Monday 31 December 2018

SMALL WIND ELECTRIC SYSTEM GENERAL IDEA




SMALL WIND ELECTRIC SYSTEM GENERAL IDEA



If you went through the planning steps to evaluate whether a small wind electric system will work at your location, you will already have a general idea about:

1.The amount of wind at your site
2.The zoning requirements and covenants in your area
3.The economics, payback, and incentives of installing a wind system at your site.

Now, it is time to look at the issues associated with installing the wind system:

1.Siting -- or finding the best location -- for your system
2.Estimating the system’s annual energy output and choosing the correct size turbine and tower
3.Deciding whether to connect the system to the electric grid or not.

Installation and Maintenance

The manufacturer of your wind system, or the dealer where you bought it, should be able to  help you install your small wind electric system. You can install the system yourself -- but before attempting the project, ask yourself the following questions:

# Can I pour a proper cement foundation?
# Do I have access to a lift or a way of erecting the tower safely?
# Do I know the difference between alternating current (AC) and direct current (DC) wiring?
# Do I know enough about electricity to safely wire my turbine?
# Do I know how to safely handle and install batteries?
If you answered no to any of the above questions, you should probably choose to have your system installed by a system integrator or installer. Contact the manufacturer for help, or contact your state energy office and local utility for a list of local system installers. You can also check the yellow pages for wind energy system service providers.

A credible installer may provide additional services such as permitting. Find out if the installer is a licensed electrician, and ask for references and check them. You may also want to check with the Better Business Bureau.

With proper installation and maintenance, a small wind electric system should last up to 20 years or longer. Annual maintenance can include:

# Checking and tightening bolts and electrical connections as necessary
# Checking machines for corrosion and the guy wires for proper tension
# Checking for and replace any worn leading edge tape on the turbine blades, if appropriate
# Replacing the turbine blades and/or bearings after 10 years if needed.
# If you do not have the expertise to maintain the system, your installer may provide a service    and maintenance program.

Siting a Small Electric Wind System

Your system manufacturer or dealer can also help you with finding the best location for your wind system. Some general considerations include:

Wind Resource Considerations -- If you live in complex terrain, take care in selecting the installation site. If you site your wind turbine on the top of or on the windy side of a hill, for example, you will have more access to prevailing winds than in a gully or on the leeward (sheltered) side of a hill on the same property. You can have varied wind resources within the same property. In addition to measuring or finding out about the annual wind speeds, you need to know about the prevailing directions of the wind at your site. In addition to geological formations, you need to consider existing obstacles, such as trees, houses, and sheds. You also need to plan for future obstructions, such as new buildings or trees that have not reached their full height. Your turbine needs to be sited upwind of any buildings and trees, and it needs to be 30 feet above anything within 300 feet.
System Considerations -- Be sure to leave enough room to raise and lower the tower for maintenance. If your tower is guyed, you must allow room for the guy wires. Whether the system is stand-alone or grid-connected, you also will need to take the length of the wire run between the turbine and the load (house, batteries, water pumps, etc.) into consideration. A substantial amount of electricity can be lost as a result of the wire resistance—the longer the wire run, the more electricity is lost. Using more or larger wire will also increase your installation cost. Your wire run losses are greater when you have direct current (DC) instead of alternating current (AC). If you have a long wire run, it is advisable to invert DC to AC.

Sizing Small Wind Turbines

 Small wind turbines used in residential applications typically range in size from 400 watts to 20 kilowatts, depending on the amount of electricity you want to generate.

A typical home uses approximately 10,932 kilowatt-hours of electricity per year (about 911 kilowatt-hours per month). Depending on the average wind speed in the area, a wind turbine rated in the range of 5–15 kilowatts would be required to make a significant contribution to this demand. A 1.5-kilowatt wind turbine will meet the needs of a home requiring 300 kilowatt-hours per month in a location with a 14 mile-per-hour (6.26 meters-per-second) annual average wind speed.

To help you determine what size turbine you'll need, first establish an energy budget. Because energy efficiency is usually less expensive than energy production, reducing your home's electricity use will probably be more cost effective and will reduce the size of the wind turbine you need.
The height of a wind turbine's tower also affects how much electricity the turbine will generate. A manufacturer should help you determine the tower height you will need.

Estimating Annual Energy Output

An estimate of the annual energy output from a wind turbine (in kilowatt-hours per year) is the best way to determine whether it and the tower will produce enough electricity to meet your needs.
A wind turbine manufacturer can help you estimate the energy production you can expect. The manufacturer will use a calculation based on these factors:

# Particular wind turbine power curve
# Average annual wind speed at your site
# Height of the tower that you plan to use
# Frequency distribution of the wind -- an estimate of the number of hours that the wind will  blow at each speed during an average year.
The manufacturer should also adjust this calculation for the elevation of your site.

To get a preliminary estimate of the performance of a particular wind turbine, you can use the following formula:
AEO= 0.01328 D2 V3
Where:
AEO = Annual energy output (kilowatt-hours/year)
D = Rotor diameter, feet
V = Annual average wind speed, miles-per hour (mph), at your site
Note: the difference between power and energy is that power (kilowatts) is the rate at which electricity is consumed, while energy (kilowatt-hours) is the quantity consumed.

Grid-Connected Small Wind Electric Systems
Small wind energy systems can be connected to the electricity distribution system. These are called grid-connected systems. A grid-connected wind turbine can reduce your consumption of utility-supplied electricity for lighting, appliances, and electric heat. If the turbine cannot deliver the amount of energy you need, the utility makes up the difference. When the wind system produces more electricity than your household requires, the excess is sent or sold to the utility.

With this type of grid connection, your wind turbine will operate only when the utility grid is available. During power outages, the wind turbine is required to shut down due to safety concerns.

Grid-connected systems can be practical if the following conditions exist:

# You live in an area with average annual wind speed of at least 10 miles per hour (4.5 meters per second).
# Utility-supplied electricity is expensive in your area (about 10–15 cents per kilowatt-hour).
# The utility's requirements for connecting your system to its grid are not prohibitively expensive.

There are good incentives for the sale of excess electricity or for the purchase of wind turbines. Federal regulations (specifically, the Public Utility Regulatory Policies Act of 1978, or PURPA) require utilities to connect with and purchase power from small wind energy systems. However, you should contact your utility before connecting to its distribution lines to address any power quality and safety concerns.

Your utility can provide you with a list of requirements for connecting your system to the grid. For more information, see grid-connected home energy systems.

Wind Power in Stand-Alone Systems
Wind power can be used in off-grid systems, also called stand-alone systems, not connected to an electric distribution system or grid. In these applications, small wind electric systems can be used in combination with other components -- including a small solar electric system -- to create hybrid power systems. Hybrid power systems can provide reliable off-grid power for homes, farms, or even entire communities (a co-housing project, for example) that are far from the nearest utility lines.

An off-grid, hybrid electric system may be practical for you if the items below describe your situation:

# You live in an area with average annual wind speed of at least 9 miles per hour (4.0 meters per second).
# A grid connection is not available or can only be made through an expensive extension. The cost of running a power line to a remote site to connect with the utility grid can be prohibitive.
# You would like to gain energy independence from the utility.
# You would like to generate clean power.

Saturday 29 December 2018

ULTRASONIC WELDING


ULTRASONIC WELDING



       Ultrasonic welding is a welding technique uses ultrasonic vibrations locally applied on the work pieces being held together under pressure to create a solid state weld. The two components are subjected to a static normal force and an oscillating shearing stress. The shearing stress is applied at the tip of a transducer. Ultrasonic assembly uses ultrasonic vibratory energy which is transmitted through the parts to melt and bond thermoplastic material and joining thin sheet gauge metals and other light weight metals. This technique is fast, economical and contaminate the work piece.  In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together. In this welding frictional heat is produced by the ultrasonic waves and force is used for the joining process, the waves are transferred to the material under pressure with a sonometer.

Set up




















Parts

1. Transducer : Produce high frequency ultrasonic vibrations.

2. Converter : Converts the electrical signal in to a mechanical                                 
                        vibration.
3. Booster : Modifies the amplitude of vibration

4. Sonotrode : Applies the mechanical vibrations to the parts to be 
        
                        welded 


Ultrasonic transducers are of two types

A. Piezo electric type: Vibrations are produced by piezocrystal

     by “Reverse peizo electric effect.PZT – LeadZicronate  

     Titanate Crystals  are used



B. Magnetostrictive type : it is a property of ferromagnetic 

    materials that causes them to change their shape or dimensions 

    during the process of magnetization.










Ultrasonic welding Mechanism

 A static clamping force is applied perpendicular to the interface between work pieces. the contacting sonotrode oscillates parallel to the interface. combined effect of static and oscillating forces produces deformation which promotes welding.



Advantages of  ultra sonic welding   

1.The process permits welding of thin to thick sections as well as       joining a wide variety of dissimilar metals.

2. Since, the temperatures used are low and no arching or current      flow is involved, the process can be applied to heat sensitive            electronic components with better efficiency for many
    electronic components.

3. Intermediate compounds very rarely form as there is
    no contamination of the weld under surrounding areas.

4.The required penetration is less than most competing processes      for example, resistance welding and correspondingly 
  lesser energy is needed to produce the welds.

Disadvantage

1.Ultrasonic welding is restricted to the lap joint welding of; thin       sheets, foil and wires and the attaching of thin sheets to heavier       structural members. The maximum thickness of weld is about 2.5     millimeter for aluminum and about 1 millimeter for harder                materials.


Applications of USW

  •  Aerospace and automotive industries

  •  Medical industry

  •  Packaging industry

  •  Electrical and electronics industry

  •  Toy’s
D
                                                             


























Tuesday 25 December 2018

SOLAR INSTALLATION

SOLAR INSTALLATION



SOLAR INSTALLATION


Solar power is arguably the cleanest, most reliable form of renewable energy available, and it can be used in several forms to help power your home or business. Solar-powered photovoltaic (PV) panels convert the sun's rays into electricity by exciting electrons in silicon cells using the photons of light from the sun. This electricity can then be used to supply renewable energy to your home or business.

To understand this process further, let’s look at the solar energy components that make up a complete solar power system.

The roof system

In most solar systems, solar panels are placed on the roof. An ideal site will have no shade on the panels, especially during the prime sunlight hours of 9 a.m. to 3 p.m.; a south-facing installation will usually provide the optimum potential for your system, but other orientations may provide sufficient production. Trees or other factors that cause shading during the day will cause significant decreases to power production. The importance of shading and efficiency cannot be overstated. In a solar panel, if even just one of its 36 cells is shaded, power production will be reduced by more than half. Experienced installation contractors such as NW Wind & Solar use a device called a Solar Pathfinder to carefully identify potential areas of shading prior to installation.

Not every roof has the correct orientation or angle of inclination to take advantage of the sun's energy. Some systems are designed with pivoting panels that track the sun in its journey across the sky. Non-tracking PV systems should be inclined at an angle equal to the site’s latitude to absorb the maximum amount of energy year-round. Alternate orientations and/or inclinations may be used to optimize energy production for particular times of day or for specific seasons of the year.

Solar panels
Solar panels, also known as modules, contain photovoltaic cells made from silicon that transform incoming sunlight into electricity rather than heat. (”Photovoltaic” means electricity from light — photo = light, voltaic = electricity.)

Solar photovoltaic cells consist of a positive and a negative film of silicon placed under a thin slice of glass. As the photons of the sunlight beat down upon these cells, they knock the electrons off the silicon. The negatively-charged free electrons are preferentially attracted to one side of the silicon cell, which creates an electric voltage that can be collected and channeled. This current is gathered by wiring the individual solar panels together in series to form a solar photovoltaic array. Depending on the size of the installation, multiple strings of solar photovoltaic array cables terminate in one electrical box, called a fused array combiner. Contained within the combiner box are fuses designed to protect the individual module cables, as well as the connections that deliver power to the inverter. The electricity produced at this stage is DC (direct current) and must be converted to AC (alternating current) suitable for use in your home or business.

Inverter
The inverter is typically located in an accessible location, as close as practical to the modules. In a residential application, the inverter is often mounted to the exterior sidewall of the home near the electrical main or sub panels. Since inverters make a slight noise, this should be taken into consideration when selecting the location.

The inverter turns the DC electricity generated by the solar panels into 120-volt AC that can be put to immediate use by connecting the inverter directly to a dedicated circuit breaker in the electrical panel.

The inverter, electricity production meter, and electricity net meter are connected so that power produced by your solar electric system will first be consumed by the electrical loads currently in operation. The balance of power produced by your solar electric system passes through your electrical panel and out onto the electric grid. Whenever you are producing more electricity from your solar electric system than you are immediately consuming, your electric utility meter will turn backwards!

Net meter
In a solar electric system that is also tied to the utility grid, the DC power from the solar array is converted into 120/240 volt AC power and fed directly into the utility power distribution system of the building. The power is “net metered,” which means it reduces demand for power from the utility when the solar array is generating electricity – thus lowering the utility bill. These grid-tied systems automatically shut off if utility power goes offline, protecting workers from power being back fed into the grid during an outage. These types of solar-powered electric systems are known as “on grid” or “battery-less” and make up approximately 98% of the solar power systems being installed today.

Other benefits of solar
By lowering a building’s utility bills, these systems not only pay for themselves over time, they help reduce air pollution caused by utility companies. For example, solar power systems help increase something called “peak load generating capacity,” thereby saving the utility from turning on expensive and polluting supplemental systems during periods of peak demand. The more local-generating solar electric power systems that are installed in a given utility's service area, the less capacity the utility needs to build, thus saving everyone from funding costly additional power generating sources. Contributing clean, green power from your own solar electric system helps create jobs and is a great way to mitigate the pollution and other problems produced by electricity derived from fossil fuel. Solar-powered electrical generating systems help you reduce your impact on the environment and save money at the same time!

Sunday 23 December 2018

MAGNETIC ABRASIVE FINISHING PROCESS

MAGNETIC ABRASIVE
FINISHING PROCESS





                                                   Finishing processes may be employed to: improve appearance, adhesion or wettabilitysolderability, corrosion resistance, tarnish resistance, chemical resistance, wear resistance, hardness, modify electrical conductivity, remove burrs and other surface flaws, and control the surface friction. In limited cases some of these techniques can be used to restore original dimensions to salvage or repair an item. An unfinished surface is often called mill finish.

                         Abrasive machining is a machining process where material is removed from a work piece using a multitude of small abrasive particles. Common examples include grinding, honing, and polishing. Abrasive processes are usually expensive, but capable of tighter tolerances and better surface finish than other machining processes. Abrasive machining processes can be divided into two categories based on how the grains are applied to the work piece, in bonded abrasive processes, the particles are held together within a matrix, and their combined shape determines the geometry of the finished work piece. For example, in grinding the particles are bonded together in a wheel. As the grinding wheel is fed into the part, its shape is transferred onto the work piece. In loose abrasive processes, there is no structure connecting the grains. They may be applied without lubrication as dry powder, or they may be mixed with a lubricant to form a slurry. Since the grains can move independently, they must be forced into the work piece with another object like a polishing cloth or a lapping plate.



                              
                                  Traditionally finishing processes are crucial, expensive uncontrolled and a labour intensive phase in the overall production. It also includes total production cost and time. The ever increasing demand from the industry for better quality & cost competitive product with complex design material need to good surface finishing. In case of some application like internal finishing of capillary tube, machining of titanium alloy, aircraft application, medical application where high surface finish parts are required. Magnetic abrasive finishing (MAF) is the process which capable of precision finishing of such work pieces. Since MAF does not require direct contact with the tool, the particles can be introduced into area which are hard to reach by conventional techniques.




      















                             







   

            
MAF Process can be classified based on the type of magnetic field used and type of work piece

BASED ON TYPE OF MAGNETIC FIELD


1. Magnetic Abrasive Finishing with Permanent Magnet           
2. Magnetic Abrasive Finishing with Direct Current
3. Magnetic Abrasive Finishing with Alternating Current

BASED ON WORK PIECE

 1. Lathe based MAF
 2. Milling based MAF








                               MAF is process in which mixture of non-ferromagnetic abrasive and ferromagnetic iron particle is taken and magnetically energized using a magnetic field. The work piece is kept between the two poles (N&S POLE) of a magnet. The working gap between the work piece and a magnet is filled with magnetic abrasive particle (MAPs). MAPs can be used as bonded or unbounded. The magnetic abrasive particles join each other along lines of magnetic force and form a flexible magnetic abrasive brush (FMAB). This brush behaves like a multi point cutting tool for the finishing operation.


                The main advantages of Magnetic abrasive finishing process are

    1. The setup is independent of work piece material; it can efficiently
         finish ceramics, stainless steel, brass, coated carbide and silicon.
    2. This method can have used to finish ferromagnetic materials but as well
        as no ferromagnetic materials.
    3. Self-adaptability and controlability.
    4. Due to the flexible magnetic abrasive brush, it can finish any
        Symmetric work piece shape, if electromagnet designed accordingly.
    5.  The finishing tool requires neither compensation nor dressing