Design, simulation, and prototype testing of a portable hydrogenerator for cruising and racing sailboats

Abstract

This thesis focuses on the design, simulation, and prototype testing of a new portable hydrogenerator with a non-axial propeller configuration intended for use as an auxiliary power source on cruising and racing sailboats. The iterative CAD approach resulted in the design of a hydrogenerator unit utilising commercially available standard components and eight modelled parts, along with a robust mounting system. Geometric and form-factor analyses were performed using physical prototypes produced via 3D printing and manual stator winding tests. Static structural FEA showed that the mounting structure can achieve a very high safety factor under an exaggerated static operational load, whether the transom bracket was mounted with bolts or epoxy.

Hydrodynamic testing determined a baseline propeller angular velocity utilised in the 2D transient magnetic FEA analysis in ANSYS Maxwell, which showed that the initial design with a model depth of 30 mm limits power output, making it incapable of generating the targeted 200 W at normal operating speeds of 10 to 20 knots. Nevertheless, parametric scaling showed that increasing model depth would make generating 200 W feasible. This research sets the basis for non-axial hydrogenerators for portable applications, with future research focusing on marine fatigue testing and seaweed entanglement resistance testing.