ADAM SYKES

WIND POWERED LIGHTING SOLUTION

9457

At The Blandford School mobile floodlights are requiredduring any night time events. Whether or not you buy,own or rent mobile floodlighting (and the fuel thirstygenerators) they’re extremely expensive whichever wayyou look at it. Their price is only one downfall, as theyalso have a damaging impact on the environment byburning up fuel. Not only their impact on theenvironment can be seen as a downfall as they areunsightly, costly and the generators are loud and emitodorous fumes. One place at The Blandford Schoolwhere an opportunity for a lighting solution comes tomind is outside the front entrance. This is the mainreception for events, and therefore requires a mobilelight during such events. Whereas a permanent windpowered light could be installed. This would not onlylook a lot more attractive but would also show the effortthe school goes to, to protect the environment (as wellas the solar panels the other side of the block.)

PAGE ONE

CLIENT PROFILECONTEXTDESIGN BRIEF

-I am aiming to design and manufacture a fullyfunctional prototype wind powered street light. Tobe used at The Blandford School to illuminate themain reception. My design will require a series oftests and smaller models to ensure the plausibilityand complexity of it is achievable and viable in theterms of costing.

-The design must appeal to both school childrenbetween the school years of 7 and 13 as well asteachers, parents and anyone else visiting theschool.

-I shall aim to produce a design that is in keepingwith schools efforts on becoming a more modernand environmentally friendly place.

-Although my design will be aimed at the school ingeneral, my specific client shall be the headteacher Sally Wilson, who has agreed to liaise anddiscus ideas with me about the possible futureinstillation of the light.

RESEARCH OBJECTIVES:-best fan type?-full size or scale prototype?-exact location-fit product around clients needs and requirements-components needed-electronics-aesthetics

ADAM SYKES9457

THE SITUATIONThe Sun heats our atmosphere unevenly, so some patches become warmerthan others.These warm patches of air rise, other air blows in to replace them - and wefeel this as wind blowing.We can use the energy in the wind by building a tall tower, with a largepropeller on the top.The wind blows the propeller round, which turns a generator to produceelectricity via the rotation a magnet through a copper coil.

Initial construction thoughts:I am aiming to use recycled and recyclable materials when possible as this will cut down on CO2 emissions produced in the creation and shipping of newproducts, as well as not adding any strain to resources. To generate the electricity I may use either a second hand bike dynamo or the generator located insidea wind up torch as they would be perfect to attach to the rotating blades, as their original function was to spin a magnet through a copper coil, inducingelectricity created by the spinning of a cog or wheel. This electricity is then either used directly through a light, or is stored in a battery so that it can be usedwhen required.

Key Issues:The materials I use to make my product must be of good enough quality so thatcomponents will be durable and withstand a long life of working. The moving parts ofmy design must be well secured and made of strong materials that will not break overtime. It’s essential that not only my client likes my design but also the school students.I will aim to design my product in a modern style but keeping the manufacturing assimple as possible.

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Mar24-

Mar 07-AprActivities

Finalise the client and their needs:

Research into project: holiday holiday

Initial designs and client feedback:

Making and modelling: Further tests, models and CAD drawings: holiday

Begin manufacturing:

Present work to client for feedback:

Make any nessisary changes:

Evaluation and conclusion of Project

Bi-weekly Beginning

ADAM SYKES9457PAGE TWO

DESIGN BRIEF ANALYSIS

Project Brief-Wind powered light.

THEMES

ENVIRONMENT

SAFETY

TARGETAUDIENCE

COMPONENTS AND MATERIALS

AESTHETICS

Environmental factors-appealingto modern living in which styleand the environment are bothincreasingly popular withdesigners.

Reception at the BlandfordSchool. To light up ground fornight events.

Will ensure the product is safeduring it’s operational life span.

Schools, specifically The BlandfordSchool. For a free light source.

The quality of materials,depending on my price limit ,recycled where possible to fit withenvironmental theme.

Physical size, colour and shape.

Should appeal to teenagers topromote the values of protectingthe environment.

could be taken further and usedalong roads and streets in areaswith a fair amount of wind.

Electrical components will be fullyinsulated and rotating blades willbe secure.

Must be designed to fit withlocation of its intended use.

Could be made from aluminiumsheets with polymers used forelectronic component housings.

Type of turbine, vertical axis orhorizontal and fan type.

This page addresses key issues I will have to address throughout the designing andmanufacturing stage of my wind powered light.

ADAM SYKES9457PAGE THREE

INITIAL SPECIFICATION

ADAM SYKES9457

POINT SPECIFICATION

TIMESCALE To ensure I finish my product on time, I will am to keep as close to my Gantt Chart as possible, putting in extra hours to deal with any unforeseen errors.

TARGET MARKET

My design will be aimed as a single product at my school, to illuminate the reception area. But if it were to go into mass production I would aim it at county

councils to be installed as street lights.

FUNCTION The function of my design is to convert wind energy into light by turning rotor blades connected to an electric generator which in turn charges a battery.

SIZE

I will aim to keep the main section of my product (the rotor and light) as small and compact as possible, fitting it around the dimensions of the battery and

electric generator. If my product is successful and weather proof I will then install it in the school grounds, I will then have to attach it to lamp post.

DURABILITY My light must stand up to British weather, therefore being water tight and structurally able to withstand impacts from birds and tree debris.

AESTHETICS I will aim to keep my design as simplistic as possible, with function as the main concern, still holding aesthetics in high regard.

MATERIALS/

MANUFACTURENG

Where possible I shall use reclaimed and recycled materials (as this also fits in with the sustainability aspect. ) Whether or not I manufacture my product from a

combination of polymers or metals will depend on my clients wishes.

SAFETY I will ensure all electronics are enclosed and sealed from water, whilst the rest of the product conforming to the required British standards.

COST

The manufacturing costs would be dramatically reduced if my design was to be mass produced as the production could make use of buying materials in bulk and

would therefore reduce costs. As I am only making a one off product I shall still aim to keep costs low, but not as low as they would be in mass production. I will

aim to spend no more than £50 on my product.

ENVIRONMENTAL ISSUES

The main aim for this product is to create free clean energy in the form of light. Therefore I shall base my project on sustainability and environmental factors such

as: having 0 air miles in my design with none of the materials I use coming from over sea, using recycled components and using materials which can be recycled.

QUANTITY I shall aim to produce one working prototype product.

TESTING I will make and model multiple designs, finding the most simplistic and efficient design before I begin manufacturing.

PAGE FOUR

ENVIROMENTAL AND FINANCIAL IMPACTS OF STREET LIGHTING

In 2011 the 9 million street lights in the UK cost £110 million on electricity bills to power.Nottingham county council released this statement: “The electricity bill for street lighting has increased dramatically from £1.05m in 2004/05 toan estimated £6m in 2015/16 and, over the long term, energy prices are likely to continue to rise. Meanwhile the County Council is predictingthat it will have to take £150m off its current budget over the next three years to deal with the financial pressures it faces.”Dorset county have recently refitted the old inefficient sulphur street lights with whiter and brighter LED ones. Despite being a lot more energyefficient they still cost a lot to manufacture as well as the cost fit the new ones and to transport the old ones to be recycled, on top of all thisthey still do require the burning of fossil fuels to produce the electricity required to run them

“Every time we switch on a light or turn on the central heating, or even eat a hot meal we use energy. Whatever kind of fuel we use, whether we burn it directlyor indirectly by buying electricity generated from fossil fuels (coal, oil or gas), we are releasing Carbon Dioxide (CO2) into the atmosphere. CO2 is one of themain gases that contributes to global warming, which is now scientifically recognised as a real threat to today's climate. This doesn't just mean warmersummers and milder winters, global climate change is responsible for there being more floods, storms and droughts around the world than ever before.Over the past 20 years, scientists have gathered conclusive evidence temperatures have been rising sharply since the start of the industrial revolution, and thatmankind is the main cause of global climate change.” http://www.nef.org.uk/knowledge-hub/climate-change-energy/climate-change

Advantages of Wind Power:1. The wind is free and with modern technology it can be captured efficiently.2. Once the wind turbine is built the energy it produces does not cause green house gases or other pollutants.3. Although wind turbines can be very tall each takes up only a small plot of land. This means that the land below can still be used. This is especially the case in agricultural areas as farming can still continue.4. Many people find wind farms an interesting feature of the landscape.5. Remote areas that are not connected to the electricity power grid can use wind turbines to produce their own supply.6. Wind turbines have a role to play in both the developed and third world.7. Wind turbines are available in a range of sizes which means a vast range of people and businesses can use them. Single households to small towns and villages can make good use of range of wind turbines available today.

Disadvantages of Wind Power:1. The strength of the wind is not constant and it varies from zero to storm force. This means that wind turbines do not

produce the same amount of electricity all the time. There will be times when they produce no electricity at all.2. Many people feel that the countryside should be left untouched, without these large structures being built. The landscape should left in its natural form for everyone to enjoy.3. Wind turbines are noisy. Each one can generate the same level of noise as a family car travelling at 70 mph.4. Many people see large wind turbines as unsightly structures and not pleasant or interesting to look at. They disfigure the countryside and are generally ugly.5. When wind turbines are being manufactured some pollution is produced. Therefore wind power does produce some pollution.6. Large wind farms are needed to provide entire communities with enough electricity

ADAM SYKES9457PAGE FIVE

EXISTING PRODUCTS

PAGE SUMMARY: On this page I have looked into other existing products and designs. The majority of wind powered lights I have found online are all CADconcepts, very few have actually been made, and of those few the majority are one off products, not batch or mass produced. When looking on Googlefor “Wind powered street lights” in the “shopping” section there were none for sale, the closest I could find were small garden ones on Amazon.

This lighting solution, like many of the others is only a computer concept. The design itself can be seen as an art peace as well as a functionalproduct. It is a very attractive piece of which would be happily welcomed into an urban environment, unlike the generic wind turbine which iswidely regarded as unattractive. This product not only uses wind power it also uses solar energy. Due to this, this product would be better suitedin a sunnier climate than Great Brittan.

Unlike the last design, this one was actually manufactured as a one off product, out of galvanized steel and aluminium sheets. Unlike the lastdesign this one is focused much more on practicality rather than looks. I believe that a design compromise between the two would be best,as it would still be aesthetically appealing whilst being fully functional.Due to its fully metal construction and the fact it is a single sand alone product, it would have cost a lot to produce, as well as not containingany recycled materials.

This design, like the fist one, is only a CAD animation. Also like the first one it features a solar panel as well as a wind turbine. The keydifference between this design and the other two is the style of turbine blades. This one being a horizontally orientated design, meaningthat it must turn to face the wind, whereas the other two are always facing the wind. The design of this model is very minimalistic with onlyone colour ad a lack of elaborate shapes, meaning its contraction would be more difficult than the first one..

CLIENT FEEDBACK TO RESEARCH: Adam has clearly completed a lot of research and has focused on what matters to us as a school. Price is always key but quality and style should not be compromised. Our new reception area is contemporary and minimalist in style and the light needs to be designed to fit in with this. Lighting across the site is difficult so as much light as possible needs to be produced by this product.

ADAM SYKES9457PAGE SIX

INITIAL IDEAS

1) My first design is a basic Google Sketchupmodel which features a simple andunderstated look. This design features avertical rotary system, as do the others on thispage, a drive shaft would come off thespinning blades indirectly to a generator via acog or pulley system. The colours of this designwouldn't fit completely with the generalmauve/burgundy colours associated with TheBlandford School. Despite this, I believe thesimplicity of both the colours and the designdisplay a minimalistic feel, although this is anissue as this product is designed to go at thefront of the school, and should therefore holdaesthetical value highly.

2) The second designs sharesmany features with the first, suchas the arrangement of the rotorblades driving a generator, in turncharging a battery and powering alight, with all the componentsstored in the base of the turbinehousing. However, this designcontains a vacuum formed lid,rather than one assembled out oflayers of polymers. Furthermore,this design features a differenttype of rotor blades, in this casethey are two semicircles whichcatch the wind.

3) My third concept has takenthe environmental factor evenfurther , using a tree to supportthe turbine and light, rather thanmanufacturing and installing apost. This design is limited tolocations with an abundance oftrees near to where the light isrequired, and would thereforebe unnecessary at theBlandford school as the area Ihave proposed the installationof the light is free of trees.

4) My fourth idea would be thesimplest and sturdiest idea. The foursupporting beams on each cornerwould be stainless steel tubes withthreaded ends screwed to milledend caps. The main body of thisdesign would be made from oakplanks, cut to size and coated with aweathering agent. The turbineblades will be the same simpledesign as the first one, with multiplelengths of laser cut acrylic fitting viaa mortise and tenon joint to acircular acrylic disk.

PAGE SUMMARY: Out of my four designs on this page, I prefer the first two due to their simplistic and circular design, both being similar in construction differing with the types of blades and the amount of them. Although the 3rd one would be the most environmentally conscious eliminating the need for a stand and base due to the straps temporally fixing it to the tree. However, this concept would be inefficient due to the tree reducing the amount of wind which would be utilised by the blades.

ADAM SYKES9457PAGE SEVEN

INITIAL DESIGN MODELS

LDR on the top. Light is inactive when sunlight is on the lamp, when it gets dark the light activates. Turbine housing.

Turbine blades.

Battery, circuit board and Dynamo housing.

Super bright LED’s in translucent housing.

I began by looking into the turbine housing and blades, making similar versions to the Googlesketch up design below. I created these models above out of MDF and acrylic sheets, usingpolypropylene to act as the rotor blades. In doing this I found these designs to be very inefficientand also very easy to catch the wind in the other direction and therefore stop spinning. I used themotor and circuit board from a rechargeable torch to attach to the drive shaft and produce light. Ifound that a redesign of the rotor blades was essential. One final drawback of the models is theneed for bearings so that they run even smoother.

To the left is where I intendmy final product to go. Thisis so that it illuminates themain reception as well asbeing one of the first thingsvisitors see when enteringthe school. Its aim is toreflect the schoolsenvironmentally consciousimage to visitors andstudents.

Despite being an inefficientsystem, I shall attempt toimprove the blades whilekeeping the same overall look tothe design, as I believe thesecolours and shapes look veryaesthetically pleasing whilehaving environmentalconnotations and being quiteminimalist.

CLIENT FEEDBACK TO INITIAL DESIGNS: I like the style of Adam’s product so far, it builds on the contours of the building and will not be an eyesore, it will more likely be a ‘talking point’ for visitors. The testing and changing of the rotor blades is good and helps provide me with confidence that the final design will meet need.

ADAM SYKES9457PAGE EIGHT

Vertical-axis wind turbines (VAWTs) are a type of wind turbine where the main rotor shaft is set vertically and the main components are located at the base ofthe turbine. Among the advantages of this arrangement are that generators and gearboxes can be placed close to the ground, which makes thesecomponents easier to service and repair, and that VAWTs do not need to be pointed into the wind. The Savonius turbine is one of the simplest turbines.Aerodynamically, it is a drag-type device, consisting of two or three scoops. Looking down on the rotor from above, a two-scoop machine would look like an"S" shape in cross section. Because of the curvature, the scoops experience less drag when moving against the wind than when moving with the wind. Thedifferential drag causes the Savonius turbine to spin.

FURTHER RESEARCH AND MODELLING

After my initial models not being very good, not spinning without the help of a hairdryer, Idecided to look into the Savonius rotor. Using a band saw I cut a section of Pringle tubing intwo and then laser cut the turbine housing from 4mm corrugated card, using a 4mm mildsteel rod I then glued the rod to the blades and cut a plastic tube to act as the stem of thelamp. Despite not having bearings and the crude construction and imperfections of hot glueadhesive, this model worked far better than the other two. Not only did it catch the wind alot more than the others, it only spins in one direction, meaning unlike the other designs thisone won’t be limited to the wind direction.

-As the blades do not cut across theairflow, there is less stress on the blades.-Lower maintenance requirements thantraditional designs as there are noelectronic systems to control blade pitch orrevolution speed.-No gearbox and no brake pads means easymaintenance and no expensive parts toreplace.-Wildlife friendly compared to traditionaldesigns as there are no flight windowsbetween rotations, keeping birds away.-Can be scaled up and down making itsuitable for industrial or domesticembedded generation scenarios.

ADAM SYKES9457

BELOW ARE EXAMPLES OF SAVONIUS SYSTEMS:ADVANTAGES:

Identical top and bottom laser cut corrugated cardboard disks with a 4mm whole cut for the mild steel rod in the centre and two engraved semicircles so I knew where to adhere the blades. Two laser cut corrugated cardboard supporting sections which hold up the top section of the turbine .

Pringles tube cut down the centre on the band saw to act as the blades for the Savonius rotor.

Further laser cut corrugated cardboard sections which act as a housing for the spinning blades as well as supporting the tube.

uPVC tubing acting as a guard to the steel rod. Glued to the inside of the corrugated cardboard circular sections which hold it in place.Mild Steel drive shaft glued to the spinning blades with an epoxy resign.

PAGE NINE

FURTHER MODELLINGAfter the success of my cardboard model on the previous page, I decided to make a housing for the generator and the circuit board. Below is the process in which I made it.

Initially I designed the component housing around my previous cardboard model on Corel Draw X6 and then laser cut it out of 4mm acrylic. I also cut out s series of cogs to gearup the speed of the generator when spun by the drive shaft. I then temporarily glued in place the circuit board and LED’s to the acrylic . Due to the tension caused by the elasticband on the cogs, it caused the rotor to slow , if I had used a bearing instead of simply allowing the cardboard to rub then I believe it would spin a lot more freely.

I then began to make a stronger model (as the card one rubbed when rotating and felt very flimsy.) I decided to cut an aluminium coke can in two and use these sections for the rotor. Thetop right image on this page is a corrugated cardboard test of the MDF housing below (I cut it from card first to ensure that it was drawn to the correct dimensions before cutting into themore expensive MDF.) Once I ensured my Corel drawing worked, I then cut the same pieces from MDF as to give my model more structural rigidity. I had to cut and thread three lengthsof 4mm mild steel rod, two to support the top of the turbine and one to act as a drive shaft. I then cut a small length of PVC tubing to enclose the driveshaft, adding even more structuralintegrity. This model worked far better than the previous one, but due to the friction caused by the rubbing of MDF to MDF and steel to MDF, slowing down the spinning, bearings willdefinitely be needed in the next model. The image in the bottom right hand corner of this page is a successful test of what the final circuit board will need to be like.

ADAM SYKES9457PAGE TEN

GOOGLE SKETCHUP MODELLING After the success of my past two Savonius models, I began redesigning myGoogle Sketch Up model. With my new design I put in a lot more attention todetail when creating it, creating a proper turbine housing (unlike with theinitial SketchUp design.) I will aim to use recycled and recyclable materialswhen possible, to in keep with the eco friendly theme. When possible I shalltry to reuse items such as bearings, battery and the dynamo. This designwould be manufactured using layers of laser cut 9mm acrylic sheets, with twoPolypropylene blades created by cutting a sheet to size and securing it in twosemicircle holes, one at the top and one at the bottom of the blades. Thecover on the top would be created by vacuum forming an acrylic sheet over acurved mould. The battery would be stored in a specialist jig cased inside thebottom part of the housing, with the generator connected directly by cogs ora chain to the driveshaft.

Improved design-With this design I have included two supporting beams acting as the turbine housing to hold the protective roof section in place over the blades.Furthermore, the Savonius blades have been included for maximum efficiency. I have also focused more on the colour scheme in this design, aiming to replicate the colours of the sky so that it blends in better with its environment and isn't an eyesore.

Initial design-With the initial design I forgot to incorporate the housing for the fan blades. Furthermore the blades on the initial design were inefficient, being slow and libel to rotate either direction. In addition, the design was too simplistic and the colours were too basic and would have looked out of place on the school grounds.

ADAM SYKES9457

Light dependant resistor on the top of the turbine housing which will activate the lights when the ambient light falls below a set luminosity.

Supporting beams made from either Mild Steel or Acrylic rods which will hold up the top section of the turbine housing.

New blade design-Savonius blades. Made from either Polypropylene or a piece of Acrylic tubing cut in two.

Improved design for the lamp post, applying a metallic texture onto the CAD design, with the final post most likely being Galvanised Steel.

PAGE ELEVEN

FURTHER MODELLING DEVELOPMENT

I decided to create a more refined and functional Savonius model so thatI understood the procedures required to make the blades myself, ratherthan cutting a tube in two. I initially cut two identical sheets ofaluminium and then measured the length and thereby worked out half ofthe circumference of a whole circle. I then laser cut a the correct sizedsemicircle out of 6mm MDF and used it as a guide to bend thealuminium sheets to. Using the sheet rollers I bent the two sheets intoperfect semicircles. I then drew a circle on Corel Draw X6 with the twocut outs for the blades and cut it out of 4mm corrugated cardboard.After gluing the two blades in place I found this to be an extremelyeffective and efficient rotor system.

One thing I did find with the Savonius rotor is that when it stopsrotating it can end up facing side on to the next oncoming wind,and It therefore struggles to spin again, unless there is a newdirection of wind. Below I have drawn a small diagram of thisproblem. To solve this I may have to design a third rotor blade sothat it will not only function in any wind direction, but the thirdblade would increase the surface area in contact with the air,thus increasing the speed of rotation.

ADAM SYKES9457

PROBLEM AND SOLUTION:

PAGE TWELVE

DESIGN IMPROVEMENTS

CLIENT FEEDBACK TO MODELLING: As a client I am impressed by the detailed work going into the design of this product and am pleased Adam is concentrating on efficiency and aesthetics. The contours continue to match those of the building and I like the ease of attachment to a structure (eg the basketball post). The eco friendly theme will appeal to students, staff and governors.

Once I decided I needed a third rotor blade for increased efficiency, I began designing a new system. This time, instead ofcutting the spaces for the blades into a large circle, I designed the housing of the blades to be as small and light as possible,decreasing weight and therefore requiring less wind to move it. This new design also allowed me interlock the two sectionstogether on the laser bed, thus reducing waste materials. I included strengthening beams to ensure the flexing polypropyleneblades don’t break the MDF whilst trying to return to their original shape. I laser cut a 4mm hole in the centre of the housingfor a mild steel rod to be glued in place. As this was only a model, I only cut out very small sections to act as the blades, thefinal design will be a lot taller to catch more wind. I then moved on to design the housing for the turbine. I did this by lasercutting 3mm MDF for the main section and 6mm for the three support beams. With this design I included small bearings towhich I accounted for and cut out two tight fitting holes in top and bottom section, allowing a tight friction fit. I am extremelypleased with the outcome of this design, as it is both the most efficient and aesthetically pleasing design. Even with this modelbeing very shallow, it still caught a lot of wind, especially when I attached it to a basketball post.

ADAM SYKES9457PAGE THIRTEEN

MATERIALS

I looked into the sort of LEDlighting cyclists would useon their bikes. I discoveredthat a brand new one(considering I would belooking to buy one secondhand) costs around £20. Ithen looked into alternativelighting and found thatpowerful surface mountedLED’s are not only brighterbut significantly cheaper. Ialso found a 12V 7AHrechargeable battery whichwhen fully charged can runthe 600MA light for 11.6hours, which is more thanenough for what I require.

For the section under therotor blades I designed itto be a cylindrical tube,after looking at the pricesfor acrylic tubing of thesame diameter I wouldneed to house the batteryI found them to be far tooexpensive. Therefore Icould try to create a tubeby rolling a single sheet ofaluminium and spotwelding it to itself.

As the majority of my design will involve laser cut acrylic sheets I needed to ensure that thebonding agent used to join two sections of acrylic would be %100 watertight. I tested this bycutting an acrylic disk to loosely fit an acrylic tube and then sealed the gap using plasticweld. Although being messy this method worked to ensure the join was watertight. Toreduce the amount of plastic weld required I cut another acrylic disk, this time I measured itto the exact dimension of the tube (unlike before when I made it intentionally too small )and the friction fit was enough to hold water at bay. This has shown me I need to be extracareful when cutting and measuring with my final product as I would like to use as little ofthe environmentally harmful plastic weld as possible.

Above is an example of the acrylicsheet I would need for the twosandwiching sections of theturbine, with a thicker 10mmsheet for the two sandwichingsections of the turbine housing.To the right is an example of theacrylic rods I could use to supportthe top section of the turbine(mild steel rods were used in mycoke can model).

ADAM SYKES9457PAGE FOURTEEN

POSSIBLE COMPONENTS

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H-217mmW-180mmD-180mm

H-95mmW-65mmL-150mm

ID-4mmOD-16mmD-5mm

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D

I have decided to look into alternative methods to achieve the tube section needed for my product.As this is a one off prototype, it would be very cost and time ineffective to create this section from thetwo previous methods I had considered (buying a large acrylic tube and cutting it to size, or rolling asheet of aluminium into a tube and welding it.) I have also looked into products which could serve asan alternative, leading me to find this small bin, as it not only fits the size criteria correctly, but it isalso relatively cheap. However, I will probably have to apply a different finish to it, depending on theclients wishes for colours. Furthermore, I will have to measure and cut a jig to go on the inside to holdthe battery, circuit board and LED.

To the right is the battery I have purchased to power my light. I made sure that I bought not only apowerful battery, but a relatively small one, as others I have looked at were around four times thesize. It is also perfect as it fits into the housing I have looked into, which is 180mm wide, whereas thebattery is only 150mm in length, and 163mm from corner to corner.

D

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To the left is a bearing which matches the exact dimensions I require, with an internal diameter of4mm, the same as the mild steel rod I plan on using, and with an external diameter of 16mm. One ofthe most commonly used bearings, these types are manufactured with metal shields inserted into theouter raceway, fitting in closely to the inner race providing protection against light mechanical damage,some protection against the entrance of moisture, dust and other foreign matter and serving to retainthe pre-filled grease in the bearing. Benefits: Provides light mechanical protection, limits moisture anddirt ingress, lubricated for life, cost effective solution

ADAM SYKES9457

PAGE SUMMARY: On this page I have looked into various readymade components which I may use in my final product, in the case of the 4mm bearings I am certain I shallpurchase a similar item, however, in the case of the tube section I am still unsure as to whether I will use this bin (or one like it) or if I'll attempt to make a tube frombending Aluminium or if I will come across a piece of tubing which will fit my criteria. Similarly with the battery, although purchasing one, I am still unsure of its suitabilityfor the wind powered light.

PAGE FIFTEEN

DESIGN IMPROVEMENTSTaking both function and aesthetics into account, I have re-designed the turbine blades. With this updated design Ihave focused more on smoothing out the areas with sharpangles, as this will reflect the look of nature, with smoothflowing curves. Furthermore, I have added an extrastrengthening beam behind each rotor to ensure a higherstructural integrity. in addition I have added spacers in theslots for the blades, as the flexing of the polypropylene wascausing structural weaknesses along the blade, whereaswith these extra sections of material, the polypropylenewon’t be able to flex open the gap, meaning gluing will beeasier.

Taking both function andaesthetics into account again, Ihave re-designed the turbinehousings, as before I havefocused on curves and morenatural shapes, eliminating theharsh right angles. FurthermoreI have decided to use acrylicrods rather than a laser cutrectangular section to supportthe top of the turbine, as eitherrods or possibly sanded downrounded rectangular sectionswill consist of curves andtherefore look more attractive.Unlike my initial plans to lasercut these sections out of acrylic,I may try to mill them out onthe three axis milling machine,using a Pro Desktop file tocreate a 3D CAD design,allowing me to add bevels tothe edges, rather than the 90⁰wedge created by laser cutting.

Above is a scanned in image of a sketch for myfinal idea. This idea incorporates the changes Ihave made on this page, with the curves andadditional structural beams. I have also coloured itin with the colours my clients agreed to, matchingand blending in with the sky as much as possible.

ADAM SYKES9457PAGE SIXTEEN

CAD DESIGNOn this page I have taken the sketch from my previous page and created a Google SketchUp model, focusingon what my final design will look like, drawn to scale with the colours agreed to with my client. I have alsodisplayed my design in various ways, including X-ray and wire frame to show the interior of the housing unitat the base.

CLIENT FEEDBACK TO DESIGN CHANGES: Adam is clearly focusing on how sturdy the product is, and he needs to as this will be very important – the area outside Reception is not covered so it will be exposed to all weathers.

ADAM SYKES9457PAGE SEVENTEEN

CAD DESIGN ANALYSIS

ADAM SYKES9457

Laser cut 5mm translucent blue Acrylic will act as the top and bottom sections for the turbine housing. This is due to the aesthetical value of laser cut translucent Acrylic on top of the fact that it is a thermo plastic and therefore recyclable, meaning any off cuts which can’t be used can still be recycled.

Laser cut 1.5mm Stainless Steel pieces which will hold the Polypropylene blades in place. Brushed with fine wire wool for aesthetical value.

10mm x 10mm x 500mm Acrylic rod cut to size and glued using an Acrylic weld to the 5mm translucent blue Acrylic. These rods act as the supporting beams which hold up the top section of the turbine housing as well as being visually appealing with the transparent Acrylic reflecting and refracting light which falls upon it.

210mm x 240mm x 0.8mm blue Polypropylene blades with specially designed locking tabs to ensure that they are securely fitted to the Stainless Steel without the requirement of an adhesive. As with the Acrylic sheet , I have chosen to use Polypropylene as any off cuts too small for somebody else to use can be recycled.

uPVC tubing cut to size on the band saw and then sprayed with a white primer base coat, followed by several layers of light blue.

Milled Aluminium ‘T’ shape sections which will slot into the top and bottom of the uPVC tube. The top one will have three holes cut into it so that it can be attached to the 5mm Acrylic via three identically cut holes. The bottom piece will have a hole cut into it for the lens of the LED as well as for the pole which will hold the entire object.

Supporting post possibly made from galvanised steel. However this will not be important in my design process as I am focusing on the aesthetical aspects of the main sections of the turbine and its housing.

PAGE EIGHTEEN

DESIGN ALTERATIONS Due to a range of testing and experiments with trying to run a wind up camping light directly off a drive shaft from a spinning rotor, and coming acrosscomplications with the electrical components, I have decided to take my design in a slightly different direction. I now aim to make a .75 scale spinningprototype as before, only now I do not intend for it to charge a battery and power a light, it will now be a purely non functioning model with a separate breadboarded circuit board to show how the light dependant resistor will function as a switch.

To the left is a screen shot of theinitial correspondence betweenmyself and external contact whoworks at a local metal workingcompany. I have sent a file of anattachment of the top and bottomsections of the rotor, as I hadindented for these two sections tobe laser cut out of stainless steelrather than acrylic as this wouldadd a more premium look to myproduct. Furthermore, thestainless steel would be bettersuited for the function than acrylicwould, being able to withstandimpacts without shattering . MrOpen has stated that he his unsurewhich thickness would be ideal tocleanly cut the pieces whilst stillretaining structural integrity,however he will test out a 2mmthickness first, as we both believethis will most likely work best.

ADAM SYKES9457PAGE NINETEEN

CLIENT FEEDBACK TO PLAN CHANGE: I am pleased Adam has taken the advice of an industry specialist and is keen to try different approaches based on theadvice provided.

STAINLESS STEEL SECTIONSOn this page is the continuous communication between myself and anexternal metal working contact . After clarifying a few issues, such as thethickness of material and the scale of the drawing to be cut I thenreceived an email stating that they had been cut.

I am extremely pleased with the outcome of the laser cut sections ofstainless steel , as they are far better than I had imagined, being thinneryet stronger than I had thought, whilst being identical to the CAD file,despite my expectations that cutting such thin lines into such thinmaterial might lead to it welding itself back together. Admittedly therewere a few inconsistencies and imperfections , however these areextremely fine details that can only be observed from close inspection.

ADAM SYKES9457PAGE TWENTY

POLYPROPYLENE BLADESFirstly, I did laser cutting tests on a sheet of 0.8mmthick polypropylene, changing the power level ofthe laser to reduce the melted burrs which build upalong the path of the laser, making it harder to slotinto the sections of stainless steel. Once satisfiedwith the power of the laser I then cut out a 300mmpiece with the specific grooves to fit into the steel.Although fitting reasonably well I found that due toits length it began to bow in the centre, which thenled me to re-design a smaller blade.

I then decided to re-design the length of the blades to 200mm inan attempt to reduce the bowing effect created by the previousblade . I found that reducing the length of the blades workedwell, as now there was no bowing. However, I found it extremelydifficult to slot the blades into both sections of stainless steel, aswhen one went in the other popped out. Furthermore difficultiesI have encountered include attaching the blades once in position,as using an epoxy resign which would be the strongest way ofattaching the components together would also be messy andleave unsightly blobs of glue.

Re-designing the top and bottom sections ofthe blades so that they not only slotted intothe steel groves without easily coming out butfit so well that they required no externaladhesive at all proved to be quite challenging.Requiring three attempts to create sufficientlocking tabs I was eventually pleased with mydesign which allowed the blades to be slottedin place with the additions of the locking tabsmaking it almost impossible to simply pull theblade out (without breaking it)

ADAM SYKES9457PAGE TWENTY ONE

For the static top and bottom sections of thehousing for the rotor I have decided to use asheet of 5mm Acrylic , which I will then laser cutthe CAD design from. To the far left is a testpiece I cut from a piece of clear 5mm acrylic toensure the correct measurements. Despitebeing far larger than I need, the 1000x600sheet is the smallest sized sheet which would fitthe pieces I need cutting on it. Due to this I haveensured the excess Acrylic does not go to waist,as a classmate of mine is splitting the piece withme. I have decided to go with a translucent bluesheet as this is in keeping with the idea of itblending into the environment, using coloursassociated with the sky .

Light Blue Tint Acrylic SheetCode: 5MMK2I7092£20.63Sheet Size:1000mm x 500mm x 5mm

POLYPROPYLENE SHEET OPAQUE ICE BLUECode: POL0005£5.83Sheet Size: 650mm x 1100mm x 0.8mm

Based purely on aesthetics Ihave decided to use 10x10mmclear acrylic rod to act as thesupporting beams to hold up thetop section rather than usingthe same blue acrylic.

For the three blades I have decided touse a sheet of 650 x 1100 x 0.8mmPolypropylene which I will then lasercut the CAD file from. As with theAcrylic sheet , this sheet far exceedsmy requirements . I shall use thesmallest amount of material I can,reducing the waste off cuts betweeneach piece meaning that there will bemore spare material for other peopleto use in the future. Again, as with theAcrylic, I have ordered blue material sothat it merges with the sky and won’tstand out too much.

For the base sectionwhich will hold thelights and battery (anddynamo in the realthing) I have decidedto use a piece of u-PVCtubing cut to size andsprayed to match thecolours of the rest ofthe turbine. I shallinitially spray a whiteprimer coat and thenseveral layers of lightblue in order to matchthe colours of the restof the product..

ADAM SYKES9457

FINAL MATERIALS

PAGE TWENTY TWO

MANUFACTURING PLAN

ADAM SYKES9457

STEP ONE: Ensure Stainless Steel sections are laser cut before I begin to manufacture other sections as these arethe main pieces and due to the complexity of the design and my lack of experience with the external metalworking company meaning I don’t know how long it will take them to process the file and cut the sections.

STEP TWO: Apply an even matt finish to the Stainless Steel pieces with wire wool to increase aesthetical value.

STEP THREE: Once materials have arrived, cut 5mm Acrylic sheet to minimum size needed so that it not only fitson the laser bed but this also means there will be more material for my classmate to use who is sharing the sheetwith me.

STEP FOUR: Laser cut out the pieces of 5mm Acrylic and 0.8mm Polypropylene, firstly cutting the files out onpaper to certify the correct sizes.

STEP FIVE: Cut 10mm X 10mm clear Acrylic rod to desired size, guaranteeing that they fit into the laser cut slots inthe 5mm Acrylic.

STEP SIX: Slot the three Polypropylene blades into the Stainless Steel pieces.

STEP SEVEN: Apply an Epoxy Resign to adhere the 4mm Mild Steel rod to the Stainless Steel pieces through theholes cut in the centre.

STEP EIGHT: Use an Epoxy Resign to glue the bearings in place in the 5mm Acrylic.

STEP NINE: Using a Plastic Cement, adhere the three 10mm X 10mm clear Acrylic rods to the 5mm Acrylic pieces,around the blades, ensuring that the Mild Steel rod is fed through the top and bottom bearing.

STEP TEN: Once in place, add an external bonding agent to adhere the Mild Steel to the bearings (on top of thestrength of the friction fit.)

STEP ELEVEN: Cut uPVC tube to desired length.

STEP TWELVE: Apply a white base coat of paint to the tube, once dried, spray multiple layers of blue onto thetube.

STEP THIRTEEN: Solder required resistors onto a circuit board with Star LED and Battery pack.

STEP FOURTEEN: Mill out top and bottom Aluminium ‘T’ sections for the uPVC tube to fit into, as well as toconnect the tube to the base of the 5mm Acrylic.

STEP FIFTEEN: Mill out holes for the light in the bottom Aluminium section.

STEP SIXTEEN: Attach the bottom and Aluminium ‘T’ sections to the tube using an Epoxy Resign and secure thetop section to the 5mm Acrylic using three nuts and bolts.

FINISHED.

POINT UPDATED SPECIFICATION

TIMESCALE

To ensure I finish my product on time, I will am to keep as close to my Gantt Chart as possible, putting in extra hours to deal with any unforeseen errors.

TARGET MARKET

My design will be aimed as a single product at my school, to illuminate the reception area. But if it were to go into mass production I would aim it at county councils to be installed as street lights.

FUNCTIONThe function of my design is to act as a scale prototype for a wind powered light.

SIZEI will aim to keep the main section of my product (the rotor and light) as small and compact as possible.

DURABILITYMy light must be tough, however not as durable as if it were to be an actual working product

AESTHETICS

The aesthetical value of my design is of paramount importance and surpasses the functionalities importance as I am only making a prototype. .

MATERIALS/MANUFACTURENG

Where possible I shall use reclaimed and recycled materials (as this also fits in with the sustainability aspect. ) Whether or not I manufacture my product from a combination of polymers or metals will depend on my clients wishes.

SAFETYI will ensure all electronics are enclosed and sealed with no chance of shocks.

COST

The manufacturing costs would be dramatically reduced if my design was to be mass produced as the production could make use of buying materials in bulk and would therefore reduce costs. As I am only making a one off product I shall still aim to keep costs low, but not as low as they would be in mass production. I will aim to spend no more than £50 on my product.

ENVIRONMENTA

L ISSUES

I shall base my project on sustainability and environmental factors such as: having 0 air miles in my design and using recyclable materials when possible.

QUANTITY I shall aim to produce one scale prototype product.

TESTING

I will make and model multiple designs, finding the most simplistic and efficient design before I begin manufacturing.

PAGE TWENTY THREE

MANUFACTURING

ADAM SYKES9457

To the left I have laser cutthe 5mm translucent lightblue Acrylic for the top andbottom sections of theturbine housing. Thesepieces will hold the bearingsin the centre which will holdthe 4mm Mild Steel rod, theyalso contain squares for the10mm x 10mm transparentAcrylic rod to be glued inplace .

After I cut the 5mm Acrylic I knewthat it would be an insufficientthickness to fully support the10x10mm Acrylic rod, so Idecided to cut further Acryliccircles with a 10x10mm squarefor the rod to go through. Thismeans that when I go to glue theAcrylic sections together therewill be more support for the rods,thus ensuring that they aresecure.

Before I cut the Polypropylene blades Ialtered the power setting on the laser toreduce the burr and burning along the pathof the laser. Once I reduced the powersufficiently I then cut out the three blades.

I cut the section of1000mm x 500mmdown to 600mm x400mm so that it fitinto the laser bed,utilising all thespace when cuttingby rearranging thetwo sections in away which requiredthe least space.

PAGE SUMMARY:To the right is my product afterthe first week of beginningmanufacturing. I havesuccessfully cut all the Acrylicand Polypropylene that I need.Furthermore I have also cut andsprayed the uPVC tube. ThePolypropylene fit well into theStainless Steel as did thebearings into the Acrylic.

TO DO:- Wire up a battery with the star

LED- Cast Aluminium- Mill Aluminium - Glue all components together

I initially cut the uPVC tubeto 155mm using a bandsaw. I desired the length of150mm but knew that theblade of the band sawwould not only take off afew more millimetres butit would also cut slightlyunevenly and notcompletely square.Because of this I then putthe tube onto the latheand faced the two edgesuntil they were square. Ithen coated the tube withmultiple layers of a whiteaerosol primer, allowingeach coat time to drybefore applying the next.Once fully dried I followedthe same process but thistime with a light blueaerosol paint.

In the image to the right I have gluedthe bearings in place in the 5mmAcrylic. Before mixing the two partEpoxy resign, I masked off the areaaround where I would be gluing toeliminate the possibility of any excessglue adhering to the surface of theAcrylic which would have lookedunsightly. After this, I coated the edgeof the bearings with an Epoxy resignand glued them in place.

To the right I have cut the two 500mmAcrylic rods into four 240mm rodsusing a band saw. I initially measuredthe 250mm half way mark on each rodand then measured back a fewmillimetres on each side and appliedmasking tape to the areas I didn’t wishto cut, and then cut on the centre line.Following this I then used a belt sanderto face off the uneven faces and bringeach rod down to 240mm.

PAGE TWENTY FOUR

Laser cutting the two MDF disks from 12mm MDFwith a following 3mm smaller disk being cut afterthese two.

Coating the three MDFdisks with polyvinylacetate glue.

Leaving the three disks todry and the glue to set in avice.

Drilling and threading ahole for extraction of themould from the sand.

Coating MDF mould inpowder so that extractionis easier.

Packing sand around theMDF mould in the Dragmoulding frame.

Smoothening the sand ofthe bottom layer of themoulding frame.

With the help of a class mate I then packed thesand around the wooden sprue pins in the Copemoulding frame.

Smoothening the sand on the top of the Copemoulding frame around the sprues.

Pulling out the woodensprues leaving the riserand runner hole.

Taking the Cope moulding frame off the Drag andthen screwing a screw into the threaded hole sothat I can remove the MDF mould.

Removing the MDF mould and removing excesssand which crumbled inwards.

Creating a path for the molten Aluminium toget into the mould and one for the air to escape.

Fastening the Cope ontothe Drag and preparing topour the Aluminium

ALUMINIUM CASTING

ADAM SYKES9457

Ensuring all safetymeasures are in place andigniting the flame.

Leaving for a while toset and then begin tocool.

After an hour or so,separating the Cope andDrag.

Removing the piececarefully using long tongsand gloves, then quenching.

Once the Aluminium is molten at700°C pouring until it fills upboth the riser and runner.

PAGE TWENTY FIVE

FURTHER MANUFACTURING

ADAM SYKES9457

Above is my initialdimensional sketch for theAluminium T-section, alongwith a Google SketchUp 3DCAD design. I produced theCAD design so that I knewwhat the final piece wouldlook like before actuallymanufacturing it , using it asa guide to work to.

After the casting process I had to cut off the two pieces of Aluminium whichwere formed in the runner and the riser. After which I filed off any burs andextruding imperfections and began to turn the piece on the metalworkinglathe. Firstly I reduced the material down to size (since I intentionally madethe Mould oversized so that I could carefully remove the rough outer layerof Aluminium.) once almost down to the right sizes in each dimension, Islowed the tool paths so that the finish would be finer than the rough oneachieved my the initial turning. I then applied a shallow bevel to the edgesto eliminate the risk of cuts caused by sharp edges.

Once the T section was to the desired dimensions, I laser cut an MDF jig withthree 4mm holes cut into it to represent where I would need to drill into theAluminium. I then used these holes to centre punch an indentation into theAluminium before drilling a 3.5mm hole. Once drilled, I threaded the insideof them with a 4mm tap, meaning that a 4mm bolt would fit securely intothe Aluminium. Lastly, I drilled a 16mm centre hole for another bearing to fitinto.

PAGE TWENTY SIX

ADAM SYKES9457

I then repeated the casting process a second time to produce a second Aluminium T section. Once I reduced the excess Aluminium and brought the piece down to size, I then created a 38mm hole trough thecentre on the lathe for a steel tube to fit into. I then used the vertical axis milling to bore out a second hole for the lens of the super bright LED, I used the milling machine rather than a pillar drill as there wasno drill bit of the exact size, however there was a bit of the correct size for the milling machine. I then cut two Acrylic sections; one a frosted ring and the other a clear disk. I glued these together and insertedthem into the Aluminium with the lens placed behind, as the minimalistic styling of the Acrylic section surpassed the aesthetical value of the lens.

Next, I began work on the internal and external electronics. I wired a battery pack to a switch and then to the LED with a resistor inseries to limit the current flow. I also applied heat shrink over the soldered wires to ensure there were no exposed areas and thateverything was fully insulated. I also made a small acrylic disk with a section cut out for the two wires which I used to secure the LEDonto the lens inside the Aluminium.

To counter the bowing of the blades (which was so severe that the rotor couldn't turn withoutcatching on the Acrylic supports) I created a device (below) to ensure the blades remainedstraighter. This in turn allowed the rotor to freely spin.

FURTHER MANUFACTURING

PAGE TWENTY SEVEN

ADAM SYKES9457

FINAL PRODUCT To conclude my manufacturing process I drilled a holein the side of the uPVC tube and screwed the switch inplace. Before gluing the Acrylic sections together Idrilled three holes into the bottom piececorresponding with the holes drilled into theAluminium which I then screwed three 4m boltsthrough, thus attaching the Acrylic to the Aluminium. Ithen proceeded to use plastic cement to adhere theAcrylic sections together and a two part Epoxy Resignto attach the Mild Steel rod to the bearings.

PAGE TWENTY EIGHT

ADAM SYKES9457

FINAL PRODUCT

PAGE TWENTY NINE

RISK ASSESSMENT

ADAM SYKES9457

CASTING:Process-Theproductionof a singlepiececomponentfrom moltenmetalpoured intothe cavity ofa sandmould.

HAZARDS:Explosions- Water, on or in themould material , can boilexplosively when heated by hotmetal.Burns- Contact with hotcrucible or molten metalsplashed onto skin can causesevere burns.Chemical reaction- Moltenaluminium can react violentlywith metal oxides such as rust.

RISK ASSESSEMENT:Explosions- The risk ofexplosions is high in thefollowing cases: Whengreen sand moulds areused straight from a coldstore or are cooled inwater before being re-used. Also when plastermoulds are notthoroughly dried beforeuse.

RISKASSESSEMENT:Burns- Moltenmetal can besplashed aroundwhen movinghand-heldcrucibles andladles or as aresult of anexplosion whilstpouring.

RISKASSESSEMENT:Chemicalreactions- Thereactionbetween moltenAluminium andiron oxide is veyviolent, howeverit is very rare inschoolworkshops.

CONTROL MEASURES:Casting should only becarried out in a dry area,with equipment designedfor that purpose andunder the supervision ofcertificated staff.Observers must alsowear personal protectiveequipment and shouldbe at least two metersback from the operation.

METAL TURNING:Process-The productionby turning, facing,boring , screw cutting,centre drilling, tappingand knurling ofprimarily cylindrical orspherical forms fromboth ferrous and non-ferrous raw material ,possibly using oil basedcoolants.

HAZARDS:Trapping- Closing movements between partsunder power feed can present a trapping hazard.Flying workpiece- Workpieces, chuck keys ortools can be ejected violently if not heldcorrectly or if the machine starts unexpectedly.User injury- Human contact with swarf cancause cuts or abrasions .Entanglement- Long hair, dangling jewellery orloose clothing can become entangled withrotating parts, dragging the operator into themachine.

RISK ASSESSEMENT:Trapping-Movements underpower feed areusually slow, thusminimising the riskof trapping whichwould most likelyoccur when themachine is beingmanuallycontrolled.

RISKASSESSEMENT:Flyingworkpiece-There is a highrisk thattrainees willnot clampitems securely.

RISKASSESSEMENT:User injury-There is a highrisk of puttinghands orfingers in fastmovinghazardousplaces

CONTROL MEASURES:There should be sufficientspace around the lathe toensure that the user is notpushed into the machine by apasser by. The floor surfaceshould not be slippery to avoidaccidental slips while using themachine. Guards over themoving areas should preventanything from flying towardsthe user.

Process-Use of ahigh poweredlaser to cutplastics, rubber,wood, card andtextiles undercomputercontrol as anexample of CAM.

HAZARDS:Burns- High power lasers can cause severeburns to skin.Blinding- Reflective beams can causeblinding if entering the eye with powerfullasers.Toxic flumes- The use of the laser to cutPVC generates toxic vinyl chloride.Polyurethane foams may give hydrogencyanide and nitrogen oxides when heated.Fire- The material being cut may be ignitedby the cutting process.

RISKASSESSEMENT:Burns- The riskof burning isminimalproviding thatthe laser beamsare totallyenclosed.

RISKASSESSEMENT:Blinding- Therisk of blindingis minimalproviding thatthe laser beamsare totallyenclosed.

CONTROL MEASURES:Interlock to prevent the use ofthe laser unless the system isenclosed and the lid is shut.Servicing should be carried outregularly by professionals. PVCand polyurethane should notever be cut. The power andspeed settings must be setcorrectly. An extractor fanmust be on to reduce fumesand the chance of fire.

LASER CUTTING: RISKASSESSEMENT:Fire- If theinstructionsprovided by themanufactureare followedthen the risk ofignition of theworkpieceshould be low.

RISKASSESSEMENT:Toxic fumes-PolyvinylChloride andPolyurethanefoams presenta serious risk.

PAGE THIRTY

SPECIFICATION COMPARISON

POINT / UPDATED SPECIFICATION COMMENT

TIMESCALE To ensure I finish my product on time, I will am to keep as close to my Ganttchart as possible, putting in extra hours to deal with any unforeseen errors.

I was able to keep closely to my Gantt chart, finishing slightly ahead f schedule due to the removalof the electronic components.

TARGET MARKET

My design will be aimed as a single product at my school, to illuminate thereception area. But if it were to go into mass production I would aim it atcounty councils to be installed as street lights.

As my product was initially aimed at one specific client, it has remained the same throughout .

FUNCTION The function of my design is to act as a scale prototype for a wind poweredlight.

My final product succeeded at being a scale prototype as I had intended.

SIZE

I will aim to keep the main section of my product (the rotor and light) as smalland compact as possible.

I was successful in keeping the main components as small as possible, with the obvious exceptionof the blades needing to be relatively large, however, my new design for the tree bladed Savoniusrotor was able to minimise the size.

DURABILITY

My light must be tough, however not as durable as if it were to be an actualworking product

Because of the materials I was limited to due to limitations of the cost my final prototype itsucceeded in being a scale model, however it was not structurally the same as it would have to befor the full sized working product.

AESTHETICS The aesthetical value of my design is of paramount importance and surpassesthe functionalities importance as I am only making a prototype.

My final product ended up looking almost identical to my final Google SketchUp CAD model andinitial sketches and was extremely aesthetically pleasing.

MATERIALS/MANUFACTURENG

Where possible I shall use reclaimed and recycled materials (as this also fits inwith the sustainability aspect. ) Whether or not I manufacture my product froma combination of polymers or metals will depend on my clients wishes.

Although I was able to use primarily recyclable materials, such as the Acrylic and Polypropylene aswell as some reused elements (the uPVC tube) the majority of materials used were brand newand not recycled as I had hoped for.

SAFETY

I will ensure all electronics are enclosed and sealed with no chance of shocks. All electrical components inside the uPVC tube were correctly soldered and subsequentlywrapped in heat shrink to eliminate any chances of shows or shorting.

COST

The manufacturing costs would be dramatically reduced if my design was to bemass produced as the production could make use of buying materials in bulkand would therefore reduce costs. As I am only making a one off product I shallstill aim to keep costs low, but not as low as they would be in mass production.I will aim to spend no more than £50 on my product.

As my product was a one off and benefitted from the charity of Bristolmaid who supplied me withthe laser cut stainless steel free of charge, I was able to keep the overall cost of my product wellbelow my initial maximum price limit.

ENVIRONMENTAL ISSUES

I shall base my project on sustainability and environmental factors such as:having 0 air miles in my design and using recyclable materials when possible.

I was able to attain all materials and components from mainly local sources with the exception ofTrent Plastics and Hindleys, however even these two locations remained in England, meaningthere are no air miles associated with my product. Furthermore the majority of the materials usedin the prototype are recyclable.

QUANTITY

I shall aim to produce one scale prototype product. I succeeded in producing one scale prototype.

TESTING

I will make and model multiple designs, finding the most simplistic and efficientdesign before I begin manufacturing.

I produced a number of different models and tested their efficiency before settling on my finaldesign.

ADAM SYKES9457PAGE THIRTY ONE

PRODUCT DISASSEMBLY 10mm x 10mm x 500mm square Acrylic rod cut to size and glued using an Acrylic weld to the 5mm translucent blue Acrylic. These rods act as the supporting beams which hold up the top section of the turbine housing as well as being visually appealing with the transparent Acrylic reflecting and refracting light which falls upon it.Costing: £4.20

210mm x 240mm x 0.8mm blue Polypropylene blades with specially designed locking tabs to ensure that they are securely fitted to the Stainless Steel without the requirement of an adhesive. Costing: £5.83

Laser cut 1.5mm Stainless Steel pieces which will hold the Polypropylene blades in place. Brushed with fine wire wool for aesthetical value. With a 5mm Mild Steel rod running through the centre attached to bearings in the Acrylic.Costing: Free

Laser cut 5mm translucent blue Acrylic housing the Steel and Polypropylene rotor, with three holes drilled into the bottom piece for screws to fasten to the Aluminium. Costing: £20.63 sheet split with classmate, equalling £10.32

Laser cut 5mm translucent blue Acrylic sections to keep the blades from warping, cut from the offcuts of the main Acrylic sections.

uPVC tubing cut to size on the band saw and then sprayed with a white primer base coat, followed by several layers of light blue with a hole drilled near the base for the switch.Costing: £5 for the spray paint, the tube was free

Cast and milled Aluminium ‘T’ shape sections which slot into the top and bottom of the uPVC tube. With the top piece having three holes cut into it so that it can be attached to the 5mm Acrylic via three identically cut holes, and the bottom piece having a hole cut into it for the lens of the LED as well as for the Steel pole.Costing: £1 for the LED, however the Aluminium was free due to using reclaimed pieces of aluminium and then melting them together.

Stainless Steel tube which fits through the central hole cut into the bottom piece of Aluminium, elevating the rotor off the ground.Costing: Free, due to it being a reclaimed pole from a past students project.

COSTING SUMMARY:Overall, this project cost me roughly £26, howeverthis is not an accurate representation of how much itwould cost to produce a full sized working product.This is down to the fact that I was able to receivemultiple items free of charge, whereas that wouldn’tbe possible if I were to mass produce my product.Furthermore, my prototype is only a .75% scale of theintended size of the real product, meaning therewould be greater material costs.

QUALITY CONTROL:1- When cutting the rods I had to ensurethe were all cut and sanded to the exact same length,otherwise the housing would have been lopsided.2-5- Designing these sections on a CAD file and lasercutting them reduced and QC issues as they were cut soprecisely.6- When cutting and spraying, accuracy was veryimportant to ensure a precise finish.7- With both the casting and the turning process I imposedQC checks regularly to guarantee the Aluminium fitperfectly into the uPVC.8- initially ensured the strength of the tube to certify itcould hold the weight of my product.

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ADAM SYKES9457PAGE THIRTY TWO

QUESTIONNAIRE

ADAM SYKES9457PAGE THIRTY THREE

CLIENT FEEDBACK TO FINAL PRODUCTI really am very impressed with the final product. Adam listened to what was required and has focused on what matters in terms of the school. He has taken our school population into consideration and designed a product which is durable enough to survive in a school with a population of 1000 adolescents. The quality of diagrams and level of detail should be credited as he has been able to show how the design process has unfolded to a client who does not have a background in this area. He has thought carefully about audience, the clarity of his work is exceptional. I would have confidence in the product and Adam as designer.

Question One: Based on your initial comments on the design of thisproduct and its aesthetical appeal, are you pleased with the final visualoutcome?

Question Two: The rotor section on this prototype is ¾ sized of theplanned real product, with the pole being ½ size, do you feel that a ¼sized larger rotor section would appear too large (irregardless of possibleadded efficiency)?

Question Three: Do you believe that the addition of wind powered lightsto the grounds of The Blandford School will be welcomed by staff andstudents?

Question Four: Would you prefer a compromise of lower qualitymaterials for a cheaper overall price?

Question Five: Despite the overall colour scheme of the school beingpredominantly burgundy in the past, are you happy with the overall bluetheme of my design?

Answer One: Yes, I am extremely pleased with the final product which is extremelyappealing and would suit this environment well.

Answer Two: I do believe larger rotor blades would be useful if the product was larger.

Answer Three: Absolutely, staff and students are always keen to look at ways of usingthe natural environment . As Headteacher I am always concerned man-madeproducts enhance the landscape and the buildings.

Answer Four: Value for money is extremely important. I would compromise on quality ifnecessary, we often have to. However, I would need a product which lasts and so would bekeen to discuss longevity with Adam. I would pay more if he could prove this would be bettervalue for money over time.

Answer Five: Yes, blue is acceptable as the school is gradually moving away from thecorporate burgundy and introducing new colours in carpets and the fascia of Block 4. I feelthe blue would suit the environment.

EVALUATION IN RESPONSE TO CLIENT FEEDBACK

ADAM SYKES9457PAGE THIRTY FOUR

“I am extremely pleased with the final productwhich is extremely appealing and would suit thisenvironment well.”

I am pleased that my client found then end productaesthetically pleasing, however the majority ofmaterials I used were brand new and not recycledas I had initially aimed for. Although I was able touse primarily recyclable materials, such as theAcrylic and Polypropylene as well as some reusedelements (the uPVC tube) in an improved version Iwould source more eco friendly, recycled supplies.

“He has taken our school population intoconsideration and designed a product which isdurable enough to survive in a school with apopulation of 1000 adolescents.”

Despite my client praising the strength anddurability of my final product, I was actually not aspleased with it as her, believing it could be madestronger. Because of the materials I was limited todue to limitations of the cost my final prototype, itsucceeded in being a scale model, however it wasnot structurally the same as it would have to be forthe full sized working product.

“Value for money is extremely important. Iwould compromise on quality if necessary, weoften have to. However, I would need aproduct which lasts and so would be keen todiscuss longevity with Adam. I would pay moreif he could prove this would be better value formoney over time.”

I agree with my clients response to thisquestion, as I too believe that although theinitial price of the product is important, thedurability and longevity are more important inthe long run, therefore a compromise ofcheaper materials should be avoided for a oneoff product such as this, whereas if the productwas to be mass produced, cheaper materialsshould be considered which would be moresuitable for industry.

“I do believe larger rotor blades would be useful ifthe product was larger.”

As I had initially planned, my client agrees that therotor section would be more efficient an well suitedbeing .25% larger.

“Yes, blue is acceptable as the school isgradually moving away from the corporateburgundy and introducing new colours incarpets and the fascia of Block 4. I feel theblue would suit the environment.”

I am pleased that my client is happy with thefinal colour selection of light blues, which Ihoped would then blend into the sky on a clearday, reducing visual disturbances oftenattributed with lighting. I felt this was moresuitable that the burgundy colour scheme theschool currently has, especially as they areaiming to move away from the burgundy.

ITEM SOURCEInformation about climate change . http://www.nef.org.uk/knowledge-hub/climate-change-energy/climate-

change

Information about VAWT’s. http://makezine.com/projects/wind-lantern/

Website from where I purchased the ball bearings for my product. http://simplybearings.co.uk/shop/Bearings-Deep+Groove+Ball+Bearings/c3_11/p170615/634ZZ+Budget+Metal+Shielded+Deep+Groove+Ball+bearing+4x16x5mm/product_info.html

Website from where I purchased the Acrylic rods and Polypropylene sheet. http://www.hindleys.com/index.php/materials/plastics-foam/sheet.html

Website from where I purchased the blue Acrylic sheet. http://www.trentplastics.co.uk/2012/

Website from where I purchased the 12v battery. http://www.cts-direct.net/power-sonic-ps1270-12v-7ah-rechargeable-sla-battery-ps1270-power-sonic?language=en&currency=GBP&gclid=CKSZls6Ijb4CFQEXwwodKysAdA

Company who laser cut the Stainless steel sections. http://www.bristolmaid.com/

BIBLIOGRAPHY

ADAM SYKES9457PAGE THIRTY FIVE