This project accomplished two correlated goals of designing a new rotor blade to be used with the Cal Poly Wind Power Research Center, as well as defining the methodology required for the aerodynamic analysis of an optimized blade, the procedure required for generation of an accurate CAD model for the new blade geometry, and structural integrity verification procedure for the new blade via finite element analysis under several operating scenarios. The new rotor blades were designed to perform at peak efficiency at a much lower wind speed than the current CPWPRC rotor blades and incorporated a FEA verification process which was not performed on the earlier rotor blade design. Since the wind characteristics relative to the location of the CPWPRC are essentially unchanging the most viable option, in regards to generating power for longer periods of time, is to redesign the HAWT rotor to capture more of the wind energy available. To achieve this, the swept area of the rotor was increased, suitable airfoils were utilized, and the new rotor blades were optimized to maximize their performance under the CPWPRC location’s wind conditions. With an increased magnitude of wind energy being captured the aerodynamic loading on the rotor blades simultaneously increased which necessitated a structural analysis step to be implemented, both with classical hand calculations and with the assistance of an adequate FEA program, to ensure the new rotor blades did not fail under normal or extreme wind conditions. With the completion of this project the new rotor blade designed and analyzed in this report may be finalized and refined in order to be incorporated into the CPWPRC system in the future or the methodology defined throughout this project may be used to design an entirely different aerodynamically optimized rotor blade, including a CAD model and FEA structural integrity verification, as well.

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This study presents the design and optimization of a test rig tailored for upcoming wind turbine design applications. Initial decisions were made regarding component selection, focusing on a gearbox, electric motor, and motor controller. Requirements included continuous power output of 300 kW from the electric motor and the gearbox's ability to handle specified torque and reduce input speed to match the structural limitations. Key challenges revolved around gearbox design and performance, necessitating a right-angle configuration for converting horizontal to vertical torque efficiently. To meet the rotational speed requirements, a 30 to 1 ratio gearbox was selected, ensuring compatibility with the maximum structural rotational speed of 50 revolutions per minute. The electric motor, pivotal in the drivetrain, was chosen based on a balance between economic viability and rotational speed, resulting in a four-pole motor configuration. Coupling mechanisms were employed to connect the motor and gearbox, facilitating energy transfer between shafts. A motor controller was integrated to regulate current flow, voltage application, and frequency modulation, enhancing operational control and adaptability to specific requirements. Radial ball bearings were selected to minimize energy expenditure during rotation, particularly due to downward compressive forces. The test rig setup, situated indoors on a concrete floor, mandated a metal plate foundation to ease component attachment without drilling into the floor. Data simulations were conducted to determine bolt specifications capable of withstanding motor-induced forces. Furthermore, collaboration with industry experts facilitated component selection and quotation analysis, ensuring an optimized drivetrain solution meeting both technical and economic criteria. This research contributes to the advancement of wind turbine design testing methodologies, providing insights into component selection, integration, and optimization for enhanced performance and reliability.