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DIY 1000 watt wind turbine by sspence on June 2, 2006
Table of Contents intro: DIY 1000 watt wind turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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step 1: Build the magnet disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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step 2: Build the coil disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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step 3: Build the bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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step 4: construct the blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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step 5: Bolt it all together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Customized Instructable T-shirts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
intro: DIY 1000 watt wind turbine We built a 1000 watt wind turbine to help charge the battery bank that powers our offgrid home. It's a permanent magnet alternator, generating 3 phase ac, rectified to dc, and fed to a charge controller. The magnets spin with the wind, the coils are fixed, so no brushes or slip rings necessary.
step 1: Build the magnet disks We had 12" steel disks hydro cut. We cut a template for mounting the magnets. Then we mounted 12 grade n50 magnets around the outside edge. We then built a form, and poured the resin with hardner.
http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
step 2: Build the coil disk We wound the nine individual coils, soldered them in a 3 phase wye configuration, and encased them in resin. We used 35 turns of 2 parallel strands of 14 gauge enameled wire for 12 volts. Use 35 turns of single strand for 24 volts.
http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
step 3: Build the bearing assembly Two Harley Davidson wheel bearings are inserted into the pipe, with a smaller pipe locked between them to keep them in place.
step 4: construct the blades The blades are 2" x 6" pine, cut at 10 degrees on a table saw, and sanded into a rough airfoil. Not perfect, but close enough. More can be found at http://tech.groups.yahoo.com/group/axialflux/ http://www.green-trust.org http://youtube.com/watch?v=o9EEHFKEckM
step 5: Bolt it all together
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Pringles Wind Turbine (Pleech) Faroun - Version One by Lenz v2 Vertical mikejedw Axis Wind Turbine by faroun
http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
Faroun Savonius Wind Turbine by faroun
Harnessing sound power by Applebohn
KNEX WIND MILL....... by meming
Advertisements Customized Instructable T-shirts
Comments 50 comments Add Comment
netbuddy says:
view all 471 comments Sep 30, 2008. 6:31 AM REPLY
Coils. I haven't a clue. How do you calculate what you need? I am using N42's which are not a powerful as yours and mine are small disc ones so I would need a smaller gauge wire and my coil size is limited. I would like to wind coils to optimize current output and also give off at least 12 volts. How can I do that? I have been looking at coil winding but all I find are manufacturers selling services or pre made coils. If you know where I can go to get this information, I would appreciate the link.
netbuddy says:
Oct 4, 2008. 2:02 AM REPLY
Any help on this? How many turns of SWG26 does it take to get any size able voltage? 35 turns may get 24 volts out of SWG14 wire but it don't produce much when I wind a coil with anything smaller.
sspence says:
Oct 4, 2008. 5:45 AM REPLY The number of turns determines the voltage, the size of the wire determines the current that the coil can produce. 35 turns gets you 12v, 72 turns gets you 24v when 3 coils are in series. We have more info on our discussion group at http://tech.groups.yahoo.com/group/axialflux/
bedeboop says:
Sep 6, 2008. 6:51 AM REPLY Being new to becoming "green", I would like to ask, at the risk of sounding totally ignorant, how do you get your house "off-grid" in the first place? I am assuming "off-grid" means you are no longer connected to any power or gas companies? Please correct my assumptions if wrong! :)
garalee says:
Sep 25, 2008. 5:47 PM REPLY You're right,"off grid" does mean you are not connected to the power company. Usually houses that are off the grid are houses that are just too far away for it to be feasible to run power lines. Houses that are connected to the grid can use solar panels and wind power to generate their own electricity and sell back to their power company (if the company allows "net metering"). Some states have programs in place to compensate you for the power you create even if your power company doesn't have "net metering". The set up is very expensive, you not only need solar panels or a wind mill. You also need an inverter which changes DC to AC and synchronizes the power back to the grid. Does anyone have plans for building an inverter?
Derinsleep says:
Oct 4, 2008. 4:00 AM REPLY
as i remember "truley free electricity" on the giant instructables.com had an inverter design on the bottom
sspence says:
Sep 6, 2008. 7:43 AM REPLY I built on a road that has no power lines or gas lines. I make my own power, and although I use propane right now, I'm building a manure digester to make bio-methane as a replacement.
bedeboop says:
Sep 6, 2008. 9:44 AM REPLY Manure digester? I know what it sounds like it means. ;) Lots of manure around the area I live in....please tell me more. Have you found it hard trying to do this on your own? Do you have a blog telling about it?
http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
sspence says:
Sep 6, 2008. 10:56 AM REPLY A methane digester is a simple tank that manure and crop residue gets poured into (slurry with a 30:1 C/N ratio) and digested anaerobically for 40-50 days. Gives off a gas that contains methane. Our blog is at http://www.green-trust.org We have lots of help from our "community".
Derinsleep says:
Oct 4, 2008. 4:02 AM REPLY
it can also be fed into an ng engine (lawn mower with CNG kit,maybe?) to make electricity
bedeboop says:
Sep 6, 2008. 12:16 PM REPLY
Thank you very much! :) Both for the information about the methane digester and the link!
bedeboop says:
Sep 6, 2008. 12:30 PM REPLY
Sorry, meant to say manure digester! :)
dustyplans says:
Sep 12, 2008. 12:10 PM REPLY
How thick were the magnets???
sspence says:
Sep 12, 2008. 1:10 PM REPLY
1.2" thick, 1" wide, 2" long.
dustyplans says:
Sep 15, 2008. 8:47 AM REPLY
So your magnets are producing a pull of 195 lbs?? Is that about correct??
sspence says:
Sep 15, 2008. 9:11 AM REPLY
Could be. We didn't test that parameter. Sounds about right for a N50 of that size.
netbuddy says:
Sep 25, 2008. 5:56 AM REPLY
So how are the magnets lined up to each other? The plates they are mounted to are pulling each other? right? Also, does the proximity to the magnet make any change to the amount of voltage or current? Any idea on what the "Optimal" placement is in relation to the coils? I notice on your build that you have a gap, can you remember how large it is?
sspence says:
Sep 25, 2008. 6:17 AM REPLY
The magnets are arranged "N" up, "S" up, "N" up, etc. The plates do attract each other, but there is a 1/8" gap between the plates and the rotor. The closer the magnets are to the coils (without rubbing) the more power you make.
vimal roy says:
Sep 24, 2008. 3:34 AM REPLY
there is no detailed explanation about construction
LancePenney says:
Sep 22, 2008. 2:30 PM REPLY
This is a really great setup but you should give much more detail into how to build it.
freakinbill says:
Sep 20, 2008. 6:13 PM REPLY
I see your solar panels in the background are they the 45 watt harbor freight setups?
sspence says: Yes. I no longer have those. I know have five 110w mitsubishi panels, and 6 sanyo 200 watt panels on order.
http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
Sep 21, 2008. 6:31 AM REPLY
abhaqkhawa says:
Sep 16, 2008. 11:34 PM REPLY
1- here is fiberglass but not in cloth style, that is in powder style. is it right to use that? and is it possible to we donot use fiberglass? 2- i found that magnets N50 in a website but that are in so high price, can not effort that and now i attach you some pictures of them, check it if it is possible to use: BX0411" x 1/4" x 1/16" thick Grade N50 - Nickel Plated Magnetized thru Thickness BX0421" x 1/4" x 1/8" thick Grade N42 - Nickel Plated Magnetized thru Thickness D727/16" dia. x 1/8" thick Grade N42 - Nickel Plated Axially Magnetized check these and infor me thanks guys
sspence says:
Sep 17, 2008. 5:34 AM REPLY as long as there is a N side and s side, any of those will work, but your coil shape will need to be adjusted. The round one would be the less desired. the fiberglass cloth is to give the coil pack strength. as the coils do not spin, you may get away without it. Not sure.
A Wise Hobo says:
Sep 16, 2008. 2:34 PM REPLY
Where do you get your magnets? And how much are they?
sspence says:
Sep 16, 2008. 6:12 PM REPLY
http://www.wondermagnet.com should be able to help you.
dustyplans says:
Sep 16, 2008. 12:03 PM REPLY How do you keep the tower from winding up the power leads? You know as the wind changes direction, and the generator swings to account for the change, it would eventually wind up the leads. Do you have a was to prevent that? I am trying to find a brush pivot that would allow that to spin freely.
sspence says:
Sep 16, 2008. 2:02 PM REPLY
Every month I go out and untwist them. They don't twist up to much.
dustyplans says:
Sep 16, 2008. 12:08 PM REPLY
How Long are the blades??
sspence says:
Sep 16, 2008. 1:51 PM REPLY
Five foot.
abhaqkhawa says: 1- What kind is that white color thing which you use on coil? 2- what is that which you use in second picture? help me
http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
Sep 15, 2008. 9:08 PM REPLY
sspence says:
Sep 16, 2008. 6:02 AM REPLY The white cloth is fiberglass, which gives the coil pack strength. The second picture shows us filling in casting defects with bondo, a body putty used on cars.
A Wise Hobo says:
Sep 15, 2008. 5:11 PM REPLY How much do you think this project would cost? And do you have more information on the actual mounting of the turbine on a post or something?
sspence says:
Sep 15, 2008. 6:16 PM REPLY
Our turbine cost about $500. You can see the mounting pictures at http://www.green-trust.org/photoalbum
abhaqkhawa says:
Sep 15, 2008. 5:03 AM REPLY
Hello, again about magnets, i found some magnets and i attach its picture, 1- Can i use them? 2- what kind liquid i can use for to tight the magnets on iron plate? please check it and inform me, i really love to fix and build a turbine. please help me
sspence says:
Sep 15, 2008. 6:28 AM REPLY I have no idea what kind of magnets those are. For maximum output, you want neodymium magnets, but others will work, just less output. For low rpm application, superglue tend s to hold up pretty well. We have gone to bored and countersunk magnets, and use brass screws. This is done during the manufacturing process.
dustyplans says:
Sep 15, 2008. 8:45 AM REPLY Another process that works is to cut a recess on the rotor to put the magnets on. Then cover with 2 part epoxy. Not to hard and fairly cheap. Source is otherpower.com for that info.
Wondering says:
Sep 14, 2008. 8:50 AM REPLY
Does anyone know where I could order or get these 12" flat round plates at 12" x 1/8" thickness. Thanks for the help :)
sspence says: find a local welder / metal worker. We found one with a hydro cutter.
http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
Sep 14, 2008. 2:12 PM REPLY
xchesterxx says:
Sep 14, 2008. 11:01 AM REPLY Hi, I am in the process of building a wind turbine but would like to keep the AC. By using diodes will i automatically change the current to DC. Are there diodes available that wont change the current to DC? Can the wye configuration be wired in a different way, say without diodes, to have the voltage output remain as AC. Thanks in advance, you have a great site.
sspence says:
Sep 14, 2008. 1:36 PM REPLY diodes turn ac into dc. That is the purpose of diodes. if you don't install the diodies, you get three phase ac, where the frequency and voltage are dependent upon rpm. these two parameters will be all over the place unless you are in a fixed rpm application.
abhaqkhawa says:
Sep 14, 2008. 5:35 AM REPLY
Hello , This is abdullah from Afghanistan, i found your web site and want to build a wind generator, but i need your help, here I try much to find some magnets like used in the picture but can not found, now i has some question please answer it, 1- If i use the load speakers magnet, is it work? 2- Coil: With out the liquid which you mentioned in your instructor, Can i use any anther one , if YES then please tell me what. iam in wait for your positive replay, thanks
sspence says:
Sep 14, 2008. 6:13 AM REPLY melted plastic would work as a replacement for fiberglass resin. magnets can be found in hard drives, wire can be found in motors and alternators.
bluiwolf says:
Sep 13, 2008. 4:56 PM REPLY does the size of the coils affect output power in anyway? I made a coil just to see what one is like. It's a 24v one so it has 72 turns. The internal hole is about 12 by 31mm and the outside is about 48 by 60mm and is about 20mm high. sorry if its mm but divide by 25.4 to get inches. great project by the way!
sspence says:
Sep 14, 2008. 4:53 AM REPLY
the coil size is determined by the magnet size. If it doesn;t pass the mmagnet correctly, output suffers.
dustyplans says:
Sep 12, 2008. 11:15 AM REPLY I teach at a middle school in MN. We are thinking about trying to build a generator to place on top of the building. Any pointers for us??? Remember they are 8th graders that will be tackling this. Cool site, and great info.
sspence says:
Sep 12, 2008. 12:24 PM REPLY You won't get much output on a roof, and vibration will be an issue. Get your shop teacher involved, and you should have few problems building one of these. Get the free (with subscription) 4 issue step by step hand holding instructions at http://backhomemagazine.com/
dustyplans says:
Sep 12, 2008. 4:01 PM REPLY I am the shop teacher for the Middle School. I teach 7th and 8th grade students. Starting this year we are focusing on renewable energy, mainly solar and wind. vibrations is an issue, but can be minimized by proper balance of the motor. As far as mounting on the building, we do not have a yard in which to put it. The building is 4 stories high. We are the tallest building in town, without any obstructions like trees or other buildings. My initial plan is to build something similar to something from otherpower.com and put it up 20 - 30 feet in the air. Thanks for the reply, I will look at the magazine article. If you think of anything else, give me a line. Thanks
iamdenteddisk says:
Sep 13, 2008. 3:00 AM REPLY
just check it out..http://www.instructables.com/id/truley_free_electricity/
dustyplans says: I have looked at it. But as sspence put it it soes not have amything to do with wind. Talk to you later.
view all 471 comments
http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
Sep 13, 2008. 6:21 AM REPLY
