The primary objective of this project is to develop a three-blade MHK rotor with low manufacturing and maintenance costs. The proposed program will design, fabricate and test a novel half-scale low cost, net shape fabricated single piece three-blade MHK rotor with integrated health management technology to demonstrate significant Capital Expenditures (CAPEX) and Operational Expenditures (OPEX) cost reductions due to the novel design and manufacturing process. The proposed project is divided into three major tasks: Task 1: Single Piece Three-blade Kinetic Hydropower System (KHPS) Rotor Full-Scale and Half-Scale Design; Task 2: Composite Manufacturing Trials and Half-Scale Prototype Rotor Fabrication; and Task 3: Material Characterization and Half-Scale Prototype Test and Evaluation. These three tasks include design and analysis of full-scale and half-scale three-blade rotor prototypes using computational fluid dynamics (CFD) and finite-element analysis (FEA), demonstration of a novel half-scale net shape fabrication process, determination of a fatigue threshold composite strain allowable, three-blade rotor mold design, manufacture of half-scale rotor clam shell mold, three-blade rotor test fixture design and fabrication, development of final manufacturing and test plans, manufacture of the half-scale net shape composite single blade and three-blade prototypes, and test and evaluation of the half-scale rotor.
- PPTX8.1 Full-scale Rotor Design FEA Assessment.pptx
- stp8.2 Full-Scale 3-Blade Rotor CAD Model.stp
- stp8.3 QS Single Blade CAD.stp
- XLSX8.4 Geometry Inspection of QS Single Blade Clam-Shell Tool.xlsx
- XLSX8.6 Geometry Inspection Results of As-Fab Single Blade.xlsx
- XLSX8.7 10M Cycle Threshold Fatigue Test Data.xlsx
- PPTX8.8 Single Blade Fabrication Demo.pptx
- XLSX9.3 Geometric inspection of QS 3-Blade Clam-Shell Mold.xlsx
- XLSX9.1 CAPEX OPEX First Estimate.xlsx
- PPTX9.4 QS Fixture Design and Instrumentation Suite.pptx
- DOCX9.5 Testing and Validation Plan.docx
- stp9.7 QS 3-blade Rotor Test Fixture.stp
- XLSX10.1 CAPEX OPEX Second Estimate.xlsx
- DOCX10.2 Component Design Report.docx
- XLSX10.3 Comparison of Measured and Predicted QS 3-Blade Rotor Test Data.xlsx
- XLSX10.5 Final CAPEX OPEX.xlsx
- XLSX10.6 Actual Cost to Fab Single Blade 3-Blade Rotor and Prototypes.xlsx
- XLSX10.7 Updated Metrics Table.xlsx
- DOCX10.4 Final Test Report.docx
- DOCX9.2 Interim Design Report.docx
- ZIP8.5 As-Fabricated Single Blade.zip
- ZIP9.8 Image of As-Fab QS Test Fixture.zip
- ZIP9.6 Images QS 3-Blade Rotor.zip
- ZIP7.1 CFD Simulation Data.zip