Brassac GREC Lab Model v2

This is a short description of the parts of the Brassac Green Revolution Energy Converter Lab Model v2, now under construction and almost all parts are already manufactured in Brassac France. Assembly started in Motala Sweden and is continued at FabLab in Brassac.

Revolving Energy Converter Hot Fin The first version of the GREC Lab Model delivered very promising but non documented results. When we opened it up to provide it with syncronised sensors for temperature and pressure, we decided to put in new Revolving Shutters as well.
But finally it was easier to build a completely new Lab Model instead. We updated all our FreeCAD dxf drawings and in autumn 2018 we started to manufacture a completely new set of parts using the Brassac FabLab high precision CNC cutter. Click this link to see current status of the project.
Below are the original 3D generated images that we used when updating our .dxf files for the FabLab CNC cutter and also photos of the resulting machined parts.

Starting with the "End Plate"

Green Revolving Energy Converter End Plate First 3D generated image is the 600x600x10mm end plate with a circle of holes to keep the construction together but also to be sure that all added layers will be perfectly aligned. The centre hole for the roller bearing is cut at the same time. Download Shell600GabaritHoles_a.dxf here.
nilsinside green revolution
green revolution
We used a blue composite material for the "End Plate". The centre hole holds its SKF roller bearing and some of the holes in the peripherial circle have a screws inserted.
(Sorry for the conflicting colours between the 3D sketch and the real model)
Revolving Energy Converter End Plate

Building the first layer of insulating and conductive "Fins"

Revolving Energy Converter Nil-Fin The Green Revolution Energy Converter is built in layers. The layer following the "End Plate" is a layer with heat conductive and insulating fins. This scematic 3D generated image shows adding two 6 mm insulating "Nil Fins" for insulation between the heat conductive fins of the cold and the warm side of the Green Revolution Energy Converter. In this version of the Lab Model we have choosen to integrate the first layer of fins directly in the endplate (see photographic images)

nilsinside green revolution

The two "Nil Fins" in the 3D drawing are identical. The drawing to the right is in larger detail and you may also see the circle of holes that aligns all the layers. Download nil fin .dxf here. GREC Nil-Fin Detail
nilsinside green revolution revolution energy
GREC Nil-Fin Detail

As mentioned earlier, an alternative to adding a first layer of nils-fins, you may cut down the 6mm conducting fin profile directly into the end-plate. We have choosen to do so in this Lab Model integrating the first layer of conducting and insulating areas into the end-plate.

GREC Conducting-Fin with Solar Interface GREC Conducting-Fin with Solar Interface

Adding two conducting fins at the same layer as the insulating fins. The conducting aluminium fins will be the area that transfer heat in and out of the "Work Generating Volume". Both of the conducting fins are made of 6mm aluminium as seen in the photograph, and they will be gued in place. The 3D image has conducting aluminium fins in colours blue and red to mark out that one is situated on the cold side (blue) and the other one on the warm side (red). Again, so sorry for the conflicting colours between the 3D images and reality. In this Lab Model we decided to make them a bit longer so we can “interface” with external cold and hot sources. Download conducting fins here .

nilsinside green revolution

Building a layer to contain a "Work Generating Volume"

GREC Insulating Boundary Shell When you look close at this picture there are "Nil Shells" on top of the fin layer. Download the nil shells here .

The nil shells will create the boundary of the system volume together with the conducting shells that you may see in the following 3D generated image.
Both the nil and the conducting shells will be glued on the fin layer so the "End Plate", the "Fin Layer" and the "Shell Layer" will become one unit.

GREC Conducting Boundary Shell GREC Conducting Boundary Shell
The conducting shells, blue and red, will complete the system volume boundary. They are both identical and made of aluminium. Download the conducting shells here. Looking at the photo you will confirm that both the conducting shells and the nil shells are placed on top of the conducting fins. They will be glued in place at a later moment.

Alu and Nil shell sealing the system volume

green revolution

Adding the Revolving Shutter

Revolving Shutter with Work Generating Volume

Revolving Shutter with Work Generating Volume

Both 3D image and the photo shows a grey Revolving Shutter. The quarter opening of the Revolving Shutter is the most important detail of them all! This important opening is the Work Generating Volume. This is where it all happens. On the warm side the pressure mounts in the Work Generating Volume resulting in higher pressure of the whole GREC System Volume and when the Work Generating Volume is on the cold side the pressure drops within the whole system. Download the Revolving Shutter .dxf here.

Building a second "Fin-Layer"

Insulating Nil-Fin second layer The following 3D images shows how we add the middle layer of fins starting with the nil fins and then adding the conducting fins.

Fin second layer

The photo shows the middle layer. Note the pre-manufactured traces for sensors (temperature and pressure) and electrical wires. Also showing two spools of Teflon coated wiring that we will use.

Building a second layer to contain an additional "Work Generating Volume"

Starting with the boundary shells on top of the fins.

And adding a Revolving Shutter giving the second layer a Work Generating Volume.

Finally sealing it all with a "Layer of Fins" and an "End Plate"

An additional layer of fins to transfer heat in and out of the Work Generating Volume of the Revolving Shutter.

Photo shows layer side up of the integrated "End Plate". We just have to turn it, fit the roller bearing and start fit screws in the circle of holes to seal the complete system volume.

The GREC system boundary is finally sealed by an End Plate on top of the last layer of insulating and conducting fins.

nilsinside Green revolution

nilsinside Green revolution

By fitting it all together and using an electrical motor to turn the revolving shutter the GREC Lab Model v2 will start to deliver real world values on pressure difference in relation to rotation speed and temperature difference so that anyone can calculate on its usefulness in their applications. That’s it!

Bill of Material for CNC

To conclude, a parts list of the Brassac GREC Lab Model version 2 with downloadable CAD files in .dxf format,
click on the corresponding icon to download :

Note: The download attribute is not supported in IE, Safari or Opera version 12 (and earlier).

Component Pcs info comment
End Plate 600x600x10mm 2 pcs End Plate template drawing Shell600GabaritHoles_a.dxf (Same End Plate both for motor side and control side)
insulating Nil Fins thickness 6mm 6 pcs insulating fin drawing Fin600r41iso6Holes_a.dxf isolant 6mm
conducting Alu Fins thickness 6mm 6 pcs conductive fin drawing Fin600r41alu6Holes_Solar.dxf alu 6mm with extended base for Lab connection
insulating boundary Nil Shells 10mm 4 pcs insulating shell drawing Shell600r286iso10b.dxf isolant 10mm
conducting boundary Alu Shells 10mm 4 pcs conducting shell drawing Shell600r286alu10b.dxfcale en alu 10mm
Revolving Shutter with Work Generating Volume 2 pcs RSr285r40r10Clavetage6Holes_c.dxf revolving shutter surface drawing2x alu 2mm (double with internal foam)
Revolving Shutter internal distance 2 pcs RSr40distClave.dxf revolving shutter internal distance drawingalu (to set internal foam measure)
Revolving Shutter shaft 1 pcs RS_shaft002.dxf revolving shutter internal shaft drawingsteel (Length 47mm, Dia 20mm)
Revolving Shutter bearing 2 pcs SKF 20 47 14 32 000 1204 ETN9
nuts and bolts lots of M3 et M5

Good luck in building your own Green Revolution Energy Converter supplying you with lots of free energy!

Click this link to go to the nilsinside PROJECT page.

updated by KITS