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WIND SAIL STATUS REPORT

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					     WIND SAIL STATUS REPORT

•    Investor Search:
a.   Brian McCarthy, ESM, Japanese market.
     The Japanese are interested in the design and technology but they
     are not willing to invest in product development. If we complete
     a prototype they would be willing to have us present it again.
b.   Hugh O’Brien: Windmills in combination with oil pumps
c.   Gary Philippi: Windmills in combination with oil pumps
d.   Martin Bidart: Penn Engineering, interested in high volume
     production of alternators. Owns Pittman Motors and MAE Motors
WIND SAIL STATUS REPORT

e. Martin Lin: Lin Engineering. Interested in high volume production of
    alternators but wants to move the production to China.
f. Al Coddington: Arrgh Manufacturing. Interested in production of
   electronics.
g. Jim McDermott – (son of senator from Washington state)
h. Jack McClure: interested in water purification systems
i.      Venture capital firms contacted:
            1. United Venture Partners
            2. Several more via brokers
WIND SAIL STATUS REPORT

J.   SBIR proposal via NREL – rejected for bogus reasons.



k.   NREL Industrial Growth Forum: Applications rejected.
     Due to Russian connection and no product ready for
     market.
 WIND SAIL STATUS REPORT
l.   Brokers:
     1. Robert Coleman: seeks government funding
     2. Greg Henthorne: broker for Chinese companies
     3. Ron Weiner: VC access Seattle area
     4. Hancy Mohler: Harvey & Co.
     5. Brandon Walsh: Westgate Financial
     6. Hanna Smith: Sperry Mitchell & Co.
     7. Harry Hartz & Associates
     8. John Treese: Fina Financial Services
     9. Ed Margolin: First Consolidated Capital
     10. Abby Molano
     11. David Bannister: Business Team
     12. Bart Basi: CFT
WIND SAIL STATUS REPORT

m. Various Other Contacts:


     1. Christopher Tilley
     2. Steve Patterson (energy sales)
     3. Christopher Lynch (Former Trade Counsel Bonn)
     4. Russ Kennedy (North Bay Angels)
     5. Mark Schmidt: (buying a company)
     6. Alan Caldwell: (Prime Energy)
WIND SAIL STATUS REPORT

Via brokers, a number of VC contacts were made, resulting in zero
   response. Generally speaking the replies were: Russia is too risky.

We want to invest in the production phase, not in R&D.

Come back AFTER you have a revenue stream.



Since we are very early in the product development cycle, as business
   managers we have not been able to provide adequate answers to the
   following questions:
WIND SAIL STATUS REPORT

What is the estimated Return on Investment? (ROI)
What is the time frame for return of capital?
What assurance can we give that capital will be returned?
What are projected revenues?
What are projected Gross Margins?
What are projected product costs?
What are projected operating costs?
Why should we believe we can do business in Russia?
WIND SAIL STATUS REPORT
Thus far we have to report no success in getting investors. As such,
  Empire Magnetics, Inc. and Rick Halstead have carried the financial
  load to date, but the reserves are now exhausted.

The last three years have been exceptionally brutal in the industry segment
   that Empire Magnetics, Inc. serves. Approximately 30% of
   distributors and customers we served in 1999 have gone out of
   business and many others are just hanging on. We do see a significant
   upswing in process, but it will be July 2004 before this converts into
   working cash for Empire Magnetics.

Without investment funds Empire will not be able to complete the terms
  of the existing CRADA agreement.
WIND SAIL STATUS REPORT
Empire Magnetics, with its subcontractor Uralmet, has been working on
  the design of the alternator for the 1500 and 3000 watt units. This
  design is still being revised as we resolve the mechanical issues of
  mating the alternator to the windmill. The ability of the bearing
  system on the windmill to maintain the air gap in the alternator is in
  question.

Three different approaches to the manufacture of the windings for the
   3000 watt alternator are being explored. All are technically feasible.
   The exploration is focused on which approach will be cost effective in
   production.
WIND SAIL STATUS REPORT

A design of a magnetic bearing system has been done but initial review
   indicated the cost is too high for the small windmills. However, it does
   appear to be useful for larger windmills. Build of a prototype is
   waiting on funds.

Design work on a 30 Kw alternator is in progress. It builds upon the
  things we have learned in the design phase of the smaller units.

Electronics!
WPU Control

                         WPU Control


                  Rich McClellan, PhD
                       Wind Sail
                             707-664-9611
                         lichau@starband.net
                           December 6, 2003
Empire Magnetics/Wind Sail • Lawrence Berkeley National Laboratory • Makeyev State Rocket Center
          To Discuss Today
• Prototype Control Electronics Objectives
• WPU Control Approach
• Electronics Simplified Block Diagram
          Prototype Objectives
• Simple and Flexible
  – Use Standard Products Where possible
     • Consumer Electric Space Heaters for Power Dump
     • Battery Voltage Input Inverters (either Solar Oriented or
       Consumer (RV))
  – Microprocessor Control
  – Oversize Electronics. Non-Optimized.
  – Ability to Explore Different Configurations
     • Battery charger
     • Inverter input
     • Space heating.
     WPU Region of Operation
• Following Figure is for Illustration and Discussion
  Only—not Real Data.
• STALL Region– RPM below Max Efficiency
  Point.
   – Unstable Operation, but Tolerant of Wind Gusts
• STABLE Region– RPM above max efficiency.
   – Stable Operation, but high rpm, more energy dump
     required to slow down.
                        WPU ControlFigure 1: Available Power vs Rpm


        3500



        3000          Keep out



        2500


                    Pow er                         Max
        2000        Dum p                          Efficiency
                                                                                      8 m /s
                                                                                      10 m /s
Watts




        1500                                                                          12.5 m /s
                        Stall Region                                                  14.5 m /s
                                                                                      16.5
                                                                Stable
        1000
                                                                Region



        500



          0
               0-      50    100       150   200     250   300      350   400   450


        -500
                                               rpm
    WPU Operation Philosophy
• Low Winds—Seek Max Efficiency Point
• Medium Winds—Slow down into Stall Region.
  – Maintain Power Dump Margin for sustained gusts.
  – Limit cycle operation. Long time constant—minutes.
• High Winds– Operate Deeply in Stall Region.
   WPU Operating Philosophy
• Maintain WPU RPM at desired point by
  – First Transfer Power to Battery/Inverter.
  – Second, Transfer Power to Power Dump.
  – Switch between two based on monitoring of
    output voltage—too high, transfer to Power
    Dump.
     • No inverter or battery—control circuit becomes a
       space heater driver.
Simplified Block Diagram

               400VDC to 12/24/48 VDC                        110/220VAC
WPU             Buck/Battery Charger              Inverter   50/60 Hz




                                        Battery
  Power Dump

                   Microprocessor
                      Control
    Simplified Block Diagram
• Power Dump is two (one per phase) space
  heaters. Triac Controlled.
• Inverter can be
  – Sunny Boy or Xantrex for grid connection
  – Multiple (Cobra, others) for non-grid
    connected. Much Cheaper.
     Simplified Block Diagram
• Buck Circuit (300-400VDC to 12/24/48VDC) is
  programmed by microprocessor.
  – Battery Charge State is determined by voltage and
    temperature.
  – Battery Capacity chosen to accommodate max capacity
    of WPU (Battery ampere-hours> max output current/5).
  – Buck Circuit uses one large International Rectifier
    IGBT Half Bridge (600V; 200A) and a big inductor.
     Simplified Block Diagram
• Leave out the Battery and Inverter
  – Power transfers only to Heaters, or other
    resistive load
  – Buck circuit can be left out. Microprocessor
    and Triacs do the control
     • Micro is probably <$10.

				
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