Building an 8-foot wind turbine Brent Summerville Appalachian State University
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Building an 8-foot wind turbineBrent SummervilleAppalachian State University
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Research: In search of Plans
• Backhome Magazine article www.backhomemagazine.com
• www.otherpower.com
• …derived from Hugh Piggott’s axial flux plans or “How to build a wind turbine”
• Go with the source and follow plans closely
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Research: Hugh Piggott
Workshops in Washington, Scoraig, CAT, Edinburgh, Ghana, France, Costa Rica, Liverpool…..
This is Jay from France. He also came to a Beech Mountain workshop.
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Resources: Woods Lab• Sat in on Intro to Wood
Technology • Trained on techniques, tools,
machinery and safety• Practice…Sanding block,
cedar tool box• Last semester for Bill Hanner
•Draw knife•Hand plane•Spoke shave•Lathe•Jointer•Sanders•Gluing panels•Planer•Bandsaw•Drill press•Table saw…
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Resources: Metals Lab
• Sat in on Intro class• Trained on techniques, tools,
and machinery• Copper nameplate, dinner
bell, apple butter stand• Nice working with Leo and
Dave•Welding•Mill•Lathe•Plasma torch•Blacksmithing•Grinding•Tapping•Sheet metal fab•Drill press•Iron worker…
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Bladecarving
Basswood with termites Thickness, width, length Layout
Carve with draw knife and spoke shave
Sand, sand, sand Check, carve, sand…
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Jointer, planer, table saw, and belt sander to form 1-1/2”x6”x52” blanks
Finished length is 48”. Keep long until finished carving. Makes for a nice blade tip.
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Start with a precise layout
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Simple tools
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Carve the taper with the drawknife
Clamp and sand to keep the blades
matched
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Carve the twist and check the drop
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The drawknife can remove a lot of material quickly, and it’s a good workout
Carve the thickness
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The spoke shave is pleasant to work with
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Carve the airfoil, keep watch on the
30% line
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Bladecarving: Suck not Push
Source: http://www.graphics.cornell.edu/academic/archartpcg/spring01/students/rr63/ROA/windworks01.jpg
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Cut to length, cut the 120o angles, ready for the rotor hub
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Layout holes for wood screws and studs
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Drill the through holes for the ½”
studs square to the hub
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Sanding the hub on the lathe
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Assemble the rotor, keep the tip-to-tip distance within ½”
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After painting and re-assembly, tip-to-tip was 84”, 84-1/8”, 84-1/4”
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Decided to skip the wedges
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Axial Flux Alternator: Stator
Wind coils Build a mold and layout coils Solder a 3-phase star
Cast in polyester resin Cleanup casting Drill and mount
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Keep em’ tight so they will fit into the mold
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Clamp coils in position for soldering
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Strip with knife, solder, shrink tubing
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Build a mold
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Fiberglass cloth for strength
Mold release
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Place the coils, position the three output wires in conduit, pour in polyester resin and cloth, clamp and cure
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Free the stator and clean it up
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Axial Flux Alternator: Rotors
Buy laser-cut plates, machine the holes
Careful with those Neo magnets! Position magnets with a jig
Cast in polyester resin No screws needed Clean up and be careful
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Flat, not flat
My attempt at a rotor plate is on the right. Laser cut plate on the left.
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Superglue magnets to plate to avoid movement
during casting
An index hole in every plate keeps things aligned
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Build a mold
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Do all three castings together and do it outside (strong smell)
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Cast in Polyester resin with fiberglass cloth
Checking the alternating polarity
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Stator and rotors, minimal
air gap
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Axial Flux Alternator: Magic
Most of the electric power in the world is 3 phase. The concept was originally conceived by Nikola Tesla and
was proven that 3 phase was far superior to single phase power. 3 phase power is typically 150% more
efficient than single phase in the same power range. In a single phase unit the power falls to zero three times during each cycle, in 3 phase it never drops to zero. The power delivered to the load is the same at any
instant. Also, in 3 phase the conductors need only be 75% the size of conductors for single phase for the
same power output. source: www.windstuffnow.com/ main/3_phase_basics.htm
An electrically charged particle moving in a magnetic field will experience a force
(known as the Lorentz force) pushing it in a direction perpendicular to the magnetic
field and the direction of motion: Source:
http://www.wondermagnet.com/magfaq.html#q18
Rectified to DC(one phase shown)
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Fabricate the Alternator Mount
Salvage steel Visit a junkyard Prep steel, fabricate
Make strong welds Machine holes Clean, prime, paint
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Plasma torch…upping the embodied energy
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The angle grinder cleans up ugly welds
The type disc with flexible
sanding flaps works nicely for
finishing and smoothing
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Fabricate the Tail
Vintage Jacobs whale tail
My version
Cool ideas
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Assembly
• Too much time in Kerr Scott
• Moved the operation home for final assembly
• Wife and dogs were happy
• Stand borrowed from Whisper 200 demo
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Assembly: Tower adapter
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Assembly: Alternator Bracket
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Assembly: Hub
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Assembly: Back Rotor
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Assembly: Stator
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Assembly: Front Rotor and J-Box
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Assembly: Tail
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Assembly: Ready for Blades
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Costs
• Minimum for a new 1kW turbine is about $1700
• My cost = $836
Description Source Total(24) Neodymium Iron Boron (NdFeB) magnets Forcefield 156.00$ (2) 6-lb spools of #15 AWG magnet wire Forcefield 110.00$ (2) 35 amp bridge rectifiers Forcefield 11.00$ Shipping Forcefield 23.60$ Basswood for blades Tech Dept 50.00$ Chevrolet Cavalier rear wheel hub T&T Auto Salvage 30.00$ Fiberglass cloth Walmart 7.88$ Wax polish Walmart 1.88$ Super glue Walmart 1.47$ Bondo polyester resin NAPA 47.60$ SS fasteners and spray paint New River 40.86$ 2-3/4" hole saw Lowes 17.47$ Drill bit set Lowes 17.64$ 1/2" Plywood Lowes 4.15$ 3" hole saw Lowes 13.66$ Plugs Lowes 1.98$ White box cover Lowes 0.98$ White exterior house paint Lowes 8.97$ White primer Lowes 10.27$ 1-1/4" pipe Lowes 12.64$ Paint brush Lowes 8.47$ Grinder disc - resin Lowes 2.97$ Grinder disc - sanding Lowes 7.47$ 3/8" plywood Lowes 17.75$ 3/4" plywood Lowes 10.98$ Steel and SS threaded rod Triplett & Coffey 220.00$
Total 835.69$
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Conclusion
• Well done plans• Slight customization
– No wedges– Wiring details– Nose cone
• Lots of work• Use of magic
– Lift– Electricity
• Economical• To do next: controller and
tower
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Questions?