APPLICATION OF REVERSE ENGINEERING IN MANUFACTURING A PROTOTYPE MECHANICAL WATER-PUMPING WINDMILL ROTOR

تطبيق الهندسة العكسية في تصنيع نموذج أولي لدوار طاحونة الهواء الميكانيكي لضخ المياه

Abstract

ABSTRACT

This study (research) focuses on applying the reverse engineering (RE) process (approach) to design, manufacture, install, and test a mechanical water-pumping windmill rotor prototype. The selected rotor design is based on a commercial model with a height of 12 meters and a diameter of 4.88 meters. The reverse engineering process involves three key steps: digitizing the components (parts), evaluating the measured data, and generating the CAD (computer-aided design) model. CATIA (computer-aided three-dimensional interactive application) V5 is employed for deviation analysis, which validates the 3D models of the rotor by comparing them with the original scanned data. The validated models serve as the basis for creating a final 3D assembly model, ensuring the feasibility of component assembly and design approval. The 3D models, serving as the foundation for fabricating the prototype components of the rotor, were subsequently installed at a pilot location in a suburban area of Tajoura, Libya.

The windmill's rotor underwent testing as part of a groundwater extraction system, drawing water from a Well. The testing occurred under an average wind speed of 2.7 meters per second, measured at a height of 2 meters above the ground. The assessed average water flow rate was 1 liter every 10 seconds.

CATIA V5 is utilized as an integrated system throughout the design and development process, bridging reverse engineering and CAD activities. The successful implementation of reverse engineering in manufacturing the water-pumping windmill rotor components with promising results is indeed a noteworthy achievement, which can significantly positively impact access to clean water and renewable energy in various regions of Libya, particularly in areas isolated from the electricity grid.