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DIY 1000 watt wind turbine

by sspence on June 2, 2006

Table of Contents

intro: DIY 1000 watt wind turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 1: Build the magnet disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 2: Build the coil disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 3: Build the bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 4: construct the blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 5: Bolt it all together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
intro: DIY 1000 watt wind turbine
We built a 1000 watt wind turbine to help charge the battery bank that powers our offgrid home. It's a permanent magnet alternator, generating 3 phase ac, rectified to dc,
and fed to a charge controller. The magnets spin with the wind, the coils are fixed, so no brushes or slip rings necessary.

step 1: Build the magnet disks

We had 12" steel disks hydro cut. We cut a template for mounting the magnets. Then we mounted 12 grade n50 magnets around the outside edge. We then built a form,
and poured the resin with hardner.

http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
step 2: Build the coil disk
We wound the nine individual coils, soldered them in a 3 phase wye configuration, and encased them in resin. We used 35 turns of 2 parallel strands of 14 gauge
enameled wire for 12 volts. Use 70 turns of single strand for 24 volts.

http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
step 3: Build the bearing assembly
Two Harley Davidson wheel bearings are inserted into the pipe, with a smaller pipe locked between them to keep them in place.

step 4: construct the blades

The blades are 2" x 6" pine, cut at 10 degrees on a table saw, and sanded into a rough airfoil. Not perfect, but close enough.

More can be found at

http://tech.groups.yahoo.com/group/axialflux/

http://www.green-trust.org

http://youtube.com/watch?v=o9EEHFKEckM

step 5: Bolt it all together

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http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
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Comments
50 comments Add Comment view all 751 comments

markdennis says: Jun 21, 2009. 11:55 AM REPLY

I am very interested in building this.Am I not seeing everything or do I need more detail? As in "What type rosin is used, are the coils connected in series,
why is ther an extra set of wires from 11 coil and not the others? "

sspence says: Jun 21, 2009. 12:35 PM REPLY

The rosin is standard fiberglass variety. As I have described in the answers to others, there are 9 coils, 3 phases of 3 in series, wired as a wye. there is
one wire from each phase dropping down the tower.

Rahdzhillaxxx says: Jun 19, 2009. 2:01 PM REPLY

I've been fixing on my mowers for almost all spring. I have a few of the plug coils at my disposal that are still good, can these be used as a replacement for
the coils of copper? Arent they basically the same? I know I get a FUN jolt when the magnet spins on by from the flywheel.

sspence says: Jun 19, 2009. 6:03 PM REPLY

If the coils are the right number of turns, and the right gauge, they would work. The odds are remote.

ChuckP says: Jun 4, 2009. 2:03 PM REPLY

I am on the grid, and would prefer to develop a generator that connects directly to my panel so as to avoid the cost and maintenance of batteries and an
inverter. It this possible with this system? Thanks for all the work you have put into this.

sspence says: Jun 4, 2009. 2:16 PM REPLY

This unit is not appropriate for direct grid tie.

ChuckP says: Jun 4, 2009. 2:25 PM REPLY

What would it take to make it so? I am assuming that the magnets are placed with alternating poles facing the coils which will then generate AC. I
also assume a voltage regulator would be needed. Is there something in the design of this system that makes it inherently incompatible with the grid?
Sorry to bug you about this, but I don't have $500 for batteries and $1,900 for an inverter.

Also, I read in a previous post that the steel plate was 1/4". Is that thickness essential, or can I use a piece of sheet metal that I can cut with tinsnips?
Thanks again.

mynumber1 says: Jun 16, 2009. 4:38 AM REPLY

in terms of can you a thinner metal the answer is yes but it makes it more complex i work and design large scale generators and we dont normally
use large single peices of metal if you used a thinner metal but layered it would work the same for but what we normally do is layer with appling
insultive coating around each layer this allows for minimizing eddy current loses in your generator due to generator action occuring in the core

ChuckP says: Jun 16, 2009. 12:01 PM REPLY

Thanks for your comment. What would suffice for an insulative layer? Sheet metal has a thin coat of zinc over the steel; would that be
enough? If not, would a coating of urethane work? And would the layers of sheet metal need to be 1/4 inch thick to have the same effect?

sspence says: Jun 16, 2009. 12:19 PM REPLY

No insulative layer is necessary, it's just a steel plate with magnets on it. There's no electricity flowing on it or through it. No layers are
necessary either. Sheet metal will not work. It has to be iron/magnetic steel. It needs to be at least 1/4" thick.

sspence says: Jun 16, 2009. 6:23 AM REPLY

There is no core in a axial flux alternator, The steel backing plate is for the magnets, not the coils. You need to examine the design before
giving advice.

ChuckP says: Jun 16, 2009. 12:03 PM REPLY

But isn't it all interrelated? The steel backing affects the magnetic field which affects the fields effect on the coils and subsequent power
generation?

sspence says: Jun 16, 2009. 12:20 PM REPLY

yes, but cogging is caused by iron cores in the coils, and that doesn't exist in this design. It's an "air core" design.

http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
 sspence says: Jun 4, 2009. 3:20 PM REPLY
it's wild ac, there's no way to synchronise to 60 cycle. thinner than 1/4 steel will not complete the lines of flux.

ChuckP says: Jun 4, 2009. 3:55 PM REPLY

I understand. Thanks. BTW, what is the diameter of the steel plate?

sspence says: Jun 4, 2009. 4:11 PM REPLY

12". I suggest you get the eBook at http://www.green-trust.org/wordpress/2009/05/07/the-woodhengeorg-green-trustorg-diy-wind-turbine/

It gives very detailed instructions on building the alternator and the blades.

Davorin says: Dec 13, 2008. 9:48 AM REPLY

Hi I'm most interested in this windmill so I have some comment. This N50 magnets you could find in Hard drives from computers, and My pal advised me as
more magnet poles you put you will cut needing rpm.
with 12 pols U need 600 rpm with 24 poles U need 300 rpm etc.

mynumber1 says: Jun 15, 2009. 12:24 PM REPLY

also as you put more poles into a generator you run the risk of cause to high of a counter torque being produced during operation and causing your
turbine to seize up during low winds at least unless you build a gear box to increase the torque during low speed operations

sspence says: Jun 15, 2009. 2:29 PM REPLY

There is no cogging in an air core axial flux alternator. It's direct drive, no gear box necessary.

sspence says: Dec 25, 2008. 6:00 PM REPLY

Your pal doesn't understand the whole equation. more magnet poles means more coils, different diameter, etc. i.e., a complete redesign of the system.

Davorin says: Jan 4, 2009. 1:36 AM REPLY

tell me if I turn the magnets on a side it will take a less space on the steel wheel but would it have the same function? Thickness of my magnets is not
the same cause I get it from hard drives they are 1mm - 2.5mm.

sspence says: Jan 4, 2009. 6:34 AM REPLY

On our magnets, the poles are on the face of the magnets. putting them on their sides would mean zero output.

Naturallighting.com says: Jun 14, 2009. 12:58 PM REPLY

hello,
do you have any actual operating/performance data on the turbine you built?

thank you

sspence says: Jun 14, 2009. 1:56 PM REPLY

Approximately 2.5 kWh daily. Some days more, some days less. We are not in a good wind area.

Naturallighting.com says: Jun 14, 2009. 2:10 PM REPLY

thank you for reply.
where is best place to buy wire? want to make one asap. i have 10 ac. near galveston, tx. high wind every day. if one works, will add several. already
approved for grid tie in, with wind turbine.

sspence says: Jun 14, 2009. 6:08 PM REPLY

try a motor rewind shop in your neighborhood.

drewbad says: Jun 10, 2009. 5:38 PM REPLY

Have you considered creating a dual coil tubine such that a mirror image of the coil pack would sit on the back of the backplate sandwiched between yet
another 12 magnets where the middleplate could share between the two coils on each side?

http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
 sspence says: Jun 10, 2009. 8:40 PM REPLY
the steel plates spin, the coil packs do not. stacking could get complicated.

drewbad says: Jun 11, 2009. 12:21 PM REPLY

Thank you for the prompt response! :)
Could you share with us the make and model of inverter that you use with your system?
You are the Ghandi of wind power! Thank you for sharing your knowledge on behalf of us all!!!

sspence says: Jun 11, 2009. 1:10 PM REPLY

Thank you for the kind words. We use a Outback 3524 inverter.

drewbad says: Jun 12, 2009. 5:22 AM REPLY

That appears to be a hefty unit. Could you tell me how many batteries your bank consists of and the ratings (amphours) they are rated at?
Do you have an estimate of how much power your harnessing/month?

sspence says: Jun 12, 2009. 6:21 AM REPLY

Eight Trojan L16 420ah 6v batteries
We are harnessing approximately 1.8 kWh daily.
We also have 1700 watts of solar.

mauser says: Jan 26, 2009. 4:05 PM REPLY

Would like to know what type and what size diodes for 12 volts unit, and can I use a 12 volt 30 amp solar charge controller with it

sspence says: Jan 27, 2009. 7:10 AM REPLY

A solar charge controller will not work. You need a diversion controller (some can do both, but get wired differently). We use a 100 amp 3 phase diode
bridge. We have them available for $35 at http://www.green-trust.org/products/

vernonstien says: Apr 28, 2009. 6:20 PM REPLY

Your diodes, how many in each bank? I have to build 3 phase rectifiers for RF welding machines, some take up to 16 diodes per column, 2 columns
per phase. I think the last one I built took 96 diodes( 1600A 2KV ) , cost me about 200 bucks, also do you put VOM's to help protect the diodes? Do
you use capacitors to filter, or do you even need to filter it? just wondering....

sspence says: Apr 28, 2009. 7:41 PM REPLY

6 diodes total, two per phase, just like a car alternator. we sell a complete 3 phase rectifier for $35

No caps are necessary, as this is a battery charger.

CARANOD says: Jun 5, 2009. 4:25 PM REPLY

Couldn't we just use a "car alternator" with the same effect?

sspence says: Jun 5, 2009. 5:29 PM REPLY

Absolutely not. A car alternator needs too high of an rpm, and has a power robbing field coil. Totally inappropriate for a wind turbine.

hans blommers says: Jun 4, 2009. 1:32 PM REPLY

Hi SSpence,

in the text of step 2 you say:

We used 35 turns of 2 parallel strands of 14 gauge enameled wire for 12 volts. Use 35 turns of single strand for 24 volts.
To make 24 volts i presume you need at least 70 turn in stead of 35.
P.S. What dimensions do the magnets have?

sspence says: Jun 4, 2009. 2:17 PM REPLY

It's 70 turns for 24v. Our magnets are 2"x1"x.5"

http://www.instructables.com/id/DIY-1000-watt-wind-turbine/
 ShadowB says: Jun 2, 2009. 5:31 PM REPLY
The Best place to learn about these is 'Otherpower.com' Every question will be answered in detail!

Jinka says: May 5, 2009. 11:38 AM REPLY

Hi Guys, You have inspired me. I have it figured out, and a small model built execpt... The coils, are they wired so the white are all connected, the red all
connected, and the black all connected. Then they all have a common ground at the other end. And the three wires, black, red, and white go through a 6
diode tree and there you have your DC out?

sspence says: May 5, 2009. 12:07 PM REPLY

Yes, you have it.

james.mcglashan says: May 3, 2009. 1:05 AM REPLY

how much does it all cost alltogether???

sspence says: May 4, 2009. 7:37 PM REPLY

About $600 or so, or less if you scrounge.

wearethepeople says: Apr 29, 2009. 4:50 AM REPLY

Can you tell me the sequence that the coils are wired in please. Are the magnets on the steel plates attracting or repelling the other side?

sspence says: Apr 29, 2009. 5:33 AM REPLY

three series coils per phase. 3 phases. coil phases go p1-c1, p2-c1, p3-c1, p1-c2, p2-c2, p3-c3, p1-c3, p2-c3, p3-c3

magnets go flat side up, N S N S N S etc. attracting the magnet on the opposite plate.

cassiorichiniti says: Apr 25, 2009. 6:05 PM REPLY

what diodes do i need to use?

sspence says: Apr 28, 2009. 7:48 PM REPLY

We provide a 3 phase rectifier at http://www.green-trust.org/products/

notanarborist says: Apr 26, 2009. 2:27 PM REPLY

How would you modify the alternator design for 48volt with roughly the same wattage? Would you use the same gauge wire? Will the performance of the
machine be negatively impacted by running 48v vs 12v? Will there be enough room to physically fit the coils in your alternator as designed?

My machine would be about 300ft away from the house and think I would like the benefits that higher voltage offers due to size and length of cable.

view all 751 comments

http://www.instructables.com/id/DIY-1000-watt-wind-turbine/