GENERATOR
By
Antonius Alex 11112074
BACHELOR’S DEGREE in
MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY EduTown BSD City
Tangerang 15339 Indonesia
August 2016
Revision after the Thesis Defense on 27th of July 2016
STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Antonius Alex
_____________________________________________
Student Date
Approved by:
Ir. Arko Djajadi, Ph.D.,
_____________________________________________
Thesis Advisor Date
Dr. Ir. Gembong Baskoro M.Sc
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Dean Date
Antonius Alex ABSTRACT
DESIGN AND IMPLEMENTATION OF TESTING SYSTEM FOR PERFORMANCE CHARACTERIZATION OF WIND TURBINE GENERATOR
By Antonius Alex
Ir. Arko Djajadi, M.Sc., Ph.D, Advisor
SWISS GERMAN UNIVERSITY
The purpose of this thesis work is to design, develop and test a measurement system for performance evaluation and simulation of a small wind turbine generator in a laboratory. There is no such system available to easily check the torque, speed and power of a motor to be used as a generator at a series of rotational speed. In order to reduce the chance of failure and to make sure that the wind turbine generator will be able to operate at maximum or at least produce favourable output power, it has to be tested with varying rotational speeds before it is installed on top of the tower of a wind power rig. The proper testing system would consist of a controllable artificial driver and device to monitor some parameters such as applied rotational speed and torque, and also the resulting voltage, current, and the power generated by the turbine generator.
An AC motor with frequency inverter is used in this project as the driver to vary the input speed. To measure the torque, an in-house designed Wheatstone bridge with 4 active strain gauges cooperated with slip rings and brushes are used to convert the mechanical torque variation on the connecting shaft into resistive change and finally into an electrical signal. Tachometer is used to measure the shaft speed. The output power is obtained by using multimeters to measure the resulting current and voltage.
Altogether, the measured parameters will determine the characteristic performance of the wind turbine generator that can be expected if the generator is installed later.
Keywords: Torque sensor, Slip rings, Strain Gauges, Generator, AC motor, Arduino microcontroller
Antonius Alex
© Copyright 2016 by Antonius Alex All rights reserved
Antonius Alex DEDICATION
I dedicate this thesis work for God, family, friends, and my lovely country, Indonesia. Dedication of this paper is done for renewable and efficiency of energy use to take care of our planet from global warming.
Antonius Alex ACKNOWLEDGEMENTS
I would like to thanks my advisor, Arko Djajadi, Ir. M.Sc. Ph D. that guide me to accomplish this thesis project.
Special thanks to Yohanes Fredhi Sangandi Pratomo A. Md. for his help especially for machining part such as lathe machining and milling machining. Also for accompanying me to make ease, safe and better decision to build this project.
I would also want to thank to all of my friends who also have their though time to raise up and support each other until this project is done. I thank for my friends who have similar project and urge to help each other to success.
Antonius Alex TABLE OF CONTENTS
Page
STATEMENT BY THE AUTHOR ... 2
DEDICATION ... 5
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 10
LIST OF TABLES ... 12
CHAPTER 1 - INTRODUCTION ... 13
1.1 Background ... 13
1.2 Thesis Objectives ... 13
1.3 Thesis Scope ... 14
1.4 Thesis Limitations ... 14
1.5 Significance of Study ... 14
1.6 Hypothesis ... 15
1.7 Thesis Structure ... 15
CHAPTER 2 - LITERATURE REVIEW ... 16
2.1 Torque Measurement ... 16
2.1.1 Torque Sensor ... 16
2.1.1.1 Slip Rings and Brushes ... 18
2.1.1.2 Strain Gauges ... 19
2.1.2 AC Induction Motor ... 23
2.1.3 DC Motor ... 26
2.1.4 Frequency Inverter ... 27
2.1.5 Microcontroller ... 31
2.1.6 Motor Generator Set ... 32
2.1.7 Tachometer ... 34
2.1.8 Digital Multimeter ... 34
2.1.9 Current Sensor ... 36
2.1.10 Speed Sensor ... 37
2.2 Previous Project Related to Thesis ... 38
2.2.1 Wheel Torque Sensor ... 38
2.2.2 Torque Measuring Device ... 38
CHAPTER 3 - METHODOLOGY ... 40
3.1 General Overview ... 40
Antonius Alex
3.2 Mechanical Design ... 41
3.2.1 Mounting Parts ... 42
3.2.1.1 Motor Generator Set Mounting ... 42
3.2.1.2 Frequency Inverter Mounting ... 43
3.2.1.3 Slip Rings and Brushes Mounting ... 44
3.2.1.4 Pillow Block Mounting ... 44
3.2.2 Design of Shaft ... 45
3.2.3 Coupling of the system ... 46
3.2.4 Connecting Rod for Torsion and Strain Gauge Calibration ... 48
3.2.5 Use of Pillow Block Bearing ... 48
3.2.6 Design of Encoder ... 49
3.3 Electrical Design ... 50
3.3.1 Variable Frequency Inverter ... 50
3.3.2 Three Phase AC Induction Motor ... 51
3.3.3 DC Generator ... 53
3.3.4 Strain Gauge Implementation ... 54
3.3.5 HX711 24-bit Module... 58
3.3.6 Microcontroller Board ... 59
3.4 Programming Design ... 60
3.4.1 Flowchart Design Program of HX711 ... 60
3.4.2 Flowchart Design Program of the Optocoupler ... 62
3.5 Torque Calibration ... 63
CHAPTER 4 - RESULTS AND DISCUSSIONS ... 65
4.1 Results and Discussions Overview ... 65
4.2 Testing System Performance of Generator Manufacturing Results ... 65
4.2.1 Testing System of Generator Parts Assembly ... 66
4.2.2 Mounting Base Plate Result ... 66
4.2.3 Variable Frequency Drive Mounting ... 67
4.2.4 Pillow Block Mounting ... 68
4.2.5 Brushes Mounting ... 69
4.2.6 Motor and Generator Mounting ... 69
4.3 Torque Calibration Result ... 70
4.4 Testing System Performance of Generator with No Load ... 72
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4.5 Testing System Performance of Generator Using Lamp as Load ... 75
CHAPTER 5 - CONCLUSIONS AND RECOMMENDATIONS ... 80
5.1 Conclusions ... 80
5.2 Recommendations ... 80
GLOSSARY ... 81
REFERENCES ... 82
APPENDICES ... 84
APPENDIX A – Technical Drawing ... 84
APPENDIX B – Programming Code ... 90
APPENDIX C – Data Sheet ... 92
APPENDIX D – Bill of Material ... 117
CURRICULUM VITAE ... 118
