Rotor module
Frame
Which frame variants were considered?
We tested different materials for the frame: pipes, flat iron, iron sheets and plastics. In the end we decided on water-jet or laser-cut symmetric flat iron, because it is easy to process and connect. It can be screwed or welded together, and plug elements can be produced with this technique.
A pipe frame is too expensive, and coating the inner wall is a further problem.
Which improvements were introduced?
We were able to reduce the flat iron to 4 mm by placing the generator directly in the center of the frame, so the heavy transmission could be omitted.
Every element of the frame should be manufactured from the same material. Improvement was a constant part of our work, during and after the tests.
Corrosion is prevented by galvanization and/or coating. The combination of stainless steel for the bearings and coated steel for the frame works very well.
What could be better?
The connection between frame and fixing rope would be the next development step. This connection weakens the frame slightly; something like a tension belt at the right fixing point would be optimal.
Current design
Pipe concept
