Instructions: Coffee
Cup Turbine
By: David Willis, Associate
Professor, University of Massachusetts Lowell
This work was supported
by a grant from the Massachusetts Clean Energy Center (MassCEC).
The materials presented do not necessarily reflect the opinions of the MassCEC.
We are grateful the MassCEC for their support and encourage you to look at some of their
online resources.
Step 1 Before
Starting: Read and understand how to do this activity safely |
á Be sure to have an adult
help you when cutting parts. á When testing your turbine,
be sure to wear safety glasses á When testing your turbine,
make sure the spinning blades are far away from your face/your body |
Step 2 Constructing
your wind turbine tower and nacelle |
á Collect the following items: o 1 x Long piece of 1Ó PVC pipe
(~18 inches long). o 1 x Short piece of 1Ó PVC pipe (~2-6 inches long). o 1 x PVC 1Ó TEE fitting o 1 x PVC 1Ó Pipe Coupler
fitting á Push the shorter and longer
PVC pipes into the TEE fitting as shown below. á Push the pipe coupler
fitting onto the end of the short PVC pipe as shown. You now have
your wind turbine Tower and Nacelle! |
Step 3a Assembling
your wind turbine rotor and generator. |
á Collect the following items: o 1 x Roll of Duct Tape (or
any other tape you may have) o 1 x DC generator (http://www.vernier.com/products/kidwind/wind-energy/kw-gen/) o 1 x wind turbine hub (note:
we will show you how to make a hub later in this instruction manual) (http://www.vernier.com/products/kidwind/wind-energy/kw-wth3/) o 3 x wooden dowels or 3 x wooden
pencils. á Connect the generator to
your hub. á Loosen the screw knob on the
hub á Insert the dowels into the
hub and tighten the screw knob. á Take a strip of duct tape
and wrap it around the generator. This will ensure a tight fit between the
generator and the nacelle. Your wind
turbine rotor, generator and hub are assembled! |
Step 3b Installing
the generator on the tower in the nacelle |
á In this step you will
install the generator in the nacelle/hub of your wind turbine tower. There
are a few steps: o Start by removing the short
PVC pipe from the TEE fitting o Next, pass the red and black
wires into the pipe, through the TEE fitting. These wires will carry the
electricity out of your turbine generator. o Carefully press the
generator into the PVC coupler fitting. Increase/decrease the amount of tape
wrapped around the motor to ensure a snug installation. á Reassemble the PVC tower
(press the TEE fitting together again) á Add some strips of tape to
attach the wires to the tower. You are now
ready to go and design some wind turbine blades. The turbine is almost
done. |
Step 4a Designing
your blades |
á Now we will explore the
blade design process. For this we will use a simple, 20oz Coffee Cup. Once
you have built one set of blades, you can try any number of modifications to
improve your wind turbine performance. á Collect the following
parts/equipment: o 1 x Safe Scissors (be sure
to ask an adult to help you use the scissors) o 1 x cardboard coffee cup o Some clear tape or glue
stick o The blade design template (see
below this step), or click here for a PDF. á
Once you have all the equipment/parts cut out the wind turbine blade
templates. á Once you cut out the wind
turbine blades, you will use them as templates for the actual blades. To do
this, you should stick the paper templates on your cup. o Hint:
Keep the printed writing facing you when you tape the template on the cup. o Hint: Put the root of the blade into the lip
of the cup (where it says Òlip of cupÓ). |
Step 4b Cutting and
mounting your blades |
á With an adult, use the
scissors to carefully cut out the blade shape. You should have 3 nearly identical
blades if you do this correctly: Notice: Your blades are curved and twisted. If you try
different blade shapes and designs, they will likely perform differently. A
challenge for you is to find what you think are the best blade shapes. á Use duct tape to mount the
blades on the rotor wooden dowels. Make sure the blades are all facing the
same way. (Hint: The part of the coffee cup that was Òinside the cupÓ should
face toward the wind). Now you should have a working turbine. Start by trying
different blade angles and seeing how that affects your design. |
Step 5 Making your
own COFFEE CUP HUB |
If you donÕt
have a KidWind Turbine Hub, you can make your own
using the bottom of the coffee cup you used to make your turbine blades. á Have an adult help you to
carefully cut the bottom of the cup off. á Once you have cut the bottom
of the cup off, you should measure and mark the locations where the blades
will be installed. o If you have 3 blades we
recommend first finding the center of the cup and then marking 3 x locations
on the outide of the cup that are each separated by
120 degrees. á At each of the locations
that you plan to install a blade, cut a Vee-shaped
cut or notch carefully using your scissors. We find that it is best to make
these notches on the very bottom of the cup. These notches should be big
enough to allow the wooden dowels/pencils to sit in. á
Place the blades into the notches as shown below (left). Carefully, using
small strips of duct tape, secure the blades onto the coffee cup hub. Next you need
to attach the hub to the generator. Depending one what type of generator you
have, you may need to get creative. In this example a pulley that is designed
for this motor is used. This pulley is duct-taped to the hub in the center
(if you donÕt get the center, your turbine will likely wobble). You may
consider using glue, chewed gum or some other creative approach. Talk with
some adults to figure out a way to attach the hub to the generator if you
canÕt come up with a solution. Once your hub
is complete, put the hub onto the generator. You are all done. Go and test your wind turbine now! |
Step 6 Hints for
making better blades |
One of the
nice things about the coffee cup turbine is that it is very cheap and easy to
make and test new blades. Some of the design parameters you may want to
explore are: á The overall blade pitch angle: The angle of the whole blade in the hub is an
important parameter in the performance and design of wind turbines. Consider
that many wind turbines have variable pitch blades so that they can adjust
this angle for different wind conditions. Try out some different pitch angles
and assess how this affects your wind turbine performance! á The chord of the blade: How ÒwideÓ the blade is. You see that many real
world turbines have much smaller chords than their length. Is this
advantageous in your turbine? á The blade taper: The taper is a measure of how quickly the blade chord changes as you go
from the hub to the tip of the blade. Take a look at some photos of actual
turbines to determine some tapers you might like to try. á
The blade sweep angle: The angle the blade makes on
the cup affects the amount of twist the
blade experiences from root to tip. The twist is on of THE MOST important
parameters in fundamental wind turbine aerodynamics. Try different cup cut
angles and see how your turbine performs differently. You may find that the
turbine spins faster and slower. You may also want to use a protractor to
determine the angle at the blade hub vs. the tip to figure out the amount the
blade twists. Be sure to
visit KIDWIND online (https://www.kidwind.org)
to get other ideas and tips on how to improve your design. |