltage and electrical installation and testing will be done with various gauges such as voltmeters, anemometers, Mechanical testing can be done through numerous calculations and other testing such as die, Electromagnetic and tap testing will not be necessary due to the small scale of this structure. The inspection will allow us to keep on top of specifications, Fault finding and adjustments that may be required. AnalysisOur as build checks on the wind turbine will take in to consideration with great detail the engineering requirements that need to be met to make this turbine a success these will include mechanisms, dimensions, electronics systems, life cycle and possible system failures these functions are all with in the design. The analysis will be dealt with by using probabilistic and mathematical calculations, logical thinking and reasoning as part of an engineering team. These methods of testing will be used where other methods are too costly and risk to the wind turbine is minimal. DemonstrationThe demonstration of the wind turbine will be done this will allow the client and or possible future clients to see the capabilities this is a relatively cheap method of advertising the teams skills. The environment that the demonstration will be carried out is that of which it has been designed for the natural outdoors if all goes well. This will allow all to see that it has met the demands of the client and also the specifications if the weather is right and wind speeds equal 15mph the 20-watt bulb will light. TestingTests will be conducted to measure the performance and characteristics this may be carried out in either the natural environment or simulated conditions within the work shop. Testing will allow us to investigate the concept and to provide data on how it has met its brief and specifications thus allowing for future improvements where required. Equipment used to produce the data will be Voltmeter, tachometer.Testing out doors will allow a steady flow of wind around the wind turbine, this will be allowed if the conditions are suitable, a cup anemometer will be used to measure wind speeds prior to testing. This would mean that there would be 15mph winds and above without rain as these conditions would allow clearer results.Testing indoors will allow a controlled environment testing will be carried out at different distances to allow a range of data. Wind will be produced by a leaf blower although this is not ideal it will allow the 15mph winds to be produced.Verification testing is to be carried out to the letter as inaccurate results may lead to product failure and may lead to the customer’s misguidance and potentially the loss of a customer. Any changes or modifications required will be documented and approval required before verification testing commences, also if modifications and verifications cross paths the process shall be restarted as to produce true and accurate results.

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Logging ResultsCareful collection of results for the customer will be extremely important as these will need to be posted with in the report for final submission to verify testing took place, the customer can also be present during testing to witness the results. Non-conformanceIf total failure occurs through the verification strategy, it is important to make sure the failure is with the product and not due to external test equipment. If it is confirmed that failure is with the product, then the designers should witness this first-hand also a report of failure and possible solutions shall be put together this will allow solutions to be formed and resolve any problems.SamplingHere the evaluation of the results that were reached can be made by outside verifiers there for a clear and up to date paper trail should be left to ensure a clear and easy audit takes place this will allow a clear demonstration that all the paper work is in line with the rules of evidence.The evidence will be valid, authentic, current and sufficient to ensure relevant information and understanding that the entire requirement is met.

Please find mechanical and electrical flow charts (Appendices 5)



Method Statement of Works to be carried out:Electrical Method statement (see appendices 6)

Contract No:

1 Code: H&S 002

Contractors name:

Bespoke solutions Edition: 1

Activity: Building of a HAWT Page: 1Work

commences:

18/03/2016 Work Finish: 12/05/2016

Written by: Reviewed by: Accepted by:

Signed by:

Date:

Purpose:

The purpose of this method statement is to identify and communicate the system of work for the build of a Horizontal wind turbine. This shall allow the operations of Bespoke Solutions to take place without causing harm to those with in the workshop, the quality standards required and without affecting the environment.

Scope of works:

Duration: 8 Weeks

Location: City of Glasgow College Riverside Campus

Targets: Please See Attached Gantt Chart

Hazards: Restricted work space

Power tools

Other groups working in the same area

Manual handling

Tight walk ways

Key personnel and contact information

Supervisor: John Robertson



Client: JR

Subcontractor: Bespoke Solutions

Emergencies: Royal infirmary Glasgow 112

Incident Report: Incidents shall be recorded after action has been taken to ensure person and or persons have received the correct attention.

The persons listed above are required to take all reasonable steps to ensure they can be contacted in case of emergencies.

Workshop Safety

Health and safety procedures will be put in place before works commence.

Risk assessment: (See Appendices 7)

Permits: (See Appendices 8)

Manufacture processes: (See Appendices 9)

The risk assessment will allow team members to assess the work area and highlight any risks or potential hazards before works commence.

PPE Required:

The mandatory PPE with in the work shop is-

Safety boots

Overalls

Goggles

These are to be worn at all times within the work shop to apply with college regulations.

Additional PPE for this task will be (Gloves)



Stage

Platforms (1a and 2a) Photo

1 Please see work shop safety (page 2)2 The most recent drawings will be selected for this task, the

drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. Refer to drawings (1a and 2a)The tools needed to complete this task are:Tape measureTable and or BenchHand sawPencil or PenSquare rulerBattery operated drillG ClampsFileThese tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them.

3 Materials will be selected from stock 1000mm × 1000mm × 12mm marine ply woodUsing the table or bench to lay the ply wood flat onDrawings will be used for dimensions neededTape measure will then be used to measure the length needed the pen or pencil will then be used to mark the ply woodPly wood will then be measured corner to corner to ensure it is square

4 The material has been prepared for cutting; additional PPE will be worn for this stage.Double check drawings and measurementsPly wood will be moved forward so to avoid damaging the saw or bench, a team member will support the ply wood by adding weight to it on the bench another team member will support the end been cut of this will avoid awkward cutting.Take hand saw and place teeth on line marked, placing the left hand on the ply wood next to the blade for support.The saw is used gently without force to avoid any un-necessary jumping and to avoid injurySharp edges will be removed to avoid injury



5 Both pieces of ply will then be placed on top of each other.Using the G Clamps to Clamp both pieces together the centre will then be markedUsing a piece of angle iron the shape will be drawn on the ply at the CentreThe battery powered drill will then be used to drill through to make the shape of the angle iron. A file can be used to tidy up at make the proper shape.

6 One piece of ply will then be taken for additional work stages 3 and 4 will then be repeated to make the cut outs for the legs of the supporting platform.

7 Each piece will be marked to avoid confusion with other team’s materials; they will then be placed in a safe area until the final build.



Stage

Platform Braces 800 (3a) Photo

1 Please see work shop safety (page 2)

2

The most recent drawings will be selected for this task, the drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes.The tools needed to complete this task are:Tape measureBench clampsHand sawPencil or PenSquare ruler

These tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them.

3

Materials will be selected from stock 75mm × 50mm timber at 6m in length.Using the table clamps to secure the timber in placeDrawings will be used for dimensions neededTape measure will then be used to measure the length needed the pen or pencil will then be used to mark the timber.The square rule will then be used to add a mark at 90°. This will be done on the four sides; the lines should meet at the final edge. This will allow an accurate cut to be given.

4

The material has been prepared for cutting; additional PPE will be worn for this stage.Double check drawings and measurementsTake hand saw and place teeth on line marked, placing the left hand on the timber next to the blade for support.The saw is used gently without force to avoid any un-necessary jumping and to avoid injuryA team member will stand at end to hold and support the timber to avoid splittingSharp edges will be removed to avoid injury

5

Each piece will be marked to avoid confusion with other team’s materials; they will then be placed in a safe area until the final build.

This process will be the same for the 2 braces.



Step Platform braces 900 (4a) Photo 1 Please see work shop safety (page 2)

2

The most recent drawings will be selected for this task, the drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. Refer to drawing (4a)The tools needed to complete this task are:Tape measureBench clampsHand sawPencil or PenSquare rulerThese tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them.

3


4


5


This process will be the same for the 2 braces



STEP Legs (5a) PHOTO 1 Please see work shop safety (page 2)

2

The most recent drawings will be selected for this task, the drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. Refer to drawing (5a)The tools needed to complete this task are:Tape measureBench clampsHand sawPencil or PenSquare rulerThese tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them.

3


4


5


This process will be the same for the four legs.



Stage

Base Sub-Assembly (6a) Photo

1 Please see work shop safety (page 2)2 The most recent drawing will be selected for this task, the drawing

will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. Refer to drawing (14a)The tools needed to complete this task are:Tape measureBench clampsPencil or Pen,hand drillwood screws.These tools will be used to complete the task. Risk assessments will be added for tools that need them

3 Pre-made components will be taken from storage for this assembly. This will include:700mm timber ‘legs’ (4)800mm timber braces (2)900mm timber braces (2)1000x1000 platforms (2)To begin manufacture:Print drawings of all components and base assemblyDrawings will be needed for dimensionsMark 318mm up from the bottom of the ‘legs’ where the ‘braces’ will have connected in the horizontal direction

4 The components have been prepared for assembly. Double check drawings and measurements. Align the ‘legs’ against each ‘brace’ and screw together using cordless drill. Once all ‘braces and ‘legs’ are attached slip ‘platform 2’ into the frame and use drawings to ensure it is sitting at the correct orientation. Double check positioning then connect the ‘platform 2’ to each ‘brace’ by drilling a wooden screw through each. Place ‘platform 1’ on top of the frame, with each corner lining up to each boundary of the frame. Orientate ‘platform 1’ so the angle iron ‘slots’ are parallel. Double check positioning and connect by drilling wooden screws through both.

5 Place assembled base in storage until full turbine assembly takes place



Stage

Angle Iron (7a and 12a) Photo


drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. Refer to drawings (7a and 12a)The tools needed to complete this task are:Tape measureBench clampsHacksawPencil or PenSquare rulerBlue dyeDrilling machineThese tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them.

3 Materials will be selected from stock 50mm × 50mm× 3mm Angle Iron at 2m in length.Using the table clamps to secure the Angle Iron in placeDrawings will be used for dimensions neededTape measure will then be used to measure the length needed the pen or pencil will then be used to mark the Angle Iron.The square rule will then be used to add a mark at 90°. This will be done on the two sides; the lines should meet at the corner. This will allow an accurate cut to be given.This will be performed on both horizontal and vertical bars.

4 The material has been prepared for cutting; additional PPE will be worn for this stage.Double check drawings and measurementsTake hack saw and place teeth on line marked, placing the left hand on the Angle Iron next to the blade for support.The saw is used gently without force to avoid any un-necessary jumping and to avoid injuryA team member will stand at end to hold and support the Angle Iron to avoid the sudden drop of excess material.Sharp edges will be removed to avoid injury

5 The horizontal bar will then be taken for further work.A blue dye will be painted on to the areas required for marking purposesThe holes will be marked and centre punchedThe metal will then be placed on the drilling platform and clamped in place5×8mm holes will then be drilled

6 Each piece will be marked to avoid confusion with other team’s materials; they will then be placed in a safe area until the final



build.7 Additional Work Carried Out Outside work shop

During the manufacture process a piece of the wind turbine was removed from the college work shop as to get work done.The angle iron required material to be removed from it as to make it lighter this should allow it to operate better when tested.The angle iron was marked to size and safety procedures were put in place as I have been trained in abrasive wheels I used the sthil saw to cut of access material.Safety checked the saw to ensure no one was at risk. PPE was worn as to protect from shards of metal and the saws high Dba output.The access material was removed from the angle iron.All sharp edges were removed by file as to ensure there were no sharp edges.



Stage

Nylon Bar (8a) Photo

1 Please see work shop safety (page 2)2 The most recent drawing will be selected for this task, the

drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. Refer to drawing (8a)The tools needed to complete this task are:Table clampTape measureHack sawPencil or PenlatheThese tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them

3 Materials will be selected from stock 50mm Ø nylon bar at 600mm in length.Using the table clamps to secure the nylon bar in placeDrawings will be used for dimensions neededTape measure will then be used to measure the length needed the pen or pencil will then be used to mark the nylon bar.

4 The material has been prepared for cutting; additional PPE will be worn for this stage.Double check drawings and measurementsTake hack saw and place teeth on line marked, placing the left hand on the nylon bar next to the blade for support.The saw is used gently without force to avoid any un-necessary jumping and to avoid injuryA team member will stand at end to hold and support the timber to avoid splittingSharp edges will be removed to avoid injury

5 The nylon bar will then be secured in the lathes jaws.A cutting tool will be placed in the lathe and secured when centredTool will be brought forward to meet the end of the nylon bar, the digital display on the lathe will be set to zeroSafety checks will be done before work commences.The nylon bar will then strip bit by bit until the desired diameter is reached on the length.To indents will then be made for straps to hold the nylon bar in place

6 The Nylon bar will then be placed in storage for the final build.



Stage

Steel Pipe (9a) Photo

1 Please see work shop safety (page 2)Refer to ‘Hot-works’ permit to work

2 The most recent drawings will be selected for this task, the drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. Refer to drawing (9a)The tools needed to complete this task are:Tape measureBench clampsHand sawPencil or PenSquare rulerDrill & 8mm bitFileThese tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them.

3 Materials will be selected from stock 48mmOD × 42mmID metal tubing at 500mm in length.Using the table clamps to secure the metal tubing in placeDrawings will be used for dimensions neededTape measure will then be used to measure the length needed the pen or pencil will then be used to mark the Metal bar

4 The material has been prepared for cutting; additional PPE will be worn for this stage.Double check drawings and measurementsTake hack saw and place teeth on line marked, placing the left hand on the metal tubing next to the blade for support.The saw is used gently without force to avoid any un-necessary jumping and to avoid injuryA team member will stand at end to hold and support the metal tubing to avoid falling debrisSharp edges will be removed to avoid injury

5 Stage 3 will be repeated to mark the wings and 8mm holes to attach to the vertical bar.Hack saw will be used to cut out slotsWings will be bent back using table viceHoles will be drilled through the wings using drill and 8mm bit.


7 Additional Work Carried out outside workshopThe vertical tube was removed as it required to be heated to its



critical temperature to allow the metal to be shapedEnsured a hot works permit was in place before works commenced, insured a competent person was available to carry out the works.Clamped the piece in a vice grip as to make it secure and easy to work onUsing the gas and oxygen to produce a flame hot enough to heat the piece in a short time. Once heated the piece was physically manipulated into shape.After the metal was successfully manipulated it was quenched in water as to cool it to a suitable temperature.



Stage

Turbine Blades (10a) Photo


drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. Refer to drawing (10a).The tools needed to complete this task are:Tape measureBench clampsHand sawPencil or PenSquare rulerDrill &8mm bitRotating grinderThese tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them.

3 Materials will be selected from stock 150mm PVC piping at 2m in length.Using the table clamps to secure the PVC piping in placeDrawings will be used for dimensions neededTape measure will then be used to measure the length needed the pen or pencil will then be used to mark the PVC piping

4 The material has been prepared for cutting; additional PPE will be worn for this stage.Double check drawings and measurementsTake Rotating grinder and place line marked, placing the left hand on the PVC piping next to the blade for support.The saw is used with care without force to avoid any un-necessary jumping and to avoid injury or the blade shatteringA team member will stand at end to hold and support the timber to avoid debris fallingSharp edges will be removed to avoid injuryStages 3 and 4 will be carried out for each blade to ensure to make them accurate and like as possible for a balanced system.






Step Hub (11a) Photo1 Please see work shop safety (page 2)

2

The most recent drawing will be selected for this task, the drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. Refer to drawing (11a)The tools needed to complete this task are:Tape measureBench clampsHand sawPencil or PenJig sawDrill8mm Wooden bit.These tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them.

3

Materials will be selected from stock 600mm×600mm×12mm sheet of ply.Print of a to scale drawing to be used as a templateUsing a bench to place the ply downDrawings will be used for dimensions neededTo scale template will be placed on the ply wood and used to mark ply wood for cutting

4

The material has been prepared for cutting; additional PPE will be worn for this stage.Double check drawings and measurementsThe ply wood will then be clamped to the table so that the hub is over the edgeThe jig saw will then be used to cut out the shape of the hubA team member will stand at end to hold and support the timber to avoid splittingA file will be used to shape up uneven edgesA drill machine will then be used to make the holes to attach the turbine bladesThe hole to attach the motor will be left until an exact diameter is required.Sharp edges will be removed to avoid injury

5

The hub will then be marked and placed in storage with the rest of the components.



Stage

Tail fin (13a) Photo


drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. Refer to drawing (13a)The tools needed to complete this task are:Tape measureBench clampsHand sawPencil or PenJig sawDrill8mm Wooden bit.These tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them.

3 Materials will be selected from stock 600mm×600mm×12mm sheet of ply.Using the table or bench to lay the ply wood flat onDrawings will be used for dimensions neededTape measure will then be used to measure the length needed the pen or pencil will then be used to mark the ply woodPly wood will then be measured corner to corner to ensure it is square.

4 The material has been prepared for cutting; additional PPE will be worn for this stage.Double check drawings and measurementsPly wood will be moved forward so to avoid damaging the saw or bench, a team member will support the ply wood by adding weight to it on the bench another team member will support the end been cut of this will avoid awkward cutting.Take hand saw and place teeth on line marked, placing the left hand on the ply wood next to the blade for support.The saw is used gently without force to avoid any un-necessary jumping and to avoid injuryThe fin will then be placed in the drill and the holes will be drilled to attach it to the horizontal bar will be drilledSharp edges will be removed to avoid injury

5 The Tail fin will then be marked and placed in storage with the rest of the components.



Stage

Wind-Turbine Assembly (14a) Photo


drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. (14a)The tools needed to complete this task are: Tape measure Pencil or Pen. These tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them.

3 Pre-made components will be taken from storage for this assembly. This will include:BaseMain shaft‘Horizontal shaft’To begin manufacture:Print drawings of Full assemblyDrawings will be needed for dimensions

4 Additional PPE will be worn for this stage.Sub-assemblies will be put together for full assembly.Slip angle iron end of main shaft through the ‘angle iron slots’ on ‘platform 1’ and platform 2’ of the base.Place ‘horizontal shaft’ on top of ‘steel pipe’ platform and connect using jubilee clips that are connecting the motor already to ‘horizontal shaft’.Refer to drawings for positioning. Double check and verify build.

5 This wind turbine is now fully manufactured. Fit all electrical components and wire up to prepare for testing. Refer to Electrical method statement.



Stage

Main-shaft Sub-Assembly (15a) Photo


drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. Refer to drawing (15a)The tools needed to complete this task are:Tape measureBench clampsPencil or PenMasking tapeJubilee clipsThese tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them.

3 Pre-made components will be taken from storage for this assembly. This will include:300mm nylon bar (lathed to θ41mm 200mm up from bottom)300mm steel pipe D=θ48mm and d=θ42mm (originally 400mm but flaps reduce 100mm to overall length)1042mm angle iron

To begin manufacture:Print drawings of all components and shaft assemblyDrawings will be needed for dimensions.

4 The components have been prepared for assembly.Double check drawings and measurementsAlign the top of the angle iron with the machined point on the nylon bar (200mm up from the bottom). This should give an overall length of 1142mm.Align tracks (10mm) on the nylon bar for the jubilee clips with the indents in the angle iron.Double check positioning then place jubilee clips over both parts and tighten to connect both parts togetherSlip the ‘steel pipe’ over the top of the nylon bar for a Slip fitDouble check positioning and ease of steel pipes rotation. Lubricate if required.

5 Place assembled sub-assembly in storage until full turbine assembly takes place.



Stage

Top Section Sub-Assembly (16a) Photo


drawing will have the dimensions and tolerances attached as well as any additional notes where required for specifications and finishes. (16a)The tools needed to complete this task are:Tape measureBench clampsPencil or PenMasking tapeWood screws and NutsBolts and washers.These tools will be used to complete the task any additional tools will be added. Risk assessments will be added for tools that need them.

3 Pre-made components will be taken from storage for this assembly. This will include:600mm modified angle iron shaft (top bar)Tail finMotorDrive-shaft plateHubBlades (3)BrakeJubilee clipsTo begin manufacture:Print drawings of all components and shaft assemblyDrawings will be needed for dimensions

4 This sub-assembly will be prepared for full assembly. Double check drawings and measurements. Connect “blades’ to ‘hub’ by aligning up holes and securing with nuts, bolts and washers. Position drive shaft plate so the centre hole aligns with the centre hole of the hub. Clamp drive-shaft plate to hub and use cordless drill through the 3 holes on the plate so they drill holes through both hub and plate, so holes are parallel and matching. Once done, file and secure pieces together using nuts, bolts and washers. Use nuts, bolts and washer to connect the ‘top bar’ to the ‘tailfin’. Connect Motor to the ‘top bar’ with jubilee clips; use the drawings to mark position of motor and copy. Now slip drive shaft that is on the motor through the ‘hub and ‘drive shaft plate’ holes. Use a grub screw to secure. Double check all fittings and connections.

5 Place assembled sub-assembly in storage until full turbine assembly takes place.



The BuildProblems encounteredVertical TubingThe circular tubing required two wings to be folded back during manufacture this required heat to soften the metal allowing it easier to be shaped physically. This was carried out in a controlled environment outside the college. The metal was then cooled slowly as not to allow it to become brittle.

Drive shaft PlateWhen the motor arrived from Ebay it had an attachment that required alan keys to remove it from the drive shaft. This was an opportunity after removing some material from this it 3 holes were drilled allowing the hub to be attached easily with 3 M8 bolts.


Grub screw hole to secure plate to Shaft of motor.


Regulator At the end of the build when the electrics were added. To test the components, the group asked for permission and supervision to briefly test the turbine outside. When set up and the blades were turning it allowed us to see that the regulator was displaying a voltage although when the bulb was switched on it wouldn’t light. The next day the regulator was tested with 2 volt meters to ensure an accurate reading. It was established that voltage was not reaching the output terminal of the regulator. On establishing this BeSpoke went to John and discussed the use of another team’s regulator as the team would not have time to source another and lead to delay.


Voltage was reaching the digital display, but was not reaching the output

This is the regulator that was borrowed it was a lot more complex, Andy made this at home from a flat pack


TeamThe team worked hard to stick to the Gantt charts Schedule. This was not possible as the delays were impossible to avoid with late material deliveries and strikes taking place. All members of the team were enthusiastic to get started.

All paper work was ready for the workshop and updated on a regular basis allowing for small changes to the design.

Mark missed a few days with his new job this added to some delays as it was a 4-man team this left 3 to work together instead of two groups of 2, this at times got other team members disheartened.

As 1 Team member had a good back ground of man management this allowed jobs and men to be managed in orderly fashion allowing for a smooth build throughout the project.

Environment The workshop at the college had been recently built this has allowed us as HND students the chance to be the first to build the graded unit projects here. College facilities although up to date with health and safety the tools provided were new and could perform most of the tasks at hand. There was also a limit to what could be carried out without waiting on supervision (1 man could not be everywhere at once) this led to a piece of material having to be removed from college to get the work carried out. There were 5 groups taking part from this class alone and 15 over all in the 3 classes. The room that was to facilitate the 5 groups at one time was around 15 by 6 meters in size this left conditions cramped for 5 groups to be working at the one time. The storage area was the same small in size and cramped with 15 groups storing materials in the one area. In my opinion this left cramped conditions at times with difficulty finding a path.

FacilitiesThe college facilities were new and up to date. This included wash up areas and lockers to store clothes and bags. Toilets were cleaned regularly each day. The canteen provided good food that tailored to most tastes. A library that had most software and books that was required to produce a technical report.

Unforeseen circumstancesWeatherThe weather could not be predicted for testing as it was not a set 15mph meant the test could not be done under the exact brief by the client. Although the variable wind speed allowed a good test of structure and stability.

BladesThe material that the group ordered for the turbines blades was 150mmØ PVC piping as this was harder to work with, 75mmØ PVC guttering was got instead this meant the team had to do a quick redesign of the blades making them longer.

Testing and commissioningSet upAn anemometer was used to measure the wind speed this allowed a location to be found to carry out the test. The turbine was then carried out side in 3 pieces to the college courtyard, using the break to ensure the blades didn’t turn before safety checks were put in place.



ChecksUsing the flowchart and verification strategy to carry out safety checks this allowed a strategy to be followed. The electrics were set up in order that they would be used and electrical flow chart was used to follow as a guide line in case of electrical failure.

TestOnce all the checks were done the test was ready to be carried out. The camera was in place for a video to be made. I myself looked after the electrics to ensure everything was in order. At this the break was released and allowed the wind to catch the blades. Everything was working fine mechanically and the regulator displayed 23volts at this I reduced the output voltage to 12volts before turning on the bulb. The bulb lit up nice and bright as the team saw it they realised there hard work had paid off.

Tables of checks and results

The results exceeded our expectations as the turbine produced 23volts this allowed the voltage to be regulated back to 12 volts before the 20watt bulb was lit. In relation to the brief this was nearly double what the client required Voltage. As the test was taken outside the speed of the wind could not be controlled this meant the wind fluctuated between 4.4 - 7.1m/s to produce such a high voltage.

Other results (see appendices 10)



Final project thoughtsNow that the project is nearing an end I feel that I put in a lot of hard work, effort, experience and time into the project which allowed it to be a success for the whole team and not just for myself. The project was testing and hard it allowed me to use my initiative, process thoughts and the ideas of others to produce technical reports as well as building a turbine that functions to the specifications required. I hope that my late nights/early mornings and dedication to ensuring this project was a success are recognised and that my contributions have been key in the results achieved.

What I learned from the project:Throughout the project I picked up new skills that will allow me to become a more efficient team leader and member. These skills were in project management, time management and communication with my team members other team members and also the client to ensure his requirements were met. I learned that an efficient team can produce good work and on schedule.

I learned that working as a team requires patience and understanding as my previous experience was invaluable when dealing with team members with less life/work skills than myself, this involved a lot of man management from myself to ensure every step of the project was kept on track as per the Gantt Chart.

Changes if it were done againIf the project was to be carried out again there would be few changes to the report itself and no changes to the team although the concept itself could be redesigned with lighter materials and also a bearing to make it easier for rotation into the wind.

ConclusionThis report follows the documentation and manufacture of a HAWT that met the specifications stated in stage 1. This has allowed the team to learn about the documentation and the part it plays in manufacture.

The design matrix within stage 1 helped the selection of the best solution to the client’s needs. This selection was reinforced in stage 2 with the successful manufacture of this concept which exceeded expectations by producing 23 volts on its test day with a variation of wind speeds.

Project management was to change on a weekly basis this was not the case I helped the other team members make decisions.

My personal objectives will be an ongoing improvement over time as situations change between work and home on a daily basis. I have had been fortunate enough to carry forward my experience from my current employment within the construction industry. I feel my experience with managing workers on site has allowed me to bring forward and develop my project management skills on this course.



Appendix 1 Please find Gantt chart attached



Appendix 2 Please find Minutes of meeting attached



Appendix 3 please see attached drawings list and drawings.



Appendix 4 Costs for labour



Appendix 5 Verification Flow charts



Appendix 6 Electrical Method statement

Electrical Method Statement of Works to be carried out:

Contract No:

1 Code: H&S 002

Contractors name:

Bespoke solutions Edition: 1

Activity: Building of a HAWT Page: 1Work

commences:

18/03/2016 Work Finish: 12/05/2016

Written by: Reviewed by: Accepted by:

Signed by:

Date:

1. Purpose: The purpose of this method statement is to identify and communicate the system of work for the build of a Horizontal wind turbine. This shall allow the operations of Bespoke Solutions to take place without causing harm to those with in the workshop, the quality standards required and without affecting the environment.

2. Scope of works : Duration: 8 Weeks Location: City of Glasgow College Riverside CampusTargets: Please See Attached Gantt chartHazards: Restricted work space Power tools Other groups working in the same area Manual handling Tight walk ways



3. Key personnel and contact information Supervisor: John RobertsonClient: JRSubcontractor: Bespoke SolutionsEmergencies: Royal infirmary Glasgow 112Incident Report: Incidents shall be recorded after action has been taken to ensure person and or persons have received the correct attention.

The persons listed above are required to take all reasonable steps to ensure they can be contacted in case of emergencies.

4. Workshop Safety

Health and safety procedures will be put in place before works commence.

Risk assessment:The risk assessment will allow team members to assess the work area and highlight any risks or potential hazards before works commence.

PPE Required:The mandatory PPE with in the work shop is- Safety bootsOveralls GogglesThese are to be worn at all times within the work shop to apply with college regulations.Additional PPE for this task will be (Gloves)

Permits will be issued where required. The electricity at work regulations 1989 that will be followed closely whilst working with live

connections.



Steps

Electrical components Photos

1

Please see workshop safety at the front of the document.

2

Electrical components will be selected and tested for electrical faults:Tools and equipment:Voltage RegulatorMotorTesting boxVoltmeterTerminal screw driverPliers6m of 0.6mm flexible cablelugs

3

Wire will be cut into lengths with the ends stripped to see the copper allowing lugs to be attached for attachment to components

4

Components will be connected in series to allow checks for electrical continuity using the volt meter. This will establish any faults that occur before testing.

5

Each piece will be marked to avoid confusion with other team’s materials; they will then be placed in a safe area until the final build.This process will be the same for the four legs.



Appendix 7 Please find Risk assessments attached



Appendix 8 Please find permits attached



Appendix 9 Please find manufacture processes attached



Appendix 10


Documents

Stage 2 final format v3