diy wind generator

instructables

DIY Wind Generator

by DIY KING 00

The idea of generating electrical energy using thewind energy always attracts me. So now being a wellequipped DIYer its time to built the first wind

//www.youtube.com/embed/TyyTykEkc1E

generator from scratch.

The whole idea is to built a small wind generatorusing relaible techniques and the stuff thats bestsuited to serve the purpose while gathering all thematerial from the hardware store or a junkyard.

Well time to get our hands dirty.

https://youtu.be/TyyTykEkc1E

DIY Wind Generator:

http://www.instructables.com

http://www.instructables.com/id/DIY-Wind-Generator/

http://www.instructables.com/member/DIY%20KING%2000/

DIY Wind Generator:

Step 1: Material and Tools

The following list of materials and tools is what we need to get our idea into reality but the goal is to get the jobdone and thus can vary.

List of material used in this project:

Old hoverboard6 inch PVC pipe5mm round metal platees1 inch metal stripsPly woodNut and bolts2 inch galvanize pipe

List of tool used in this project:

Hand drillJig sawAngle grinderSoldering ironPliers

And some other hand tools...

DIY Wind Generator:

DIY Wind Generator:

Step 2: The Generator

Yes the generator, for that we have decided to use abrushless hub motor and the one that we found wasfrom an old hoverboard, as these days you can easilyfind one arround in a scrap yard. The reason for usinga permanent magnet hub motor is the fact that youdont need to worry about the brushes wearing out asin a brushed motor and their effiency, which is farbetter than a similar size brushed motor.

Besides that these hoverboard motors can producegood voltage even when handcranked. Now thisfactor is important for a wind generator as even withslight gusts of wind we can get voltage that can getthe system working.

Now with all the factors in mind we havedissassembled a hioverboard and get our hands onone of the motor. Most of the times these motors are

in good condition but just to make sure they are inworking condition, mount the motor on a bench withthe shaft using a clamp. Now attach a 12v bulb onany two of the three thick wire and give the motor aquick spin by hand. The bulb should make a decentglow , now you can do that with the other remainingwire as well.

Next, we dissassembles the motor with the six flathead screws on the back of the motor. Pull the backplate and remove the tyre with a screw driver. Nowtime to step on the casing and pull the stator using aplier , sure you are going to need some fore doingthat.

Once the rotor and stator are seperated,

DIY Wind Generator:

Step 3: Blades Adapter

To get the motor spinning , we need to translate thewind energy into mechanical energy. So to make themotor spin we need to mount the blades on the hubmotor and for that we are going to need an adapter.

Now the adapter is made of two 3mm thick steelplates with a diameter of 6 inch. The blades holderare going to be 1 inch wide 5mm thick steel stripesthat are going to be sandwitched between the steel

discs.

A template scetch later we did a bunch of holes thatare going to help as mount the discs on the hub motorand hold the blades aswell.

With a paint of coat all the parts are ready for theassembly.

DIY Wind Generator:

DIY Wind Generator:

Step 4: Assembling the Blades Adapter

While assembling the adapter make sure that everything is as balanced as it can be because if its the otherwayarround than bearings are now going to last much.

Once we got the adapter assembled on the rotor, we reassembled the motor and this time we cut of the five thinwires as they are useless in our case.

DIY Wind Generator:

DIY Wind Generator:

Step 5: Main Holder

To hold everything together we are going to use a 2inch wide 7mm thick steel stripe. We are going tomount the hub motor by using a pair of adapters thatthe motor is mounted with on the hoverboard and forthat we have drilled four holes.

The other end is going to hold the tail so two 6mm

holes for that as well. Now for mounting that bar onthe moving platform we have to get a 36mm holealmost across the centre of the stripe, this will allowthe head of the main bolt to be tightened across thewhole assembly.

DIY Wind Generator:

DIY Wind Generator:

Step 6: Moving Mechanism

Now to keep the blades into the wind we need amoving mechanism. To save us time and money andlots of machining we adapted the hinge mechanism ofthe hoverboard that allows the board to get tilted ineither direction for turning the board.

We first cutoff the centre piece off the hoverbaordbody, split the connecting rod into half and with abunch of holes our moving assembly is ready.

Now to mount this moving assembly onto the pole wemade a pair of adapters out opf two 4mm thick steelplates with a diameter of 4 inch.

One of the adapter plate will be welded to themounting pole on the roof top with the other one isgoing to be sandwitched with the moving mechanismto mount the whole assembly on the mounting pole.

DIY Wind Generator:

DIY Wind Generator:

Step 7: The Tail Assembly

In order to make the tail for wind turbine we are going to need a piece of 10mm plywood. We cut a triangular shapeand mounted using two 5mm metal plates. The tail holder is going to be a hexagonal rod which is going to get thetail mounted on the main plate.

DIY Wind Generator:

Step 8: Blades

The blades are made out of 6inch Dia PVC Pipe. Nocalculation but just a good assumption to get thingsgoing. The blades were cut down using a jig saw,could be done with a handsaw as well. Each blade is5 inch at the widest part and nearly 2 inch at thenarrow end. Both the ends were trimmed to give thema nice shape and make them spin smoothly.

The blades were 40 inch in length and yes the mostimportant piece of advice, make sure you use theheaviest gauge of pipe and cut all the blades with thetaper/pitch in the same direction.

DIY Wind Generator:

DIY Wind Generator:

Step 9: The Paint Job

In order to protect our wind turbine from rust we are going to paint every thing using the matalic black spray andthat gives the wind turbine pretty nice look. Simple as that....

DIY Wind Generator:

DIY Wind Generator:

Step 10: The Final Assembly

With paint dired, we assembled everything togetherstarting from the moving mechanism. Once themoving mechanism is assembled we temporarilymounted in on a wooden baord that is clamped to thetable. Next we mounted the hub motor on the mainplate. Later the blades were mounted again makingsure that they are well balances with equal distance

between their tips. Finally the tails assembly iscompleted and yes with that being done the generatoris ready to convert gusts into sparks .... Yes we needsome more work to gut those sparks into useful formof energy.

DIY Wind Generator:

DIY Wind Generator:

Step 11: Rectifier Unit

Remember three thick wires poping out of the hubmotor, yes its a three phase brushless motor and thusits going to produce a three phase Alternating current.Now to convert it into DC volatge (More useful form)we have designed and built a customized three phaserectifier unit.

To make it as neat as the rest of the parts, wedecided to built the rectifier unit on our owncustomized Printed Circuit Boards. Now thiscustomization is made possbile by JLCPCB, one ofthe largest PCB manufacturer in China, proving avast range of soultions for manufacturing yourcustomized Printed Circuit Boards at an outstanding

price right at your door step.

The Design Files for the rectifier unit can be uploadedon JLCPCB and after going through a bunch ofoptions you can easily place your order.

We recieved the boards within a week and the qualityis flawless. We than gathered all the parts andsottered them on the PCB.

With that being donw our rectifier unit is ready to beattached to the generator.

DIY Wind Generator:

https://jlcpcb.com

https://drive.google.com/open?id=13J0mqBVomIx8cV9ERI-wQ9G5bD6aEGxi

https://jlcpcb.com

DIY Wind Generator:

Step 12:

In order to mount our wind turbine unit we are goint to use 3 inch diameter galvanize pipe. The lower end of thepipe is mounted using two metal brackets on the floor and on the upper end of the pipe we have welded the 5mmthick metal plate to get the flat surface

DIY Wind Generator:

DIY Wind Generator:

Step 13: Final Results

With the rectifier unit attached to the generator, thegenerator is mounted on top of our roof.Its nearly 40foot high with decent clearance all arround.

Now the rectifier unit coupled with a buck boostconverter is allowed to charge a 12v lead acid batteryto act as a load for the generator. The generatorstarted spining with moderated gusts and startedcharging the battery.

The generator is able to produce nearly 150 watts ofpower (12-15v at 14-10 Apms) with a wind speed of

nearly 5 to 7 m/s. Now that is our first attemp atbuilding a wind generator so we are looking forwardto built a bigger one so get some more energy out ofthe winds.

Hope you like the projects.

Regards.

DIY King

DIY Wind Generator:

Brilliant. Watched the video, glanced at the rest and came away significantly impressed. Wish Ilived down the road from you guys!

Great idea to make a wind generator, but if you like how your hands are configured please clampthe metal plate to the vice table. If the bit catches the plate your hand can not stop it from spinningcausing major cuts to the hands.

You are very smart nice build how did you connect the wires down the pole to the battery so wiredoesn't twist around pole? Are did you make it so it doesn't spin around when wind changesdirection! did I miss something you should consider using dust mask just a helpful hint from yourold buddy Vern! Nice job! ��

You are very smart so if you want to be a old smart guy GET SOME DUST MASK! When you getold it's nice to be able to breathe! Very smart build did you make your own plan?

Wow. Excellent. I dont have the skills to build this but I enjoyed reading about it. The blade designis beautiful. Thanks for posting.

Maybe I'm missing something, but at minute 7:20 in your video you can see that your stator isrotating somewhat independently of your rotor so that at high speeds the stator and the rotor arespinning together. That's going to completely wash out any current generation of the device.

Great project and a good design very well done. Thanks for sharing.

DIY Wind Generator:

The power output is stated as 5-7 Km/s , at 7 that's 25200 Km per hour, quite a windspeed. I thinkyou meant 5-7 meters/second. Regardless, nice project and 10 amps is respectable.

Excellent project! I admire the way you took items that might be thrown out and repurposed them.Also, the PVC fan blades are genius, in my opinion. I would never have thought about that. Goodwork, men. Looking forward to your next project...

DIY Wind Generator:

diy wind generator

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