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A wind turbine is a simple mechanical device similar to a windmill. The flow of air pushes the blades of the turbine to rotate, and the mechanical energy of that motion is transmitted along the turbine shaft. The turbine shaft rotates the other components of the generator, creating clean energy (renewable energy) for your home, and reducing your electricity costs. Alternatively, turbines can be made from simple materials available at hardware stores.
Steps
Planning to install a wind turbine
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Determine the average wind speed where you plan to place the turbine. To generate electricity efficiently, a turbine needs a wind speed of at least 11-16 km/h. Most turbines work best with wind speeds between 19-32 km/h. To find the average annual wind speed where you live, you can check online wind maps that show average wind speeds. [1] X Research Sources[2] X Research Sources[3] X Research Sources
- You can also purchase a wind velocity measuring tool called an anemometer that measures the wind speed at the turbine site. Do this every day for a while.
- If the wind speed at that place is relatively stable, a month’s measurement is more than enough, although the wind speed varies quite a bit with the seasons. You then calculate the average of the data to see if it makes sense to place the turbine there. [4] X Research Sources
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Review of building laws related to wind turbines. Each region has different building laws, so you should check with the regulator to make sure your turbine isn’t breaking the law. Some laws prescribe a minimum distance between turbines, as well as a minimum distance from the turbine to the boundary of the estate. Local ordinances may also impose height restrictions to consider when designing turbines.
- You should discuss turbine construction with your neighbors before investing too much time in design and construction. This way you can address their concerns about wind turbines, and eliminate misconceptions about noise and potential radio interference (radio and television). [5] X Research Sources
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Assessment of space to place turbines. Although the turbine itself does not require much space, to avoid potential conflicts with neighbors it is recommended that you reserve a minimum of 0.2 hectares for a turbine with a generating capacity of 3 kilowatts and 0.4 hectares for a turbine with a capacity of 3 kilowatts. up to 10 kilowatts. The space height must also be enough to be able to build the turbine with a height such that houses and trees do not block the wind. [6] X Research Sources[7] X Research Sources
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Use pre-made turbine blades or make your own. The type of turbine blade intended to be used and the blade construction can affect the design of the entire turbine. Old farm windmills are basically small sails attached to a spindle, but wind turbines are like giant propellers and have large wings shaped like drops of water. The blades must be of the right size and spacing for effective operation.
- If you want to make your own wings, you can make them from wood or cross sections of PVC pipes. You can find tutorials online using the keyword phrase “homemade wind turbine blades”.
- Regardless of whether you buy or make your own blades, you usually need 3 blades for a wind turbine. Using an even number of blades like 2 or 4 will make the turbine more prone to vibrations when turning. Increasing the number of blades will increase torque but may slow the turbine to rotate.
- Turbine blades can also be made from household products such as shovels. If you go this method, you choose a hard shovel, then you should replace the wooden handle with a more durable material, like a metal handle. [8] X Research Sources[9] X Research Sources[10] X Research Sources
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Select generator. You need to connect the wind turbine to the generator to generate electricity. Most generators are direct current (DC), which means that to supply electricity to your home, you must connect that generator to an inverter to generate alternating current (AC) for the appliances in the house. home.
- You can use a DC motor as a generator, although the magnetic flux may not be strong enough to create a strong electric field.
- The generator depends on rotation (in this case, the motion of the turbine blades) and magnetic force to generate electricity. Pre-made generators are the easiest option for beginners, but you can make your own by searching the Internet for “making a wind turbine generator” manual.
- If you decide to buy a DC generator, choose one with a high voltage and amperage rating, and a slow rotational speed (several hundred instead of several thousand revolutions per minute). You need to generate at least 12 vpt current for continuous time.
- The generator must be connected to the maintenance battery and the charge controller at the position between the generator and the inverter to protect the inverter and the battery whenever the voltage spikes. This also helps supply power to the inverter during periods of low wind.
- You should not use a car generator as a wind turbine generator. They need to have a rotation speed much faster than that of a wind turbine. [11] X Research Source[12] X Research Source[13] X Research Source
Assemble the shaft and crank of the vertical axis wind turbine
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Assemble the rotating shaft. You need to weld the crankshaft to the base of the shaft, but many pre-manufactured wind turbine kits already weld the two parts together. If you are assembling turbines from purchased parts or from spare parts, before welding be sure to wear protective gear such as goggles, gloves, jackets and specialized boots.
- After assembling the spindle, you can assemble the rest of the parts in sequence into the spindle. This is often the most efficient way to assemble a turbine if you are doing this project yourself. [14] X Research Source
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Slide the sprocket onto the spindle. To avoid friction and damage to the crankshaft/sprocket, it is recommended that you install a bearing between these two parts. Install the bearing on the conical end of the shaft that protrudes from the shaft base, and slide the bearing ring toward the shaft base until it is fixed in the thicker position of the shaft. You then slide the sprocket into position on the bearing so that the knobs of the sprocket face up.
- The distance from the bearing to the spindle base is about 10.2 cm. When the wind is strong, the turbine can bend, causing the blades to slash and damage the shaft.
- If you’re not buying a complete set and making your own sprockets, you might want to consider using a trailer’s 4-in-4 (4-bolt-4 inch) sprocket. No 4 on 4 is available at trailer parts stores, such as auto parts stores. [15] X Research Source[16] X Research Source
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Attach the lower turntable to the sprocket. The turntable must have holes to slide into the knobs on the sprocket, and have protruding ears to connect the crank to it. Engage the rotary disc to the sprocket knobs and secure it in place. After aligning the turntable on the sprocket, you will tighten it with the wheel nut, first by turning it in by hand and then using the spool key to tighten it. [17] X Research Source[18] X Research Source
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Handwheel connection. You have two cranks for each turbine blade, which means a total of six cranks for a three-blade turbine. You need bolts to connect the crank to the ears of the lower crank, and spacers to separate the lower crank from the top crank. Afterward:
- Slide a bolt into a hole in the ear of the turntable, engage the crank on the bolt, push the spacer into the bolt, engage a second crank on the bolt and use the upper turntable to clamp the two cranks together with the bolt. cushion. The lower and upper dials must be of the same shape, with the same number of cranks connected to the crank.
- Manually screw the bolt onto the top crank to secure the turntable, then tighten the remaining bolts of the first set of cranks. Repeat this process for all cranks.
- After all of the cranks are clamped between the lower and upper cranks, use the spool wrench to tighten the bolts tighter. After tightening the bolts, the lower turntable, the upper turntable and the cranks are ready to rotate easily with the sprocket on the bearing.
- Because the turbine structure will be continuously affected by wind and other environmental factors, the connection between the bolt and the crank must be tight. To ensure a strong bond, you should use a threadlocking solution sold at hardware stores. [19] X Research Source[20] X Research Source
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Attach the four pins to the top turntable. These pins must be threaded and each pin is 6 cm long, 0.635 cm thick. You may need to use a hacksaw to cut these pins to the required length. You then manually screw the pin into the top of the top turntable so that the pins are evenly distributed around the axis of rotation.
- Only screw the pin into the turntable deep enough so that each pin stands upright and secure. All pins should protrude from the turntable an equal distance.
- If you use a hacksaw to cut the pin, be careful not to damage the thread. A damaged thread will prevent you from fitting other parts into it.
- You need to attach the pins firmly, as well as the bolts connecting the cranks. Finally, you should drip thread locking solution onto the pins. [21] X Research Source
Mounting the magnet of the vertical axis wind turbine
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Insert the bottom magnet rotor into the pins. You can make your own lower and upper rotors using the rotor disc, epoxy paint, and 5cm x 2.5cm x 1.25cm neodymium magnets, or you can purchase the pre-made item included. in a wind turbine kit, or purchase from a wind turbine parts manufacturer. Pointing the magnets upwards, engage the lower disc of the magnet rotor onto the four pin bars that you have tightened to the turntable.
- Whether you make your own or use a pre-made magnet rotor, always be careful when handling individual magnets or magnet rotor discs. Their magnetic force is very strong, so it can cause serious injury if you do not handle it carefully.
- Neodymium magnets are quite brittle. You will need 24 ingots, 12 for the top rotor and 12 for the bottom rotor, but you should buy extra in case the magnets break during mounting on the disc. This type of magnet is for sale online. [22] X Research Source
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Make a magnet rotor if necessary. If you purchased the complete set with the magnet rotor disc, simply attach it to the pins as described above. For a homemade rotor, you must evenly distribute the magnets around the edge of the rotor disc. To prevent misplacement of the magnet and damage to the rotor, it is recommended that you draw the placement of the magnet on cardstock or plain paper.
- This piece of paper will be placed in the center of the rotor where the magnet is not. The lines from the center to the edge of the paper are an indication of where you need to place the magnet on the rotor. You can use masking tape to secure the paper and check out these samples online.
- It is recommended that you use a marker to mark the poles of the magnet before you begin mounting. If the magnets are attracted to each other and you can’t tell the poles apart, make a test device by sticking a small magnet on an ice cream stick.
- Glide the “N” side of the tester over the neodymium magnet. If you feel a push then that side of the magnet is the extreme. If you feel a pull, that face is the opposite.
- Use a pea-sized amount of epoxy paint to install the magnet. You apply paint to the face of the magnet before placing it on the plate.
- Carefully keeping your fingers away from the gap between the magnet and the rotor disc, slowly move the magnet to the corner of the rotor disc. The magnet should stick to the plate, then you can slide it into place according to the line on the sample sheet. [23] X Research Sources
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Insert the spacers into the latch. You can use a 0.375cm thick metal tube and cut it into 3.175cm lengths to create a cushion. You cut the buffer length as precisely as possible. Slide the spacers into the ejection pin on the magnet rotor face.
- Irregular spacers can cause the upper magnet rotor to tilt. This is dangerous and can also adversely affect turbine performance.
- The excess space of the pin above the mattress should be only slightly more than 2.5cm. That’s enough space for the bolt belt to tighten the top magnet rotor, along with all the parts between the two rotors. [24] X Research Source
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Place the stator on top of the lower magnet rotor. The stator consists of many metal windings that play a very important role in the generator. [25] X Research Source It is included with the wind turbine kit, or you can buy it from a wind turbine parts manufacturer, or you can build it yourself. The pins around the central axis of rotation will be nested in the center of the stator, and you must align the stator to the center with respect to the axis of rotation.
- The stator consists of three beams, each consisting of three 24-gauge copper coils, each with 320 turns of copper wire. Making the stator is time consuming and not easy.
- If you decide to make your own stator, you can find a how-to guide online with the keyword phrase “how to make a wind turbine stator”.
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Making a stator winding machine at home. You can make a stator winder from scrap wood and nails. Connect two pieces of plywood with four nails so that the space between the two pieces of plywood is about 2.5cm. The four nails need to be placed in a rectangle corresponding to the size of the magnet. You can then easily wind the copper wire to create the stator.
- During stator fabrication you must keep track of the beginning and end of winding the windings. Each roll must be wound in the same direction. A piece of colored electrical tape should be applied at the beginning of winding each coil.
- To prevent the coil from unraveling after wrapping, you should glue the whole coil with electrical tape and paint two more coats of epoxy outside. After applying epoxy, let the stator dry on wax paper for the time indicated on the paint can label. [26] X Research Sources
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Install the upper magnet rotor. Special care must be taken , this is one of the most dangerous parts of the wind turbine structure. Arrange four pieces of wood on top of the stator on both sides of the shaft, with the thick pieces on the bottom and the thin ones on top. The top piece of wood should be 2 x 4.
- Hold the upper magnet rotor so that your fingers are in the gap between the stacks of wood, and slowly place the upper rotor on top of the lower rotor. Try to align the upper rotor with the pins during mounting.
- The magnetic field will hold the rotor disc on and draw it to the previously placed pieces of wood. You then lower the top rotor onto the pins by sliding each piece of wood out. First slide out each piece of wood in turn.
- Repeat this process with the bottom wood pieces to get the upper rotor in place. You then screw the hex bolt nut into the pins to tighten the rotor. Once completed, the upper rotor should rest on the spacers and the pin should have only a small amount of space left on top.
- You may have to wiggle the pieces of wood to get it off the top rotor because the magnetic field is so strong. [27] X Research Source
Complete turbine main structure
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Remove the turbine structure from the shaft. Next you will connect the shaft to the tower. If you keep the turbine structure with the shaft rotating to install it in the tower, the job will be very difficult. Then you have to turn the structure upside down to install it on the tower.
- Lift the structure (including sprocket, crank, magnet rotor, stator and all related parts) from the axis of rotation in a vertical motion. Then place the turbine connection to another place with the side with the sprocket facing up.
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Weld the shaft base to the tower. Solder the spindle base to the tower if you have the complete set (usually sold already). However, the tower can be made from a sheet of metal attached to the top of a thick metal pipe. Remember to use metal pipes thick enough to withstand the wind force acting on the turbine.
- The tower must be installed on a solid foundation. You should pour concrete into the tower mounting position to increase stability. [28] X Research Sources
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Install brackets for spindle and stator. This holder should fit on the spindle like a collar. Then you bolt the bracket to the tower. Next, you cut the thread rod 0.375cm thick into four segments with a length of 11cm. Use thread locking solution first, then use nuts and washers to connect the threaded rod segments to the outside of the bracket, facing up.
- You should screw the nut onto the threaded rod to a position about ¾ of the way from the top of the threaded rod. The nuts will allow you to adjust the position of the stator while the threaded rod holds it in place. [29] X Research Sources
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Install the tapered roller bearing on the spindle. Before mounting, you apply a lot of regular bearing grease on the tapered bearing ring. After the grease is finished, you slide the bearing ring into the spindle all the way to the base of the shaft.
- You can grease the bearing ring with your fingers. Have a tissue or rag ready to wipe your hands after you grease the bearing and install it on the spindle.
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Mount the main structure of the turbine. Raise the main structure with the sprocket face up and place it on the spindle with the tapered roller bearing below it. The holes for mounting on the stator must match the threaded rods you tightened into the holder earlier.
- After putting the structure in place, you need to install an additional tapered roller bearing ring to the sprocket cover. Remember to grease the bearing ring with normal bearing grease before mounting.
- You must tighten the flower nut on the top of the bearing, and this can be done easily by hand.
- If you cannot turn the nut easily, unscrew it until the gap in the nut matches the hole in the spindle. Slide a key into this hole and use the pin bend pliers to lock the flower nut in place.
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Tighten the stator and install the grease cap to complete the turbine construction. Use one hex nut for each threaded rod to secure the stator to the structure. Then use two locks to adjust the stator clamp nut until the stator is right between the two magnet rotors.
- After stator positioning is complete, all that remains to be done is to add a grease cap to the top of the sprocket, such a turbine structure is complete. [30] X Research Source
Install turbine electrical components
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Connect the charge controller to the battery or circuit. Connecting the charge controller to the battery before connecting it to the wind turbine will prevent excessive voltage generation. This will therefore prevent damage to the device. [31] X Research Source
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Connect the shielded power cord to the charge controller. This wire will transfer power from the generator to the charge controller. From there, electricity is transferred to the battery or electrical circuit.
- It is recommended that you use a power cord model with two identically insulated segments, or use a cord obtained from a portable outlet and cut off the plug if desired.
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Thread the wire from the base and through the tower shaft. Route the wire from the bottom of the tower to the top of the turbine structure. You may need to use a guide line or tape measure to help get the wires through the tower. Then connect the power cord to the generator. [32] X Research Source
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Connect to battery or electrical circuit. After connecting the generator to the charge controller and wiring it through the base of the tower, you’re ready to hook up the circuit in your home to the line from the turbine. Whenever connecting an external power source to a circuit in your home, you should seek assistance from an electrician. In many areas, this job requires a professional electrician to handle it. [33] X Research Source[34] X Research Source[35] X Research Source
Advice
- You should cover the charger to prevent moisture in the air, and should connect to a manometer to monitor the output current.
- Research more about migratory birds in your area. If there are migratory birds in that area, you should not build turbines.
Warning
- If you plan to sell electricity to the utility, remember that they sell you electricity at retail price, but will buy back electricity at wholesale price. You will have to install a synchronous rectifier suitable for the AC frequency of the company power line, as well as a special converter. You probably won’t be able to produce enough electricity to get your installation capital back, let alone profit.
Things you need
- Wooden pieces 2 x 4
- Bolts, nuts and washers
- Flower nut
- Charge controller
- Then lock
- DC generator or AC motor (optional)
- Maintenance battery (recommended)
- Conventional bearing grease
- Grease cap (for sprocket)
- Hacksaw
- No
- Sheathed power cord
- Iron floor flange (diameter 2.5cm)
- Iron pipe (diameter 2.5cm)
- Magnetic rotor/rotor disc
- Metal tube ( 3/8 ” /0.95 cm wide)
- Nut
- Pipe key
- Crank
- stator
- stator holder
- Tapered roller bearings (2 pieces)
- Thread lock solution
- Threaded rod ( 3/8 ” /0.375 cm thick)
- Threaded rod (0.635cm thick)
- Manometer (optional)
- Dragon Temple
- Welder
- Wrench (adjustable type)
X
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A wind turbine is a simple mechanical device similar to a windmill. The flow of air pushes the blades of the turbine to rotate, and the mechanical energy of that motion is transmitted along the turbine shaft. The turbine shaft rotates the other components of the generator, creating clean energy (renewable energy) for your home, and reducing your electricity costs. Alternatively, turbines can be made from simple materials available at hardware stores.
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