5-meter homemade wind generator. Part 1. Encyclopedia of radio electronics and electrical engineering

Encyclopedia of radio electronics and electrical engineering / Alternative energy sources

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In this article, we will consider the manufacture of a homemade wind turbine from scratch. Its device is fundamentally no different from others.

In the image above, you can see all the metal parts used in the wind turbine, except for the tail. Unlike previous wind turbines, I did not use used auto parts in this one. I started with the shaft and the hub from the trailer. The rotors for the generator are made of 12mm steel, the diameter of each rotor is 400mm. They were cut on a CNC waterjet cutting machine. This pleasure cost somewhere in the region of $ 70, but they are made with high quality and immediately with holes. The turning mechanism of the wind generator is made of a piece of a three-inch pipe 400 mm long. The shaft for the hub was fixed inside the pipe with a length and diameter of 100 mm through 2 steel rings. The steel tail bracket is made of 12mm steel, its height is 150mm, it stands at an angle of 18 degrees.

In the figure above, the welded frame is assembled. Making it again, I might have made some parts thicker. I would also increase the diameter of the turning mechanism and make the tail bracket more massive. I would also use a large axle and hub. But so far, my homemade wind generator is already working fine, although some improvements would benefit it.

Next, I welded six brackets for the stator. The stator diameter will be 500mm. Then, I made a simple template with a diameter of 500mm and drilled 6 holes in it, as well as a central hole for the shaft. I installed the template on the shaft and attached the rotor brackets to it with bolts and nuts. That. the brackets were installed very precisely and will not move from their positions during welding. Then they were well cooked.

The figure above is a drawing (template) for placing magnets on a steel rotor. This design uses 16 magnets. The magnets are quite massive, very powerful and... dangerous! Dimensions 40x75x20 mm.

Next, I drew the location of the magnets and the approximate location of the coils. In the future, this plywood template will serve as the base of the stator.

I glued the magnets to the rotor with super glue, and installed the rotor on the frame. Then it will be necessary to fill around the magnets with polyester or epoxy resin.

From plywood I made a winder, with the shape of the core, as I drew before (see picture above). The diameter of the circles is 150mm, with a homemade handle. In previous designs, I usually used slightly thinner magnets: 12mm, in this one I use 20mm thick magnets, which allows us to get a more powerful stator. The stator will be 15mm thick, so the coils will need to be slightly thinner.

First I wound one test coil. Because Since it was a new coil design, I had to size them up. I will install a test coil between the rotors and be able to determine the required number of turns at the calculated rotational speed. Because it was a 5-meter windmill, then the rotation speed is 70-80 rpm. The test coil contained 79 turns of 2.5mm2 wire.

We cut out a form from plywood and glued a coil to it, thus. we will be able to fix the coil to the stator brackets and place it between two rotors with magnets.

The next step was to measure the parameters of the coil. To do this, we used an optical tachometer (rpm was measured) and a multimeter. Tests showed a coil voltage of 2.4 volts at 70 rpm. Something needs to be clarified here... The magnets turned out to be very close to each other. The distance between the magnets closer to the center is less than 10mm. This introduces some losses into the coil, as we have 2 opposite poles. In this design, we already leave everything as it is, but note that it is possible to reduce the size of the magnets and, accordingly, the weight of the rotor.

The picture above shows the back of the windmill with the test coil installed. You can also see the ballast resistance, with which I can measure the power of the wind generator.

The force of attraction between the magnets of the rotors is very strong and dangerous! 3 holes were drilled in the front of the rotor and threaded to connect the two rotors.

Then we installed the front part of the rotor. Now, at 70 rpm, the coil showed 5.4 volts. I prefer a slightly larger min. rotational speed, so the coils will contain slightly fewer turns of thicker wire. I wound a new coil and did another test, but this time under load (large 1 ohm resistor). At a speed of approximately 104 rpm, under load it turned out 6 Volts and a current of 6 Amps (i.e. 36 watts). I'm not sure about my calculations, but I think that 12 coils in star connection will give about 400 watts at 100 rpm.

All this took 2 days.

Author: Koltykov A.V.; Publication: cxem.net

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