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PVC pipe blades and rotor for HAWT from scrap.

by Dr Qui on July 30, 2010 Table of Contents License: Public Domain Dedication (pd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro: PVC pipe blades and rotor for HAWT from scrap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . step 1: Marking the pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . step 2: Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . step 3: marking and cutting the segments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . step 4: sanding and finishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . step 5: The rotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . step 6: The bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . step 7: Attach the blades and add the bearing cage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 2 3 4 5 6 6 7 8 8 8

http://www.instructables.com/id/PVC-pipe-blades-and-rotor-for-HAWT-from-scrap/

License: Public Domain Dedication (pd) Intro: PVC pipe blades and rotor for HAWT from scrap.

I recently had an idea for a horizontal wind turbine. The idea came to me when I dismantled an old washing machine to get the stainless steel drum to make a patio heater. I discovered that the drum was mounted on a aluminum casting that had chunky bearings that though would be perfect to make a wind turbine with, the rotor of any turbine is the hardest part of the build and to find some thing this perfect I just had to see if it would work. I had a 1mtr length of 6" PVC sewer pipe left over from my VAWT built and decided that i would use it to make a set of blades to see if my idea was valid enough to continue to build a horizontal wind turbine. For the video the rotor is mounted on a test stand with a clamp. I already have my brain in gear and a rest of the turbine is already taking shape. The results speak for themselves, you can see that the blades catch even the slightest breeze. I may even put my VAWT build on hold for now to work on this turbine as I think it has more potential to get me to the goal of charging batteries for an electric bike project sooner than the VAWT. I will be continuing work on the turbine and once I have the various stages finished I shall post the Instructables. Thanks for looking and I hope this gives you some ideas for your own projects. Andy.

Image Notes 1. What remains of the first washing machine i junked.

step 1: Marking the pipe

The first thing was to mark out the pipe. I first used a length of angle iron to mark a line along the pipe, by using angle iron you get a perfect line and all your lines will be parallel. Once the first line was marked i measured the circumference of the pipe and devide it by 3 to give the spacing for the other lines. I marked the distance on the back of the tape measure so i could wrap the tape around the pipe for a more accurate mark. Once you have the equal distances marked use the angle to mark a lines.

http://www.instructables.com/id/PVC-pipe-blades-and-rotor-for-HAWT-from-scrap/

Image Notes 1. I made a Thundercats decal with a craftrobo. It was perfect fit for the tape measure and I said what the hell. Panthor must have used a tape measure when he built all those inventions of his

Image Notes 1. I used a length of angle iron to mark a straight line on the side of the pipe. 2. Lengths of angle iron like this are to good to be left lying in a skip at the recycle yard, always ask before you remove stuff or you may get asked to leave.

step 2: Cutting
Once the pipe was marked out i clamped it to the bead of my wood lathe for cutting. I used a jigsaw to make split the pipe into the 3 segments. each segment would make 2 blades so i would have 6 blades from this pipe. Once the first cut is made rotate the pipe and clamp again, after the second cut a segment will be removed from the pipe. The pie then was able to be pushed down onto the lathe bead where it sat nice and steady for the final cut.

Image Notes 1. The bed of the lathe is perfect for holding the pipe steady during cutting

Image Notes 1. The first cut finished.

http://www.instructables.com/id/PVC-pipe-blades-and-rotor-for-HAWT-from-scrap/

2. the pipe is clamped to the lathe bed here.

Image Notes 1. With the first segment removed the pipe sits over the lathe bed perfectly for the final cut.

Image Notes 1. Ready to be marked out and cut into blades.

step 3: marking and cutting the segments.

I marked each of the segments 1 1/2" in at each end and used a chalk line to mark a line along the segment. the chalk line did not show up to good so I used a sharpie marker to redraw the line before cutting. I was able to use the bandsaw for cutting the segments.

http://www.instructables.com/id/PVC-pipe-blades-and-rotor-for-HAWT-from-scrap/

step 4: sanding and finishing.

Once the segments where all cut i picked the 3 blades that where the best looking of the bunch. I sanded the blades on the sanding table and removes any fine burs with wire wool to give a smooth edges.

http://www.instructables.com/id/PVC-pipe-blades-and-rotor-for-HAWT-from-scrap/

step 5: The rotor.

The rotor came from a washing machine drum and is attached to the drum with press in rivets. to remove these either split the aluminum tube the rivet is pressed into or grind the top flat and center punch it and drill the rivet out. I marked the holes on each arm 75mm center to center and drilled with a 6mm drill bit.

Image Notes 1. The perfect rotor for a wind turbine. 2. This shaft is has an internal thread so i can attach a generator easily.

Image Notes 1. 75mm center to center.

step 6: The bearings.

The bearing casing is moulded into the plastic drum of the washing machine and need to be cut free. you can either smash the tub up or cut it out if you have a use for the rest of the tub. To remove the bearing case from the tub I used a angle grinder to cut into the segments on the base of the tub, I also did the same on the inside of the tub too. I then used a a hand axe to hack out the bearing case but not totally destroy the tub, I plan to use the remainder of the tub to make some kind of planter.

http://www.instructables.com/id/PVC-pipe-blades-and-rotor-for-HAWT-from-scrap/

Image Notes 1. The bearings removed neatly enough as to keep the tub intact. I have pans to use the rest of this tub to make a planter.

Image Notes 1. I used a wood chisel and mallet to remove the rest of the plastic from the bearing casing.

step 7: Attach the blades and add the bearing cage.

I clamped the blades in position on each arm and drilled the blade for the outermost holes first. Once all 3 blades where attached I lined up the first blade and drilled the hole for the second bolt. i then used the the tape measure to make sure the tips of the blades where at equal distances. Once all the blades where set i drilled the rest of the holes and bolted the blades on to the rotor. I was now able to test the rotor to see if the blades worked. They worked very well, so well that I decided It would be much safer mounted on a test stand than me just holding the bearing casing. The blades will need some sanding here and there to make them perfectly balanced, I will do this in the tweaking stage before I mount the turbine on a pole. I hope you like my idea for a scrappy solution to the problem of making a rotor for a wind turbine.

http://www.instructables.com/id/PVC-pipe-blades-and-rotor-for-HAWT-from-scrap/

Image Notes 1. What remains of the first washing machine i junked.

Image Notes 1. Drill this hole first 2. drill these holes once you have the tips of the blade at equal distances.

Related Instructables

Horizontal Double Helix Wind Turbine by Ultra Computers

Build a wind turbine (incomplete) by IW5 Industries

Model Wind Turbine :: KidWind Project by kidwindrob

How I built an electricity producing wind turbine by mdavis19

7 Foot Axial Flux Wind Turbine by brokengun

wind turbine (slideshow) by riyazuddin

Building a Vertical Axis Wind Turbine ( VAWT ) by rikkiesix

How to Build a Wind Power Generator (video) by doctorgig

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Comments
20 comments Add Comment

dezertdude says:
wouldn't you mount the hub on the motor / generator shaft and not on a bearing?

Jul 30, 2010. 10:38 PM REPLY

Dr Qui says:

Jul 31, 2010. 8:03 AM REPLY The end of the shaft has an internal thread, so the magnet rotor can be bolted on to the shaft, I most likely will go with a home made alternator for this build.

http://www.instructables.com/id/PVC-pipe-blades-and-rotor-for-HAWT-from-scrap/

MechEngineerMike says:

Aug 5, 2010. 7:14 AM REPLY a homemade alternator sounds like a nightmare project to me, perhaps you could find an old vacuum or drill motor you could use instead?

reukpower says:

Jul 31, 2010. 12:12 AM REPLY It helps save the generator bearings from premature death, especially if they are not designed to take the kind of forces a windmill might put on them.

MechEngineerMike says:

Aug 5, 2010. 7:14 AM REPLY i really like the idea of the PVC pipe for the blades, that was the most complicated part in my mind. Other than that, it looks like it cold eventually become a very aesthetically pleasing work! Also note worthy, the higher up your wind-turbine is, the more power it can produce, (at an increasingly increasing rate!)

discontinuuity says:
That's really HAWT

Jul 31, 2010. 3:46 PM REPLY

Dr Qui says:
Indeed I do hope so. I will be working on how to mount it etc over the next week or so all being well.

Aug 1, 2010. 7:18 PM REPLY

paracord-projects says:
Excellent, you are full of surprises. Keep up the GREAT work :-)

Jul 31, 2010. 3:47 PM REPLY

Dr Qui says:

Aug 1, 2010. 7:13 PM REPLY I was the one who was surprised when I pulled the drum out of the plastic tub and saw the aluminium molding complete with shaft and bearings. Its was like "hang on a minute, why has no one done this before?" One of those I have to do this moments. A word of caution, If you build one test it on a stand, don't hold the bearing above your head and face into the wind like I did, It got real scary after about 10 seconds when a gust of wind hit and the blades started to make that chopping sound.

eric809327 says:
I love how you put it on top of your stove made from the same washing machine.

Jul 31, 2010. 9:45 PM REPLY

Dr Qui says:
Nah, that was a different machine, you can see the rusted wreckage from it in the picture.

Aug 1, 2010. 6:52 AM REPLY

lemonie says:
Nice cutting on the blades. L

Jul 31, 2010. 11:37 AM REPLY

Dr Qui says:
Cheers,

Jul 31, 2010. 5:00 PM REPLY

So much science went into the process... it took hours to work out the formulas. and if you believe that you will believe anything. lol Just seemed to be the logical thing to do with what I had at hand The process was so scientific that the blades spun the opposite way than I thought they would. .

pleabargain says:
Please post updates when you get it connected to a generator under load! Very clever reuse of 'garbage'!

Jul 31, 2010. 1:49 AM REPLY

Dr Qui says:

Jul 31, 2010. 8:19 AM REPLY I will do an Instructable on how I build the rest of the turbine. and maybe one on building a flux type generator too. Dont worry any projects I do will be documented and posted. This Instructable was posted just to show others that you could use this washing machine part for building a turbine.

http://www.instructables.com/id/PVC-pipe-blades-and-rotor-for-HAWT-from-scrap/

bobby sissom says:

Jul 30, 2010. 6:53 PM REPLY as usual you ideas rock the rest of the instructable world benefits greatly from your shared wisdom please keep up the good work...you might like to know you are also the first person i have ever subscribed to ...just a fyi

Dr Qui says:
Cheers,

Jul 30, 2010. 7:42 PM REPLY

I'm just trying to build things as simply as possible, why build a complicated system if there is a ready made part in some junk product. The rest of the turbine will be nice and scrappy but is as simple as it gets and uses stuff you will see being junked. The goal on this one is to bring the build in at almost no cost

thirst4know says:
Great! Save the "trash" from the land fill!

Jul 30, 2010. 6:32 PM REPLY

rimar2000 says:

Jul 30, 2010. 4:59 PM REPLY Congratulations, you've squeezed the juice out of that old washing machine!! Now that's recycling! I guess you have not thrown away the plastic/metal filings ...

Dr Qui says:
Thanks,

Jul 30, 2010. 5:05 PM REPLY

'm not finished yet, I have plans for the plastic tub as a planter. I will also be using the metal case for the tail of my wind turbine. I am trying my best to recycle as much as possible from the machine. I draw the line at saving metal filings. lol My smelting phase has yet to come but ideas are already forming.

http://www.instructables.com/id/PVC-pipe-blades-and-rotor-for-HAWT-from-scrap/