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Building an 8-foot wind turbine Brent Summerville Appalachian State University.

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Presentation on theme: "Building an 8-foot wind turbine Brent Summerville Appalachian State University."— Presentation transcript:

1 Building an 8-foot wind turbine Brent Summerville Appalachian State University

2 Research: In search of Plans Backhome Magazine article …derived from Hugh Piggott’s axial flux plans or “How to build a wind turbine” Go with the source and follow plans closely

3 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.

4 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…

5 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…





10 Bladecarving Basswood with termites Thickness, width, length Layout Carve with draw knife and spoke shave Sand, sand, sand Check, carve, sand…

11 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.

12 Start with a precise layout

13 Simple tools

14 Carve the taper with the drawknife Clamp and sand to keep the blades matched

15 Carve the twist and check the drop

16 The drawknife can remove a lot of material quickly, and it’s a good workout Carve the thickness

17 The spoke shave is pleasant to work with

18 Carve the airfoil, keep watch on the 30% line

19 Bladecarving: Suck not Push Source: nts/rr63/ROA/windworks01.jpg

20 Cut to length, cut the 120 o angles, ready for the rotor hub

21 Layout holes for wood screws and studs

22 Drill the through holes for the ½” studs square to the hub

23 Sanding the hub on the lathe

24 Assemble the rotor, keep the tip-to- tip distance within ½”

25 After painting and re-assembly, tip- to-tip was 84”, 84-1/8”, 84-1/4”

26 Decided to skip the wedges

27 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

28 Keep em’ tight so they will fit into the mold

29 Clamp coils in position for soldering

30 Strip with knife, solder, shrink tubing

31 Build a mold

32 Fiberglass cloth for strength Mold release

33 Place the coils, position the three output wires in conduit, pour in polyester resin and cloth, clamp and cure

34 Free the stator and clean it up

35 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

36 Flat, not flat My attempt at a rotor plate is on the right. Laser cut plate on the left.

37 Superglue magnets to plate to avoid movement during casting An index hole in every plate keeps things aligned

38 Build a mold

39 Do all three castings together and do it outside (strong smell)

40 Cast in Polyester resin with fiberglass cloth Checking the alternating polarity

41 Stator and rotors, minimal air gap

42 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: 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: ml#q18 Rectified to DC (one phase shown)

43 Fabricate the Alternator Mount Salvage steel Visit a junkyard Prep steel, fabricate Make strong welds Machine holes Clean, prime, paint

44 Plasma torch…upping the embodied energy

45 The angle grinder cleans up ugly welds The type disc with flexible sanding flaps works nicely for finishing and smoothing

46 Fabricate the Tail Vintage Jacobs whale tail My version Cool ideas

47 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

48 Assembly: Tower adapter

49 Assembly: Alternator Bracket

50 Assembly: Hub

51 Assembly: Back Rotor

52 Assembly: Stator

53 Assembly: Front Rotor and J-Box

54 Assembly: Tail

55 Assembly: Ready for Blades

56 Costs Minimum for a new 1kW turbine is about $1700 My cost = $836

57 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

58 Questions?

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