Windmills - a promising alternative for traditional energy. Wind power, converted into electricity, promises to be cheap, simply produced and low-cost. And if you take into account the bills that are coming now for electricity, then in order to save, it is worth trying to build your own wind generator, do you agree?
There are real examples of creating plants that produce a decent amount of energy. Nevertheless, the possibilities of wind turbines are still significantly ahead of competitors who are able to withstand the traditional method of producing electricity.
We presented a guide, following which you can build a wind generator from a car generator with your own hands. In the proposed article, the widespread errors that make it possible to construct wind turbines are discussed in detail. For clarity, the article is accompanied by thematic photo and video materials.
The content of the article:
- About homemade wind turbines for home
Wind turbine assembly technology
- Step 1. Wind power screw
- Step # 2. Making a mast from a pipe
- Step # 3. How to make an aluminum vane
- Step # 4. Installation and connection of the wind generator
- Parsing design errors
- Conclusions and useful video on the topic
About homemade wind turbines for home
Of particular interest to wind energy is manifested at the level of the domestic sphere. This is understandable if you look at the next bill for the energy consumed by the corner of your eye. Therefore, all kinds of craftsmen are activated, using all the possibilities of obtaining electricity cheaply.
One of these possibilities, quite real, is closely connected with a wind turbine from an automobile generator. Already finished device - automotive generator - just enough to equip correctly made blades, to be able to remove from the generator terminals some value of electrical energy.
True, it will work effectively only if there is windy weather.
An example from the practice of domestic use of wind generators. Successfully developed and quite effective practical design of the wind turbine. Installed three-blade screw, which is rare for household appliances
Using virtually any automotive generator is acceptable for windmill design. But they usually try to choose a powerful model capable of producing large currents. Here at the peak of popularity of the design of generators from trucks, large passenger buses, tractors, etc.
In addition to the generator for the manufacture of a windmill will need a number of components:
- screw two- or three-blade;
- car battery;
- electrical cable;
- mast, support elements, fasteners.
The design of the screw on two or three blades is considered the most optimal for a classic wind generator. But the household project is often far from the engineering classics. Therefore, most often on the home design try to pick up ready-made screws.
The impeller from the fan of the car, which will be used as a screw home wind installation. The lightness and the large usable area for air power make it possible to use such options.
This, for example, could be the impeller from the external unit of the split-air conditioning system or from the fan of the same car. But when there is a desire to follow the traditions of designing wind turbines, you will have to build a wind turbine propeller from start to finish with your own hands.
Before making a decision on the assembly and installation of a wind generator, it is worth assessing the climatic data of the site and calculating the payback. The information will be greatly helped by this interesting articlerecommended by us for review.
Wind turbine assembly technology
The AT-700 model taken from a DT series tractor seems to be the optimal basis for a home windmill generator. True, this tractor generator in its original form is designed for rotor speeds up to 6000 rpm. Under the design of a home windmill such a parameter is clearly excessive.
There are two ways out:
- Apply some gear-multiplier, giving the desired gear ratio.
- Rewind the existing AT-700 stator winding under low speed.
In principle, both options for upgrading the device are achievable. But, judging by the reviews held by the designers, the option of winding the stator winding is more acceptable. Especially considering the weight of the AT-700 generator itself, reaching 6 kg.
Tractor generator AT-700. Numerous household projects were developed on the basis of this particular device, which has a high current efficiency. But a small upgrade is required.
If the device is supplemented with a gearbox, the weight of the total module will double. And this is an important parameter for the construction of a windmill. Weight always tend to reduce.
Step 1. Wind power screw
The material for the manufacture of propeller blades is a glazed aluminum pipe (d = 200 mm) with a length of 0.7 - 1.0 m. Initially, it is cut along four sections, and then the blades are cut out from two or three parts obtained required shape.
Since aluminum is a material that can be easily processed, it is not a problem to cut out the desired shape of the blade from a piece of pipe. The main thing is to correctly calculate and draw a pattern.
The prepared blades of the future screw must somehow be stapled and mounted on the generator shaft. This work is more complex, requires precise balance, and especially when performing a three-blade design. There are lots of options for making a screw disk. One of them is the creation of this part from aluminum plates.
You will need to calculate the diameter of the propeller disk, taking into account the meter length of the blades. For a wing span of 2 meters, the calculated disk diameter can be 150-200 mm. Based on the calculated diameter, the required number of round plates (6-7 pieces) is cut out of aluminum sheet.
An example of making a wind generator screw from a 200 mm aluminum pipe used in agricultural fields for irrigation. Lightweight and efficient construction.
Carved round plates overlap each other, align with edges and fasten. For bonding is best to use high-quality epoxy glue. But other methods of fasteners are not excluded.
On the finished glued disk, it is necessary to mark and drill a hole for fastening on the generator shaft in the center point. The hole to modify the keyway to the size of the key mounted on the rotor shaft of the generator.
A propeller disk prepared in this way is laid out under the blade mount. On the planned lines, drill holes for mounting brackets. These parts are also made of aluminum with a selection in thickness sufficient to compensate for the transmitted forces.
It will only be necessary to attach the previously manufactured blades to the disk at the intended connection points, balance them on a flat surface and fasten with bolts.
Step # 2. Making a mast from a pipe
The AT-700 tractor generator, equipped with a home-made propeller, is already a real windmill. In order to obtain the maximum effect from the design, it is desirable to raise it by 5-7 meters and, moreover, to provide circular movement of 360 °.
Therefore, the wind vane is placed on the mast, which is easiest to manufacture on the basis of a metal pipe.
Installed mast of metal pipe with a diameter of 50 mm with a wind generator at the top. To ensure the stability of the mast are applied stretch of metal cable
A mast with a height of 5-7 meters, equipped at the top with a wind generator, will experience significant loads. Accordingly, the diameter of the metal pipe is needed large enough - not less than 50 mm in outer size.
Fastening of the mast is performed by four rope stretch, fastened from above closer to the windmill and stretched in opposition to each other.
Under the upper edge of the pipe-mast, in the inner region, a pair of suitable bearings are pressed in or fastened in some other way. It will be the basic rotating block where the weather vane with the generator and the screw will fall. It remains to make the vane itself and install all the necessary equipment on it.
Step # 3. How to make an aluminum vane
The vane design, at one end of which there is a place for a car generator with a screw, and at the other - a place for a “shank”, is recommended to be made of lightweight durable material.
For example, an aluminum tube of a rectangular profile would fit under the base just right. As a generator fastener, it is more convenient to use clamps made of soft metal tape (preferably stainless) to the profile pipe.
An example of a possible mounting of the generator housing on the profile pipe of the wind vane. It uses a metal frame with front and rear brackets for bolting
The tail of the weather vane can be constructed from the same aluminum sheet and fastened to the profile tube with corners. At the point of the center of gravity, on the profile pipe, it is necessary to strengthen the stainless steel metal pin.
This detail is in the form of a long bolt (250-300 mm), with a diameter of about 30 mm (calculated), passes across the body of a shaped aluminum pipe and is fixed from below with a nut. A locknut is placed on top of the nut.
The thread diameter of the bolt should be slightly less than the internal diameter of the bearing rings that are pressed into the mast pipe. In the center of the bolt, along its axis, a hole of 7-10 mm is drilled. An electric cable from the generator will pass through this hole and go down the pipe to the connection point.
Step # 4. Installation and connection of the wind generator
After all the described preparations (always in calm weather) proceed to the installation:
- On the basis of the weather vane, the tractor generator is attached with clamps.
- Raise the mast from the ground by 1.5 - 2 meters and install the vane with a bearing bolt on the bearings.
- At the same time, the cable from the generator is passed through the bolt body and further inside the pipe to the lower exit point.
- Also, just below the vane base, a limiter is rigidly installed, allowing the vane to rotate 360 ° in one direction or the other, but no more.
- Raise the mast finally and strengthened with rope extensions.
- Connect the ends of the cable to the receiving device (usually through controller to the battery).
In this design of the wind generator can be considered complete. However, there are still a lot of individual parts of the process that you will encounter during the period of using the device.
Block diagram of a full-fledged wind turbine: 1 - wind turbine, 2 - battery charge converter; 3 - car battery; 4 - 24/220 inverter; 5,6 - outputs of voltages 220V and 24V
These details are connected with the automation that regulates the accumulation and distribution of energy. Such devices as a charge controller, current inverter, etc., are mandatory components of wind generators.
Parsing design errors
Building a wind generator in the home with our own hands is, of course, not infallible. Even in the construction of industrial windmills engineers make mistakes. But they learn from mistakes, which is confirmed by well-established household constructions.
So, among the errors in the device of domestic wind generators are often featured such a detail as the absence in the design of the generator of the braking module. The standard performance of such devices (automobile or tractor) does not provide such a detail. Hence, the generator must be refined.
However, not every "designer" wants to do this delicate matter. Many ignore this detail, hoping for "chance." As a result - with a strong wind, the screw spins up to incredibly high speeds. The bearings of the generator do not withstand, break the seats of aluminum caps. Rotor wedge occurs.
Destroyed wind generator due to flaws in the design. Errors in the design and installation of such structures lead to serious consequences.
The same topic relates to the flaw associated with the lack of a windshield rotation stop. Often, this component is simply forgotten to be installed and is remembered only when the wind flows begin to spin the “cock” around its axis, as in the “What? Where? When?". The result is deplorable.
The minimum damage is the twisting and breaking of the electric cable, and in severe cases - the separation of the entire structure.
Another notable build error is the incorrect calculation of the center of gravity point based on the weather vane. In this case, the device may function normally for a while. But over time, a bias is formed on the bearing assembly, the freedom of rotation is limited, the design efficiency in terms of energy efficiency decreases sharply.
How correctly calculate the wind generator, learn from the article proposed by us.
Often, the current received from the generator, trying to directly feed the battery. Soon they start to wonder - why the battery does not hold a charge or does it detect a breakdown of 2-3 cans.
This is a banal and natural error, since in any case, the battery charge should take place under certain currents and voltages. Here you need control of this process.
Home craftsmen interested in the topic wind turbine assembly, we suggest to familiarize with one more original variant. The proposed article describes the manufacture of a generating unit from waste parts of a washer.
Conclusions and useful video on the topic
Even an ordinary electric screwdriver can become a windmill, if you know the basics of a wind generator device.
Interest in wind turbines is not reduced. On the contrary, this option for the production of electric energy is increasingly being considered at the level of owners of suburban real estate.
Obviously, if you combine several types of energy - wind, sun, hydro turbines or nuclear power plants, such a combination can give an economic effect. At the same time, the user's risks of being left without electricity are reduced to zero.
Would you like to tell about how you personally assembled a windmill to provide electricity to the dacha? Would you like to share useful information that is not mentioned in the article? Please write comments in the block below, share your impressions, only you know the technical details and photos on the subject of the article.