Stage 1 Graded Unit report

2016
Bespoke Solutions
PatrickO'Donnell
[GMU2]
Team engineers:RobertMcLean,ScottMcPherson,Mark Mortimer. Client:JohnRobertson

February26, 2016 [GMU2] Patrick O’Donnell
Bespoke solutions |Introduction 1
Table of Contents
1. Introduction................................................................................................................................3
2. Design Brief ................................................................................................................................3
2.1 Aim.....................................................................................................................................3
2.2 Target Audience ..................................................................................................................3
2.3 Marketing...........................................................................................................................3
3. Specifications..............................................................................................................................4
3.1 Functions ............................................................................................................................4
3.1 Materials.............................................................................................................................4
3.2 Ergonomics..........................................................................................................................4
3.3 Manufacturing Process.........................................................................................................4
3.4 Equipment/ Tools ................................................................................................................4
3.5 Product andlife span ...........................................................................................................4
3.6 Quality assurance /control ...................................................................................................4
3.7 Cost....................................................................................................................................4
3.8 Time scale ...........................................................................................................................4
3.9 Health and Safety ................................................................................................................5
3.10 Environment........................................................................................................................5
3.11 Drawings and tolerances......................................................................................................5
3.12 Documentation....................................................................................................................5
4 Personal Objectives.....................................................................................................................6
4.1 Project Objectives................................................................................................................6
5 Report content............................................................................................................................6
6 Schedule.....................................................................................................................................6
7 Research (HAWT) ........................................................................................................................7
7.1 A brief history of (HAWT) .....................................................................................................7
7.2 Advantages..........................................................................................................................7
7.3 Disadvantages .....................................................................................................................7
7.4 How It Works.......................................................................................................................8
7.5 Calculations.........................................................................................................................9
7.6 Cost....................................................................................................................................9
7.6.1 Budget.........................................................................................................................9
7.6.2 Salary...........................................................................................................................9

7.6.3 Additions .....................................................................................................................9
7.6.4 Total costs....................................................................................................................9
8 Materials required.................................................................................................................10
9 Conceptual Design.................................................................................................................10
10 Design Matrix........................................................................................................................11
10.1 Evaluation.........................................................................................................................12
The team approach ...................................................................................................................12
10.1.1 Design process ...........................................................................................................12
11 Health and Safety..................................................................................................................13
12 Bill of Materials .....................................................................................................................14
13 Conclusion ............................................................................................................................15
14 Appendices ...........................................................................................................................16
Appendix 1...................................................................................................................................16
Appendix 2...................................................................................................................................18
Appendix 3...................................................................................................................................20
Health and Safety at work act 1974 (www.legislation.gov.uk). .....................................................20
PPE (PERSONAL PROTECTIVE EQUIPMENT) at work regulations 1992 ...........................................20
Manuel handling operations act 1992 (www.legislation.gov.uk)...................................................21
Working at height regulation’s 2005 (www.legislation.gov.uk).....................................................21
The provisions and use of work equipment regulation’s(PUWER) 1998 (www.legislation.gov.uk)..21
Supply of machinery(safety) regulations 2008 (www.legislation.gov.uk)......................................22
HSE risks related to moving parts (www.HSE.gov.uk)...................................................................22
Electricity at work regulations 1989 (www.legislation.gov.uk)......................................................22
Risk assessments (www.HSE.gov.uk)...........................................................................................23
Permit to work (www.HSE.gov.uk)..............................................................................................23
Logbook.......................................................................................................................................24
Appendix 4 Minutes of Meetings ...................................................................................................25
Appendix 5 Additional Drawings....................................................................................................26
Appendix 6 Additional Gantt chart & Mind Map .............................................................................27
Appendix 7 Concept reports 2,3,4..................................................................................................28
Bibliography.....................................................................................................................................29

1. Introduction
Due to increasedneedforreductionof pollutionsuchasCO² and global warminglevels.Ithasbecome a
priority tofindformsof renewable energy.
There will be fourconceptual designsconsideredwithinthisreportbutjustone will be chosenasthe
final product, thiswill be the windturbine thatbestfitsthe client’sneeds.Thiswill be selectedusinga
designmatrix whichwill be formedwith informationandcalculationscollectedduringthe investigation
stage.
2. Design Brief
The clientJR hasrequestedatenderforthe designandmanufacture of a windturbine fromBespoke
Solutions toproduce 12v of electricityandthatwill lighta20watt bulb byharnessingthe powerfrom
just15mph winds.The materialsbudgetwillbe setat£150.
Engineersincludedinthe projectwillbe PatrickO’Donnell,ScottMcPherson,Mark Mortimerand Robert
MacLeod. Projectresearchshall be carriedoutincollege andat home thiswill includethe use of books
and internettoallowawide varietyof information.Meetingswill be heldonweeklybasis toensure a
goodunderstandingof the client’sneeds. (MOMSee Appendices4)
The projectcommenced onthe 04/12/2015 and the deadline forstage 1 will be 26/02/2016, Stage 2&3
shall be completedbythe 27/5/2016, and the presentationshall be heldonthe 06/06/2016. Each team
memberwill receive individual tasksthiswillallow concurrentengineering;these taskswill be outlined
on a Gantt chart to allowtimescalestobe followed.Eachindividual will make theirownconceptand
research.
A designmatrix will be completetoensure the bestpossible selectionforthe detailed designand
manufacture whichwill selectthe windturbine thatbestfits the clientneeds.
2.1 Aim
 Designa viable product
 Define the customer’sneeds
 Manufacture on a largerscale
2.2Target Audience
If the designcanbe replicatedona largerscale,thenpossiblylargerturbinescouldbe producedusing
the same designandengineeringconceptswhichwouldbe of interesttowindfarmdevelopers.
2.3Marketing
Marketingwill take place onsocial media,local newspapers,largercompaniescanbe approachedas a
wayto advertise,andhavingavailable stock tosell.

Bespoke solutions |Specifications 4
3. Specifications
3.1Functions
 The turbine will produce 12 Voltsof electricity.
 It will lighta20-watt bulb.
 Poweredby 15mph winds.
3.1Materials
 Materialsmustbe robust to withstandexternal forces.
 Theywill alsoneedtocome withinthe tightbudget.
 Selectedusingstandardization.
3.2Ergonomics
 A radiusof 650mm to produce the 12 voltsneeded.
 The towerwill standat 1200mm.
 The towerwill notbe wide as to allow agood flow of airaround the turbine.
3.3Manufacturing Process
 Manufacturingwill be done byhand.
 CAD will be usedtoprovide detaileddrawings.
3.4Equipment/ Tools
 Toolswill be provided bythe collegeworkshop.
 The college workshop will be usedtobuildthe windturbine.
 Healthand Safetymethodswill be usedtoensure asafe workingenvironment.
3.5Product and life span
 Maintenance will needtobe carriedout toensure a longworkinglife span.
 Materialswill be selectedsoasto recycle at the endof itslife span.
 Non-toxicmaterialswill be usedastoallow the safe removal andmethodof recycle.
3.6Quality assurance /control
 Qualitycontrol andassurance will be carriedoutto provide the bestpossiblefinish.
 Communicationwiththe clientwillbe keptforanychangesto theirneeds.
 A final inspectionwill be giventoensure standards.
3.7Cost
 The windturbine will be designandmanufacturedfor£150.
 Thisdoesnot coverlabouror facilitiescosts.
3.8Time scale
 Thisprojectshouldnot take longerthan160 to 200 hoursto complete.
 Thiswill include research,design,manufactureandapresentationtothe client.

Bespoke solutions |Specifications 5
3.9 Health and Safety
 Riskassessmentswill be carriedoutbefore workcommences.
 Inspectionswill be carriedouttoensure strengthandstabilitythroughoutthe build.
 Everyeffortwill be made toensure asafe workingenvironment.
3.10 Environment
 The turbine will workoutdoorsonly.
 It will needtobe corrosionresistantandwithstandthe forcesof nature.
3.11 Drawings and tolerances
 All drawingsshall providedimensionandinformationforfinishedproduct
 Dimensionswill be drawnusingacontinuousthinline- Projectionlineswill indicate wherethe
dimensionsstartandfinishes
 Dimensionswill be inmm’s
 All dimensionslessthan1mmshall be writtenas0.45mm
3.12 Documentation
 Designbrief
 Manual
 Maintenance Guide
 Basic Assembly

Bespoke solutions |Personal Objectives 6
4 Personal Objectives
 The abilitytoproblemsolve
 To ensure goodtime management
 The abilitytocommunicate more effectively
 Team managementskills
 Become a viable teammember
4.1Project Objectives
 Achievingresultsandcontinuousimprovement
 Developingothers
 Team work
 CommunicatingandInfluencing
 Innovationandcreativity
 Initiative
5 Report content
Investigationstage
 Designbrief
 Specification
 Schedule
 Manufacturingconsiderations
Developmentstage
 Simulationandmodeling
 Detailsof final design
Evaluationstage
 Benefitsof ateamapproach
 Evaluationof designprocess
 Conclusion
6 Schedule
(Please findattachedonnextpage.) AdditionalGanttchartsand Mind map see (Appendix6)

Bespoke solutions |Research(HAWT) 7
7 Research (HAWT)
Please findconcepts2,3&4attached.(See Appendix 7)
7.1 A brief history of (HAWT)
In ancientEgyptiantimeswindwasusedtosail shipsonthe Nile.Large paddle wheelsformedthe first
windmillsin Persia.Hollandformedbladescenturieslaterthese werestill formedbysails.
In the 12th
century- there mainuse wasto grindgrain.
The 19th
windturbines were usedforpumpingwaterandgeneratingelectricityinrural areas.
In the 21st
centurywindturbinesare motorizedto produce electricityatanindustrial level.
7.2Advantages
 Bladescan be adjustedtogive optimumangle of attack.
 Tall towersinwindshearsitesgive accesstohighwinds.Every10m = 20% more windand34%
more poweroutput.
 Bladesare alwaysperpendiculartowindsallowingthe bladestogainpowerinthe hole rotation.
7.3Disadvantages
 Transportationcostsare highmovinglarge partsup to 90m long.
 Costsof gears,motorsand huge blades.
 Highmaintenance coststoreach Motors, gearsand blades.

7.4How It Works
Industrial sizedHAWTare made up of many components these are placedatthe topof a hightowerand
protectedbya nacelle,the bladesthatare attachedto a rotor these turnon theiraxisbywindpassing
throughthe bladescreatinga lowpressure atthe bottomand highpressure atthe top.The rotor is
attachedto a highspeedshaftthisisthen attachedto gears that helpthe movementproduce more
torque thisturnsa lowspeedshaftthatturnsthe generatorthis allowskineticenergytobe turnedto
electrical energyandthenpassedontoa transformer328ft below onthe ground.At the back of the
motor isa control box thistakesdata fromsensorsplacedonthe outside that adjuststhe direction of
the bladesto face the wind, thisisdone byturningthe turbine at the yaw whichispositionedbelowthe
nacelle,thisalsosendsasignal toa brake that can slow downor stop the rotationof the blades inhigh
winds.

7.5 Calculations
UsingBetz limitthe windturbine shouldonlycatch59.3 % of the windspower,the turbine will alsohave
otherlosesinpowerdue todrag, mechanical frictionandironlosesthis thiswill alsoreducethe power
outputby upto 30% leavinga70% output.
Estimating(see appendices1) will be done forthe turbine bladestocalculate the powerrequiredinthe
designbrief thiswillalsoallow the diameterof the sweptareato be determined.These are the
calculationsthathave metand exceededthe powerneeded.
Formula Calculation Answer Unit
Power
coefficient(Cp)
Turbine
Mechanical loses
× Betzlimit
0.7×0.59 0.41 %
Velocity(V) Mph × Metersin a
mile/Time
15×1609/3600 6.7 m/s
Density(ρ) At seaLevel 1.23 1.23 Kg/m
SweptArea(SA) πd²/4 π×0.700²/4 0.3848 m²
Diameter(d) 700 Mm
PowerOutput 0.5×ρ×SA×V³×Cp 0.5×1.23×0.3848×6.7³×0.41 29.18 Watt
7.6Cost
7.6.1 Budget
The budgetallowedforthisprojectis£150 thiswill coverthe price of the materialsinthe bill of
materials.
7.6.2 Salary
As thisisa college project the teammemberswill notbe paida setwage,If theywere tothiswouldbe
put forwardat £25 an hourto coverall deductionsandthere salary.
7.6.3 Additions
Alsocostsof facilitiesandoverheadswill notbe inthisbudget.This wouldbe around£4000 for building
and utilities.
7.6.4 Total costs
Cost £
Facilities 4000
Materials 150
Engineers×4 640hours ×£25 16000
Total 20150
Vat 17.5% 3526.25
NetTotal 23676.25

Bespoke solutions | 10
8 Materials required
MATERIALS REQUIRED SIZE NEEDED QUANTITY COST £
GALVANISED TUBING 42.4MMØ 300mm 3
GALVANISED TUBING 48.3MMØ 300mm 3.5
LENGTH OF TIMBER 75MM × 50MM 6M 2.52
DUCTING PIPE 150MMØ 2M 13.28
MARINE PLY 1220MM ×606MM×12MM 1PIECE 13.5
DC MOTOR 1PIECE 50
BOLTS 20MM×10MM 14PIECES 10
ANGLE IRON 50mm 2M 22.30
ARBOR FOR TURBINE BLADES 12.5mm 1PIECE 10
Total 128.1
9 Conceptual Design
(Please findattachedonnextpage.) SeeAppendix 5foradditional concepts.

Bespoke solutions |DesignMatrix 11
10 Design Matrix
The HAWT designwill stand1200mm to the centerof the rotors, the rotors will have adiameterof
0.700m this will allow 29.18 wattsof powerto be producedunderthe rightconditions. Thisisa simple
designthatwill be easytomanufacture inthe facilitiesprovided.The materialsneededtoconstructthe
turbine will allowustostay underbudgetwhile alsomeetingthe specifications. Itwillalsobe easyto
dismantle if requiredtobe moved.Itwill suititsenvironmentasthe materialsorrobustand will with
standnatural forces.Alsoatthe endof itslonglife spanitwill easilybe discardedof asit isnon-toxicand
easyto recycle. (See Appendix 2)
Team members Horizontal Axis Savonius Darius Giro
PatrickO’Donnell 47 40 35 37
Mark Mortimer 38 36 28 33
RobertMaclean 43 36 29 33
Scott McPherson 44 39 27 33
Total 175 151 119 136
From the resultsinthe above table it can be seenthat usingthe designmatrix hasallowedthe teamto
selectthe bestfitturbine thatwill meetthe client’srequirements. Fromthe designmatrix itwas
establishedthatthe HAWTscored the highest, power,ease tomanufacture,safetyandcostof materials
allowedforsucha high score from the engineers. The table wasproducedusingcriteriathatwere
importantto the designthisallowedascale of 1 to 5 to be made 1beingbadand 5 beengood.Each
engineerscoredthe criteriaagainsteachindividual turbineallowingascore for eachto be brought
forward.
175
151
119
136
Turbines
Horizontal Axis
Savonius
Darius
Giro

Bespoke solutions |DesignMatrix 12
10.1 Evaluation
The team approach
The team approachhelpedthe processasworkloadswere lightened betweeneveryone inthe group,
meetingswere heldregularlytodiscusstopicsandgothroughthe deadlines.Throughoutthe process
the team membersneededtomeetdeadlinesnotonlyforthisprojectbutalsoinothersubjects.This
allowedthe teamtogaingood time managementskillsandjuggle alarge varietyof subjectsatone time.
Each individual gatheredtheirowninformationforthe researchstage whichwe thenevaluatedtocome
up withthe ‘bestfit’solutionforthe project.
I thinkI broughta lot of skillstothe teambeinga mature studentandhavingworkedonlarge scale
projectsthroughoutmy15 yearsinconstructionthishelpedwiththe projectmanagement.
10.1.1 Design process
The designprocessinvolvesamethodical numberof stepsthese are asfollows; definingthe problem,
gatheringinformation,generatingconcepts,analysing andselectingasolution andimplementingthe
finishedproduct.
Thisis a decisionmaking processthatrequired goodmanagementthroughoutthe developmentand
designstage.Each individual bringingforwardtheirideasinthe brainstormingsessionswhichled toa
designthatmetthe criteriasetout by the client.Thisprocessallowedustodetermine problemsand
workas a teamto come up withour solutions.
A detaileddesignwill be producedonautocadsoftware thiswill allow dimensions,tolerances,notes
and finishingspecificationstobe added.Thiswill addtothe ease of the manufacturing processinthe
workshop.

Bespoke solutions |HealthandSafety 13
11Health and Safety
Throughoutthe manufacturingandtestingprocesshealthandsafety will be akeyissue thatwill affect
everyaspect.
Thiswill include:
 The healthand safetyatwork act 1974
 PPE at workregulations1992
 Manual handlingoperationsact1992
 Workingat heightregulations2005
 The provisionsanduse of workequipmentregulations(PUWER)1998
 Supplyof machinery(SAFETY) regulations2008
 HSE risksrelatedtomovingparts
 Electricityatworkregulations1989
 Appropriate riskassessments
 Permitstoworkwhere required
These act are nowstandardpractice in any workingenvironment,thisisnotonlydowntothe employer
to enforce asstatedwithinthe healthandsafetyatwork act each and everyemployeeisboundbylaw
to workin a safe manner. For additional informationplease(seeAppendix 3)

Bespoke solutions |Bill of Materials 14
12Bill of Materials
MATERIALS SIZES REQUIRED QUANTITY SOURCE COST IN £
GALVANISED
TUBING
44.2mmø 300mm www.themetalshop.com
& city of Glasgow
college
£3
GALVANISED
TUBING
48.3mmø 300mm www.themetalshop.com
& city of Glasgow
college
£3.50
ANGLE IRON 50mm 2m www.themetalshop.com
& city of Glasgow
college
£22.30
LENGTH OF
TIMBER
100mm×50mm 6m B&Q
cityof Glasgow college £2.52
DUCTING PIPE 150mmø 2m B&Q £13.28
MARINE PLY 1220mm×606mm×12mm 1 piece B&Q £13.5
BOLTS 20mm×10mm 20 pieces B&Q £15
ARBORFOR
TURBINE
BLADES
1 piece www.windynation.com
£10
DC MOTOR 1 piece www.ebay.co.uk £50
TOTAL £133.1

Bespoke solutions |Conclusion 15
13Conclusion
Thisreportlooks at the researchanddevelopmentof aHAWT that will produce 12vof electricitywith15
mphwinds.Due to the increasedneedformore environmentallyfriendlymeansof producingelectricity
Bespoke Solutionswere approachedtodesignandbuildawindturbine.
Horizontal windturbinesare constructedonanindustrial level,usingBetzlimitandlosesof power
throughsound,vibrationandironlosesitwascalculated thatthere wouldbe 41% of useful kinetic
energylefttoproduce electricity.
It was establishedfromthe designmatrix thatthe HAWTwas the conceptthat bestfitsthe client’s
needs.
Throughoutthe processI have beenworkingonmypersonal andprojectobjectives.Ihope byreading
thisreportit can be seenthat myprojectobjectivesare ontrack these will continue tobe metthrough
stages2&3 and can be observedfirsthandinthe workshop.
My personal objectiveswill be anongoingimprovementovertime assituationschange betweenwork
and home ona dailybasis.Ihave hadbeenfortunate enoughtocarry forwardmyexperiencefrommy
currentemploymentwithinthe constructionindustry. Ifeel myexperience withmanagingworkerson
site hasallowedme tobringforwardand developmyprojectmanagementskillsonthiscourse.

Bespoke solutions |Appendices 16
14Appendices
Appendix 1
PowerCoefficient(Cp)
Velocity(V)
SweptArea(SA)
PowerOutput(PO)
Cp = Wind Turbine Efficiencyafterloses×Betzlimit
Cp=0.7×0.59=0.41
V = Mph × Metersin a mile/Time
V = 15×1609/3600
V = 6.7m/s
Thiswill remainconstant
Swept Area
Diameter =800mm
(SA) SweptArea=πd²/4
=π×0.800²/4
=0.50265m²
PowerOutput=0.5×ρ×SA×V³×Cp
PO= 0.5×1.23×0.50265×6.7³×0.41
= 38.11watts
To high
Swept Area
Diameter =700mm
=π×0.700²/4
=0.3848m²
PO= 0.5×1.23×0.3848×6.7³×0.41
=29.18watts Althoughthisistohighit will allow foranychange inwindspeed.

Swept Area
Diameter =600mm
=π×0.600²/4
=0.282m²
PO= 0.5×1.23×0.282×6.7³×0.41
= 21.38watts
Thiswouldjustwork

Appendix 2
DesignMatrix
Horizontal Axis (HAWT) Concept 1
Scott Mark Patrick Robert
Efficiency 4 4 4 3
Power 4 4 5 4
Ease of Manufacture 5 4 5 4
Safety 4 4 4 5
Reliability 4 3 4 4
Design 4 3 5 4
Cost 5 4 5 4
Maintenance 4 3 4 4
Facilitiesavailable 2 2 3 3
Environment 4 4 4 4
Lifespan 4 3 4 4
Total 44 38 47 43 =175
Vertical Axis (VAWT) Savonius concept 2
Efficiency 2 2 3 2
Power 3 3 3 4
Safety 4 3 3 2
Reliability 4 3 3 4
Design 4 4 5 4
Cost 4 4 3 3
Maintenance 3 3 4 3
Environment 4 4 4 4
Lifespan 4 3 4 4
Total 39 36 40 36 =151

Vertical Axis (VAWT) Darrieus Concept 3
Efficiency 2 3 3 2
Power 3 3 4 4
Safety 3 3 3 3
Reliability 2 2 3 3
Design 4 4 3 3
Cost 2 1 2 2
Maintenance 2 2 3 1
Environment 3 4 3 2
Lifespan 3 3 4 3
Total 27 28 35 29 =119
Vertical Axis (VAWT) Giromill Concept 4
Efficiency 2 2 3 2
Power 4 4 5 2
Safety 3 3 3 3
Reliability 3 3 2 3
Design 2 3 3 4
Cost 4 4 4 3
Maintenance 3 3 3 3
Environment 3 4 4 4
Lifespan 4 3 4 4
Total 33 33 37 33 =136

Appendix 3
Health and safety
In the design and manufacture process for a wind turbine, Government legislation, risk
assessments and permits to work have to made and followed. Before manufacture even begins,
the following needs to be considered:
Health and Safety at work act 1974 (www.legislation.gov.uk).
The health and safety act ensures that all persons at work are protected against any possible
risks and hazards. This act considers all aspects of welfare that may be compromised in the
manufacture process of a product. A safe and practical working environment is mandatory, with
supervision at all times from a superior member.
PPE (PERSONAL PROTECTIVE EQUIPMENT) at work regulations 1992
(www.HSE.gov.uk).
This act ensures that all members of the team are supplied with suitable and appropriate
protection equipment in order to minimise risk. It is outlined that employer or supervisor free
of charge will supply all equipment. Also with use of risk assessment decide what PPE is
appropriate for the manufacturing process. Clean PPE should be used to reduce risk of
contamination and proper storage provided to eliminate any damage to equipment.
Information will be provided to every worker on how to use the equipment and when to use. In
return employees have to use provided equipment and report anything that gets damaged or
lost.
This will relate to our manufacture process, as the use of PPE is mandatory when constructing
locking system.
PPE may include:
 Safety goggles
 Overalls
 Gloves
 Boots
 Gas mask
 Ear plugs

 Barrier cream
 Hard hat
 Hair net
Manuel handling operations act 1992 (www.legislation.gov.uk).
This act protects those who may be applying a bodily force to move a load. This ensures that
there is minimal risk by finding sensible alternatives and solutions to moving objects. The three
key steps are highlighted below:
 Firstly, avoid hazardous Manuel handling operations so far as is reasonably practice.
 Secondly, assess any hazardous manual handling operations that cannot be avoided
 Thirdly, reduce the risk of injury so far as is reasonably practical.
This will be applicable when moving materials around the workshop. Also when moving the
finished turbine between storage and workshop, this act has to be considered.
Working at height regulation’s 2005 (www.legislation.gov.uk).
Whilst moving equipment, components or materials around the workshop area, going up and
down stairs will be necessary. This will qualify as working at heights. Before beginning any
operation, the following must be done:
 Take into account environment- weather, nature of frequency and duration and risks to
anyone in the vicinity of where the work is taking place.
 Plan for emergency and rescue in case the worst possible scenario occurs.
 Check region every time before work commences
 Stop materials from failing if it is practical to do so.
Each worker must:
 Report any hazard to supervisor
 Use equipment and safety devices given to them properly in accordance with training
and instructions.
The provisions and use of work equipment regulation’s (PUWER) 1998 (www.legislation.gov.uk).
Puwer covers the use or control of equipment in the work place. This act requires that all
equipment is suitable for the intended use and only to be used in a safe condition. Equipment is
to be regularly inspected by supervisor to ensure it had not deteriorated. Only those who have
received adequate information, instruction and training should be operating such equipment.
When those are using equipment, all PPE must be worn, and suitable safety equipment is
advised.

When in the manufacture stage of the project, these regulations will apply, ensuring safety
when operating hand equipment.
The equipment that may be used will include:
 Drills
 Saws
 Welding equipment
 Spanners
 File
Supply of machinery (safety) regulations 2008 (www.legislation.gov.uk).
The design and construction of all machinery under this act has to be safe, meeting all the
health and safety regulations stated before. If being manufactured on an industrial scale, it has
to be CE marked and supplied with instructions in appropriate language. A declaration of
conformity.
HSE risks related to moving parts (www.HSE.gov.uk).
Productsmustbe designdesignandmanufacturedinawaythat meansthere isnocontact withany
bodieswhilstin fulloperation.All necessarymeasuresmustbe takentoensure anythingwhilstworking
doesnotblockmachinery.Instructionsandsignsare advisedtoshow where hazardspresent
themselves.
Electricity at work regulations 1989 (www.legislation.gov.uk).
 This act ensures every worker that is using electricity is appriopately protected from any
hazards it may cause.
 All equipment constructed may be to a standard to minimise danger and may be
constructed in a proper manner that is safe.
 No electrical equipment should be used if it exceeds its needed capacity. All workers
should be aware of adverse or hazardous weather environments that may interfere with
the correct operation or control of electricity.
 Correct insulation and other safety devices such as circuit breakers and fuses must be
incorporated within a circuit to minimise the risk of fire or shock.
 If there is no electrical continuity, testing has to be done on a dead system.

 ALWAYS connect an Earth line within a system.
 Every connection within the systemhas to be mechanically and electrically suitable for
use.
 There must be efficient means for protecting from over-current.
 Isolating electrical systemfrom any live equipment. There must be a means of breaking
the circuit if required.
 No person shall be working on or near ANY live conductor if not suitability trained or
authorized.
 Ensure that there is an adequate workspace and all workers in surrounded area are well
aware of the potential hazards that may arise.
 No person should engage in an electrical operation if not competent with what they are
doing.
Risk assessments (www.HSE.gov.uk).
Risk assessments identify potential risks with aimto finding sensible solutions. This is the first
step to preventing accidents as it concentrates on what problems a worker may encounter
when carrying out a task. The following are the stages of risk assessment:
 Firstly, a worker must identify a list of hazards.
 Then decide who may be harmed and why.
 From this evaluating the risks will help find necessary precautions. Record findings on a
risk assessment document- will also act as evidence the company have reviewed a
hazard if it occurs.
 Review the assessment and update if necessary, repeat if needed.
Permit to work (www.HSE.gov.uk).
Permit to work may be acted if sufficient evidence is provided to prove the employees can work
safely considering all factors. Supervisor will sign this document and manufacture will only be
allowed to begin after this document is complete.

Logbook
Date Description Discussion
1. 04/11/2015 Startedgradedunit researching
differenttypesof windturbines.
Each team membertaskswithresearching
on internet
2. 05/11/2015 Each memberselectedawind
turbine fromthe initial resultsto
researchfurther.
I choose the HAWT
3. 07/11/2015 Discussionsaroundthe type of
generatortouse
Anetektype generatorordowe make our
ownusingcoiledwire andhighpowered
NeodymiumMagnets
4. 13/11/2015 Discussionsaroundmaterialstouse,
howto connectthe turbine blades
to the generator,Betzlimit59.26%
energyextraction
Cordlessdrill spunbackwardswill
generate 20 to 60 volts
5. 15/11/2015 E-mailedJohnRobertsontosee if
Gantt charts was okon excel
Frame scaffoldtubesandbraces
6. 16/11/2015 Newframe 4 legs
Sue trailerwheel hubsforblades
£16.99 new
7. 25/11/2015 How to connectstator towhenhub
8. 02/12/2015 Stressedandconfusedshouldhave
designandmanufacture in1st
block
to prepare forgradedunit
9. 15/12/2015 Startedfacebookchatpage forthe
project
10. 08/01/2016 Missedgradedunitmeeting was
movinghome
11. 12/01/2016 Scott completedHealthandSafety
12. 22/01/2015 ChangeddesigntoDC motorand
wentovermarkingschedule
13. 07/02/2016 Completedanew designforthe
windturbine whichwillcutcosts
and meetspecifications
14. 10/02/2016 09:00 Meetingcancelleddue
unforeseencircumstancesanew
meetingarrangedcompletethe
designmatrix

Appendix 4 Minutes of Meetings
Attachedon the nextpage

Appendix 5 Additional Drawings

Appendix 6 Additional Gantt chart & Mind Map

Appendix 7 Concept reports 2,3,4

Bespoke solutions |Bibliography 29
Bibliography
Windy Nation. (2000). Arbor & Hubs. Available: http://www.windynation.com/arbors-hubs.
Last accessed 17th Feb 2016.
Reuk. (2006). The renewable Energy Website. Available: http://www.reuk.co.uk/. Last
accessed 13th Nov 2015.
Michael Davis. (2014). How I Home-built an electricity producing wind turbine. Available:
http://www.mdpub.com/Wind_Turbine/. Last accessed 13th Dec 2015.
Blog spot Multiple autors. (2010/11). wind Energy and Wind power.Available: http://winds-
energy.blogspot.co.uk/2010/11/calculation-of-wind-energy-and-wind.html. Last accessed
10th Jan 2016.
Herman K. Trabish. (2011). Where is the best place to put a wind farm. Available:
http://www.greentechmedia.com/articles/read/where-is-the-best-place-to-put-a-wind-farm.
Last accessed 15th Jan 2016.
Dr Qui. (2010). PVC pipe blades and rotor for HAWT from scrap.Available:
http://www.instructables.com/id/PVC-pipe-blades-and-rotor-for-HAWT-from-scrap/. Last
accessed !5th Jan 2016
Union of concerned Scientists. (2015). How wind energy works.Available:
http://www.ucsusa.org/clean_energy/our-energy-choices/renewable-energy/how-wind-
energy-works.html#.Vsb3ffkS-Ul. Last accessed 5th Dec 2015.
bang-good. (2015). Neodymium magnets. Available:
http://www.banggood.com/Neodymium-Block-Magnet-50-X-25-X-10mm-N52-Magnets-DIY-
MRO-New-p-945230.html. Last accessed 18th Dec 2015.
The metal store. (2016). Materials. Available:
https://www.themetalstore.co.uk/products/mild-steel-angle-iron-5mm. Last accessed 2nd
Feb 2016.

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