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.
8.1 Full-scale Rotor Design FEA Assessment.pptx
PPTX8.2 Full-Scale 3-Blade Rotor CAD Model.stp
stp8.3 QS Single Blade CAD.stp
stp8.4 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
XLSX8.8 Single Blade Fabrication Demo.pptx
PPTX9.3 Geometric inspection of QS 3-Blade Clam-Shell Mold.xlsx
XLSX9.1 CAPEX OPEX First Estimate.xlsx
XLSX9.4 QS Fixture Design and Instrumentation Suite.pptx
PPTX9.5 Testing and Validation Plan.docx
DOCX9.7 QS 3-blade Rotor Test Fixture.stp
stp10.1 CAPEX OPEX Second Estimate.xlsx
XLSX10.2 Component Design Report.docx
DOCX10.3 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
XLSX10.4 Final Test Report.docx
DOCX9.2 Interim Design Report.docx
DOCX8.5 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
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