Learning Outcomes
After completing this assessment, the student should be able to:
1) Actively manage the design process and monitor progress.
2) Apply analytical techniques, from a range of engineering disciplines, in a design context.
3) Apply engineering knowledge and judgement to solve design problems.
4) Determine the compliance of designs relative to the relevant engineering standards.
5) Work in a “team-based” design approach typical in industry

Introduction

You are working for a company called ABC and your team have been entrusted to design a large wind turbine for a given location.
The aim of the project is to design a large wind turbine which be placed in a location given to you with relevant wind data.
A key element of this assessment is for the group to come together and work effectively as a group. There will be difficulties and delays. The initial plan will likely have to change, but the group should still all be working towards the highest quality submission they can achieve through hard work and teamwork. This assignment will use Peer assessment within canvas (Buddy check) to weight 30% of the final grade. The questions used in the peer assessment are given below.
You will be using the knowledge obtained in previous years as well some specific technical skills on wind turbine design you obtain in this module. You will be using an open source software Qblade for the design and simulation of wind turbines.

The project has the following work packages:
WP 1: Conceptual Design 10%
• Product Design Specification
• Conceptual design sketches as well as concept analysis, working principles ranking of these sketches and reasons for choosing best design with decision matrix.
• The conceptual design should confirm the layout configuration for the turbine i.e gearbox/shaft configuration/braking system
WP2: Wind Assessment of the location: Local Wind analysis, prevailing wind calculation 10%
• Analyse the wind data at the location and identify the range of the wind which is the most suitable for generating the required power
• Develop a wind speed probability distribution (at your hub height), based on wind data supplied
• Develop a wind speed probability distribution (at your hub height), based on a Weibull distribution at the proposed site
• Predicted energy yields based on power curves developed in Q-Blade.
WP3: Design and Performance Calculations: Aerofoil Selection and analysis, blade design, power curve, wind turbine performance calculations, yaw control etc 20%
• Specify the size (Qblade and conceptual design): the size of the turbine including the size of the rotor, mast, chord, Hub, nacelle, number of blades, twist and pitch angle, aerofoils.
• Carry out a performance analysis (Qblade): it should include an analysis of the aerofoils polars, performance analysis of the blades, rotor and turbine, power curves and parametric studies of the power curve, and the design rotational speed.
WP4: Structural Design: Spar and Rib design, Stress Calculations, Analysis of the Loads, Material selections 20%
• Material selections with rational for internal and external components of the blade, weight estimation of the blades.
• Internal structure design: Design of shell and internal spars (using Qblade)
• Structural load analysis (Using Qblade): Vibration mode Analysis, Static Load Calculation
WP 5: Component selection based on calculations: Shafts, gearbox, brakes, bearings, generator 10%
• Detailed design of calculations
• Shaft Design, torsional and bending moment, estimation of the main shaft diameter
• Component selection for the gearbox, braking system, generator, shaft connections
• Selecting other important main parts and their material ex: bolts, bearings, gears etc
WP 6: Design Communication, drawings and standards (BS 8888:2020) 20%
• Rendered Images of 3D cad models
• Drawings. These should include:
i) Assembly drawings i.e Gearbox, shaft with bearings, hub and hub connections
ii) One drawing of the overall design solution generated, complete with bills of materials (BOM)
iii) A drawing of the main shaft with geometric tolerances
WP 7: Manufacturing design and costs as well as manufacturing process 10%
• Detailed Costings and Returns. Must include:
1. Fixed overheads
2. Design Costs
3. variable overheads (e.g. Material Cost)

• Returns
(1) Power Generated per Annum
(2) Cost of maintenance per Annum

Outcomes from these 7 workpackages must be combined into a single submission and formatted into a concise report. Each week these workpackages will be discussed in greater detail in the lecture session.

Management of Project

Management of the design team will be critical and the group will need to effectively plan and regularly report back to the module team about progress.
1. Each group should begin by looking at available hours (from proforma) and allocate hours to workpackages, and subtasks, along with allocating group members responsible for Work packages/tasks.
2. The group should produce a Gantt chart and resource plan (stacked bar etc with hours effort etc) with all the important tasks and commitments indicated. Groups must identify other assessment deadlines/project commitments and obtain a realistic understanding of when the tasks will be done. This should be available on the canvas group page, but be updated as the project progresses.
3. Each week prior to the scheduled progress meetings, groups should prepare a ‘5 box report’ to update the module team. This should be added to the group’s canvas page, with 8 are eventually loaded onto canvas (one for each progress meeting) Each 5 Box should be updated with resources committed and any issues present each week.
4. The progress meetings will take place via MS teams and be focussed around work that has been completed, risks identified, issues preventing progress, group issues etc.