Continuously Variable Transmission Drivetrain System

for Wind Turbine Applications

Mitchell Lee David Schrock Shaheen Shidfar Ross Weaver (Miami Dolphins)

Mission
Design and develop, for research purposes, a continuously variable transmission system (CVT) for variable wind conditions

Global Impact
Disadvantage of traditional wind turbines
Compromises of traditional drivetrains Indirect Variable input, but PEs required Direct aerodynamic losses, but fixed generator input (at the grid frequency)

Advantage of continuously variable transmission wind turbine system

dual TSR and generator control elimination of expensive PEs

Wind Turbine
How it Works?

Ex: Variable Wind Model

System Schematic
Proposed Solution:

Design Approach
Three Reasonable Options: 1.Fabricate a complete CVT 2.Purchase an existing windmill and retrofit a fabricated CVT system with off-the-shelf components 3.Purchase off-the-shelf components including a reputable CVT system, resulting in a modular system fitted for future research

First Solution
First Solution Design Criteria Weighing: High operational costs due to customized nature Exceeded the technical capability of the team given the limited time constraints Required advanced methods of manufacturing that exceeded the capabilities of a typical machine shop Final: Unfeasible

Second Solution
Second Solution Design Criteria Weighing: Exceeded time constraints Weight factor issues High product costs Unable to find a suitable wind turbine (market was mostly direct drive in our budget range) Final: Unfeasible

Third Solution
Third Solution Design Criteria Weighing: Safe High performance Very reliable Energy efficient Highly modular for future research purposes Integrated control architecture Final: Feasible

Manufacturing
Based around the CVT Automation Direct
two motors (one for variable input, one converted to a generator) frequency controller

Fallbrook Technologies CVT aluminum mounting frame off-the-shelf pulleys and belts

Input Control
AC inverter duty variable torque motor 5 HP motor 460 volts 3 phase matching frequency controller simulate variable wind conditions with frequency controller

Belts and Pulleys

pair of V-belts and pulley system links CVT input and output slotted CVT frame for adjustable belt tension advantages over chain driven systems low maintenance reduced noise efficient (less problems with poor tolerancing)

Output Control
AC general purpose cast iron motor 3 HP motor 460 V 3 phase converted to six pole generator (1200 RPM 60 Hz) no market for six pole generator any electromagnetic field will produce electricity

NuVinci CVT
Invented by Fallbrook Technologies Custom fabricated for wind application
Reinforced components to support up to 50 Nm Upgraded from 1000 RPM to 3600 RPM USB interface for DAQ research purposes Custom tuned shifting maps (Excel) Shifting time response

Drive ratio 0.5 to 1.75

NuVinci CVT

traction based variable radius spherical design shifting rod manipulates contact radius of sphere

NuVinci CVT

Theoretical Appl.
Assumptions
TSR: 7 Cp: 0.30 Rotor radius: 1.76 m Pre-CVT step-up gear ratio: 5 P = 0.5*v3*Cp**Arotor TSR=*rrotor/v

air: 1.204 kg/m3 @ 20o C

Gear ratios: 0.5 1.75

Results
4.00

Power Curve of the NuVinci CVT (TSR ~7)

CVT cut-in speed: 685.71 RPM @ 3.61 m/s CVT design rated speed: 2400 RPM @ 12.64 m/s Max design rated power: 3.6 kW
Power (kW)

3.50 3.00 2.50 2.00 1.50 Power Curve 1.00 0.50 0.00
38 0 57 0 68 6 85 5 10 44 12 34 14 24 16 14 18 04 19 94 21 84 23 74 24 69 26 59

CVT Input (RPM)

Drivetrain Assm.
CVT Frame 7. Generator 6. Output Pulley and Belt

5. CVT

1. Input Motor

4. CVT Shift Actuator

3. CVT Controller 2. Input Pulley and Belt

Recommendations
Test the time response of the CVT shifting mechanism Wind gust (step response)
turbulence response

Develop a co-axial system

eliminate pulleys/drive belts & minimize power loss

Keep drive belts and implement belt variator for traction experimentation (increase efficiency at high torque load) Implement a blade rotor and turbine housing Implement a gearbox to increase energy capture and reduce noise, wear and tear.

Questions?
- Thank Dr. Pourboghrat and Dr. Jaberi - Mr. Chad Glinsky - Dr. Somerton and the MSU CoE Design Program