Free Jet hydroEngine Photo Gallery

After all components were designed, fabricated, and received, the team began assembly of the first Free-Jet hydroEngine. Pictured above, President and CTO Abe Schneider assembles the cassette.

Mechanical and Testing Technician Alex Conn adjusts the cassette belt tensioning system.

Senior Mechanical Engineer Erick Davidson assembles the blades.

Mechanical Technician Tristan Nilo assembles the blades.

After the initial machine assembly, spin tests were conducted on the cassette to ensure proper clearances were met and all mechanical systems were operational. Pictured above, Senior Mechanical Engineer Erick Davidson inspects the spinning cassette.

Here one of the 2 axles is shown spinning. A packing seal (right) creates an air-tight seal between the atmosphere and the inside of the Free-Jet housing.

The Free-Jet housing contains the water as it moves through the machine. During an emergency shutdown, a jet deflector plate will swing down and redirect the flow around the cassette, to quickly and easily depower the unit. Pictured above, the housing is shown before it is assembled onto the machine.

Senior Mechanical Engineer Erick Davidson and Mechanical and Testing Technician Alex Conn attach the deflector plate to its pivot inside the housing.

The nozzle controls the flow of water into the machine, and is similar to a throttle in a car. Opening the nozzle causes the machine to generate more power; closing it reduces power output. Pictured above, Mechanical Engineer Sean Hennessee installs synchronizing gear components onto the nozzle body.

The nozzle controls the flow of water into the machine, and is similar to a throttle in a car. Opening the nozzle causes the machine to generate more power; closing it reduces power output. Pictured above, Mechanical Engineer Sean Hennessee installs synchronizing gear components onto the nozzle body.

The nozzle is shown in its closed position, pre-assembly of seals. Once fully assembled, the seals on the fully-closed nozzle block almost all flow into the machine.

Mechanical Technician Tristan Nilo helps load the machine housing into a palette.

Once all systems passed mechanical testing, final assembly and shipping of the machine began. In addition to the Mechanical, Electronics, and Controls work, great care is taken to ensure the machine is safely packed and shipped on time. Pictured above, Mechanical Engineer Joanna Noble, Senior Mechanical Engineer Erick Davidson, and Mechanical and Testing Technician Alex Conn complete the final belt attachment assembly.

Mechatronics Engineer Jason Currie packs up the machine’s control panels and wiring system.

Commercial Associate Ben Ward helps design the blade packing fixtures.

Engineering Project Manager Katie McKinstry coordinates shipping of the machine components.

The machine was shipped to Freedom Falls, ME.

After arriving on site at Freedom Falls, ME the machine was installed into the basement of a historic mill. In the past the falls’ hydro power was used to grind grain and mill dowels.

After the machine shipment arrived, the install team gathered to discuss assembly and process.

Here the install team lowers the cassette into position inside the powerhouse.

President and CTO Abe Schneider is shown explaining how the Free-Jet works to students of a school also housed in the same restored mill as the hydro project.

Here the cassette is shown as the blades are installed.

Here the cassette is shown as the blades are installed.

After the machine was assembled, testing was conducted to ensure all mechanical components were operational. During this phase, data was also collected to help tune the machine’s control system. Pictured Above, Mechanical Engineer Sean Hennessee observes the machine as a emergency shutdown test is conducted using the machine’s jet deflector. The water seen through the viewport is redirected around the cassette, smoothly depowering the plant and avoiding excessive stress on the machine’s components.

Here the machine is shown in normal operation. The water jet is directed through the cassette, and is not visible through the viewport on the housing. The machine’s flywheel and speed increaser are shown spinning.

When the plant is fully operational it will generate 35KW of electricity during max flow conditions.