As part of my ENGR212 Design for Reliability and Manufacturability course, I collaborated with a multidisciplinary team to design and construct an innovative wind turbine and generator system. The goal was to deliver a reliable and manufacturable renewable energy solution capable of powering charging stations for electric crop harvesters.

Our team selected the Archimedes double-helix turbine design, a modern vertical-axis turbine inspired by the Archimedes screw. Its curved blades maximize aerodynamic efficiency by capturing both lift and drag forces, while maintaining performance in low wind conditions. Paired with a custom-built permanent magnet generator, the system was engineered to provide farmers with an off-grid, sustainable energy source adaptable to varying climates.

The project applied a structured engineering design process, which included identifying customer needs, defining requirements, evaluating concepts with Pugh charts, and iteratively refining prototypes through testing. Fabrication required a diverse set of techniques, including Fusion 360 CAD modeling, CNC machining, 3D printing, soldering, welding, and riveting. These processes were used to manufacture and assemble the blades, generator components, and structural frame. The team also incorporated Design for Manufacturability (DFMA) and Design for Reliability (DFR) principles to ensure durability, efficiency, and ease of assembly.

Testing confirmed the turbine’s ability to generate measurable voltage across simulated wind speeds. Although challenges such as blade weight distribution required refinements, the final prototype met all dimensional, budgetary, and manufacturability requirements.

This project strengthened my expertise in mechanical design, electrical integration, and hands-on prototyping while reinforcing the value of structured decision-making tools and practical fabrication methods. The Archimedes turbine represents an innovative, sustainable approach to renewable energy with real potential in eco-friendly farming applications.