Beruflich Dokumente
Kultur Dokumente
Art
Craft
Food
Games
Green
Home
Kids
Life
Music
Offbeat
Outdoors
Pets
Photo
Ride
Science
Tech
Table of Contents
7 Foot Axial Flux Wind Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 4: Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 5: Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 6: Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 8: Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Step 9: Testing Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Step 10: Generator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Step 11: Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Step 12: Guy Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Step 13: Guy Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Step 14: Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Step 15: Tower and Electrical Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Step 16: Excuse me while I kiss the sky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Step 17: Finish up the wiring and test it all out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
(The whole thing about the modern day Don Quixote... yeah, I don't think it's right either.)
Image Notes
1. Too big
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
For this particular design the blade diameter should be around 7 feet.
Image Notes
1. Extra piece we added
2. We removed the bearing too
3. Extra clean work environment ... yeah right.
Image Notes
1. Fishmouth the piece to weld it on securely.
2. This is special fireproof fabric to cover flammable or fragile things while you
weld
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
bearing.
Image Notes
1. A lot of time goes into winding those coils!
2. 3-Phase AC
Image Notes
1. 12 inch circle
Image Notes
1. Not perfectly round on the outside, but it will do
Image Notes
1. These bolts will actually be on the other side when mounted.
Step 4: Magnets
I used twelve 1 x 2 x 0.5 inch rectangular magnets from Magnet4less.com (very reasonable prices). On the back of the rotor, I also used an aluminum plate to keep the
magnets separated (this plate is also available from Otherpower). We used heavy duty epoxy to ensure that the magnets won't fly off at high RPMs. Be VERY careful
when you put these magnets into place - they have enough power to severely injure or break your fingers! I found that a little caution and a rubber hammer were
invaluable tools.
The magnets are placed in alternating polarities on the back of the rotor. We used a small magnet to test each magnet's polarity.
I left the magnets exposed, but I am planning on a possible renovation soon. I should've cast the magnets in some sort of resin to prevent corrosion. There is plenty of
good information on the internet on how to do this, and it's very similar to casting a stator coil.
Once all the magnets are on the rotor, remember that the whole disk is now one gigantic magnet. Do not set it on a workbench with metal shavings or magnet-sensitive
materials!
Also, you may notice that the pictures are a bit out of order (the rotor is painted already) but I am trying to lay this out in the most logical order... not necessarily the order
we did it in!
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. They are kind enough to put small plastic spacers in between these bad boys
Image Notes
1. mounted aluminum plate
Image Notes
1. Lots of magnets
2. Heavy Duty Epoxy
Step 5: Tail
The area of the tail vane and the length of the tail boom are both dependent on the diameter of the windmill. This ensures that furling takes place at the right wind speed.
The tail boom should generally be about as long as the radius of the turbine (one blade length). In this case, it should be around 3.5 feet. In reality we made it quite a bit
longer by mistake. It still seems to find the wind alright, but I think it will effect furling.
As for the area of the tail vane, it can be determined by a simple equation: D(squared) / 40 = Area of the Tail Vane (where D is the diameter in your unit of choice). This
equation is given by Hugh Piggot who has many years of small wind turbine experience.
The shape of the tail vane really has very little effect on the mill as long as the area is correct, so feel free to get creative. I spent some time with an air grinder and cut out
a neat looking tail, but it's not entirely necessary. What does matter is the angle at which the tail is mounted. It needs to be at about 45 degrees from directly behind the
center post on the opposite side of the generator. In addition to that, it should be mounted at a 20 degree angle from perpendicular - the pictures I've included illustrate
this nicely. This may need to be adjusted slightly depending on when you want to mill to furl and how heavy the tail vane is.
The tail is made of electrical tubing and brazed together. We put a lot of supporting pieces in the middle of it to strengthen it. The tail vane is made of stainless steel and it
is riveted onto the tubing.
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. Rivets
Image Notes
1. Bolt fits nicely through the tubing
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. Weld isn't finished yet in this picture
2. Good angle
3. Harley-Davidson... oh yeah
Image Notes
1. Lots of brazing to add support
Step 6: Blades
Personally, I am not a very good carpenter. My woodworking skills are pretty basic and making your own blades requires some pretty good attention to detail. So I
decided to save myself the time and effort of making blades and just buy a ready made set.
There are lots of guides and tutorials for blade-making online. Hugh Piggot even offers a nice table of useful figures for different blade diameters in Windpower Workshop
.
Now, there is a lot to consider when buying blades. First and foremost, consider the power you are taking from the wind. This is based mostly on the diameter of your
wind turbine blades. A wind turbine steals energy from the wind by slowing it down as it passes through the blades and makes the rotor turn. This is all laid out
mathematically by the Betz' Limit . These calculations show the maximum amount of energy that is possible to be extracted from the wind, though they do not account for
losses in generator efficiency... they also assume that you have infinite blades which all have no drag, and if you can hook me up with some of that, I'd be very interested
:).
It isn't so simple as bigger blades equals more power, though! No, no, no. What is most important is that you match the blades to your generator. Generators are
designed to start producing usable electricity (the voltage you want) at a certain RPM. This is where the Tip Speed Ratio comes in. Basically, you want to have blades
that provide that RPM at the most typical wind speed you'll be experiencing. Sound complicated? It is, kind of. Usually the Tip Speed Ratio (TSR) is an indicator of
efficiency, but beware of websites claiming abnormally high TSR's! I would recommend using it as a rule of thumb.
There really is a lot to blade making as well as blade theory, but that should give you some good general insight into what you're trying to accomplish. As for me, I bought
my blades from a website called Magnet4less (no 's'). At first I actually bought the wrong size blades thinking I could get away with a bigger diameter, but alas, physics
wins again (Some of the pictures may have these first blades in them). I eventually folded and bought the 6.8 ft. diameter blades. However, I would NOT recommend
buying these blades again. They have terrible reviews from wind power people around the country and with my personal experience they look like the angle of attack just
isn't enough to spin up high RPMs.
This is the part where I suggest another retailer but, to tell you the truth, I really don't know of one. Homebrew wind turbines enthusiasts seem to be mostly (but I could be
corrected) out of luck for high quality universal blades with different diameters. I suppose you could use a pair of replacement blades from another commercial turbine
assuming they are to your needs.
Other references!
For making wooden blades:
http://otherpower.com/blades.html
http://www.thebackshed.com/Windmill/PropellerBlades.asp
http://www.mindchallenger.com/wind/wgpage15.html
If you're interested in making blades out of PVC, I'd recommend using Google for instructions. I don't recommend PVC blades for a turbine like mine, though.
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. Wind turbine crash landing on a messy work bench
Image Notes
1. Note how the blade and tail boom are just about the same length
Image Notes
1. Mounting and fitting the blades, separating them perfectly was very tough.
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. These were the old blades, the turbine isn't as large now.
2. Awesome Grandfather
3. Pride and Joy
Image Notes
1. pile of speedy dry
2. The addition is bolted to the top plate here.
Image Notes
1. Excitement!
2. 1 of the 3 ten foot sections
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. Tacked in place
2. The gussets aren't the same size but we think it should be plenty of support
Image Notes
1. Right on the mark
2. Clutter
Image Notes
1. The welding gods are clearly smiling...
2. Discarded air cleaners from heavy equipment make excellent garage stools
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. Hey, it's practice! It doesn't have to be useful afterwards! C'mon though, who
doesn't need a mediocrely welded almost trapezoid...
Step 8: Controller
At first I was going to build my own controller, as I have shown in the pictures below. The project shifted locations, though, and I decided to charge a battery instead of
heat water, so I decided against it. I did have a rough idea of what I was going to do, but I think not making the controller on my first turbine was probably a good decision.
Things can get dangerous if your controller fails and lets your turbine run away at reckless RPMs. Also, believe it or not, electrical permits prefer stuff that's UL listed...
who'd have thought that?
Instead of heating water, I decided to charge a 12 volt battery that would be hooked up to a light. This cut down on costs, logistics, and other restrictions that made it a bit
easier to install. I settled on using two Xantrex C40 charge/dump controllers. One regulates the charge coming in and the other watches the charge level of the battery to
ensure it is not overcharged (it can't do both at the same time). I have a 12 volt dump load that is a water heating element, rated for 600 watts.
I used a three phase disconnect switch as the "brake" on the wind turbine. When the switch is closed, all three phases of the wind turbine are shorted out and it will slow
itself down. I also used a 750 watt modified sine wave inverter to run the light. The light has a photoelectric eye on it and is wired up to turn on at night.
Image Notes
1. Homework or something
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. This... yeah this is important
Image Notes
1. Optima lead acid battery, 65 ah, 12v
Image Notes
1. Three phase disconnect
Image Notes
1. Battery goes here
2. Charge controller
3. Dump load controller
4. 750 Watt Inverter
5. Rectifier
Image Notes
1. USB Programmable!
2. Resistors
3. Trusty iBook G4
4. Freeduino
5. Serial LCD and Board
6. Test voltage
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. Learning to use the LCD
Image Notes
1. Testing jig mounted.
Image Notes
1. Zip-ties are saviors.
Image Notes
1. Camera timer fail.
2. Jig.
3. Wind generator
4. I think this is some high voltage power supply
Image Notes
1. This allows the drill to be adjusted slightly to find a better center. It works alright
for such a cheap setup.
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
For my test load, I used six 18 ohm 25 watt resistors in parallel for a total of 3.6 ohms.
Image Notes
1. Physics lab equipment
2. Big capacitor
Image Notes
1. Test load
2. Sketchy wiring
Image Notes
1. Voltage spikes
2. Actually 7.2 volts without the voltage divider
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. Voltage from rectifier
2. From the rectifier
3. Connected to the lab equipment
Image Notes
1. Awesome Aroostook County dude
2. Big hole
3. 2 ft diameter, 6 feet into the ground
Image Notes
1. Glad I didn't have to dig this hole by hand!
Image Notes
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
Image Notes
1. Guy wires all attached
2. 4 bags of concrete
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. Typical telephone pole guy wire
Image Notes
1. These twist around the end of the wire and are surprisingly strong. They form an
eye so you can connect them to ground anchors.
Image Notes
1. Too big
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. Valuable helpers
2. Anger?
Image Notes
1. Watch out to make sure this doesn't slide off
2. Rigging
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. Blades
2. Excitement
Image Notes
1. Cold galvanized paint
Image Notes
1. Happiness.
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Image Notes
1. A little windmill, next to a little boy.
Related Instructables
Faroun
Lenz v2 Vertical
Axis Wind
Turbine by
faroun
How to Build a
Wind Power
Generator
(video) by
doctorgig
Faroun
Savonius Wind
Turbine by
faroun
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Horizontal
Double Helix
Wind Turbine by
Ultra Computers
FAWT Silo. (
vawt wind
turbine hawt
savonius )
(Photos) by
faroun
Comments
47 comments Add Comment
kbooth23 says:
brokengun says:
bertzie says:
megapix says:
You spin the magnets. That makes it easier to connect to the coils, since they are stationary.
ThreeWestCreative says:
brokengun says:
ThreeWestCreative says:
mahesh.ganpate says:
brokengun says:
mahesh.ganpate says:
brokengun says:
There are both metric and standard (english units) versions of the book available on that site.
I think you want a more in depth analysis of the generator. Most homebrew wind power folks won't get that in depth. Basically Hugh's book would
outline which generator plans seem to work best partly through trial and error.
I think to get the kind of detail you want, you might consider a different book with more mathematics. However that book might also depend on if
you are making an axial flux or radial flux generator.
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
mahesh.ganpate says:
tx brokengun,
i have agree with u u r coment i have making for axial flux genereter. but i don't know which parameter using for generotor making, only
30 mtr tower bearing ,gue rope , tail van avalable here but genertor details not avalable
brokengun says:
mahesh.ganpate says:
how much price sir , book parchasing ,im not parchasised book
mikeyeez says:
spylock says:
brokengun says:
spylock says:
brokengun says:
spylock says:
Blackice504 says:
brokengun says:
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
Blackice504 says:
brokengun says:
0087adam says:
brokengun says:
Yeah basically. It's for clearing woody plants and stuff. We live in the woods.
0087adam says:
0087adam says:
oddelyodd says:
brokengun says:
oddelyodd says:
ironforger33 says:
1234Becka says:
brokengun says:
whiterabbot says:
brokengun says:
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/
smlkurby says:
brokengun says:
rimar2000 says:
luvit says:
Rs master says:
brokengun says:
Rs master says:
ok well it look realy good i dont thin gi have the money for that yet
coopdaddi says:
rockyt says:
brokengun says:
frollard says:
http://www.instructables.com/id/7-Foot-Axial-Flux-Wind-Turbine/