Wind Turbine Design Challenge (Version 2)

thingiverse

This is the second edition of my Wind Turbine Design Challenge project where students test their skills in optimizing the blade for a small scale wind turbine by manipulating the properties of the provided Solidworks model. Students design, 3D print and test their creations, then revisit their designs to improve performance. I designed the base model in Solidworks, labeling key dimensions that students should explore. I introduced the project to my class, demonstrating how to adjust the dimensions using Solidworks. With a single class period to experiment, students learn hands-on experience with the software and discover potential issues before tackling the actual project. Next, students conduct research to determine optimal dimension values for each feature. They create models reflecting their findings, which are then 3D printed and tested in a wind tunnel. Overview and Background The design of this blade features four Lofted-Boss profiles where students can modify specific aspects at designated points along the blade's length. By adjusting profile distance from the base, students can change the overall blade length. Critical points marked by these profiles allow for shape adjustments if desired. Adding more profiles is an option for advanced students. Each profile enables students to alter angle-of-attack, cup-radius and thickness at leading and trailing edges. Anchor points facilitate creating swept or straight blades. Polishing After 3D printing their designs, students must clean and polish them using needle-files and sandpaper to achieve a finer shape and airfoil surface. This process typically takes one class period, with many students opting to work on their projects outside of class as well.