Wind Generator Fabrication Pics

Copyright 2008 by Otherpower.
com
Otherpower.com
Dan Bartmann and Dan Fink

Copyright 2008 by Otherpower.com
Wind is the most difficult energy resource to harvest

Solar, hydro, and fossil
fuel sources give smooth
and steady energy, so
efficient generators for
them are easy to design.

The wind varies wildly
and unpredictably, with
an exponential power
curve.

Power available in the
wind (in watts) =
½ x air density x swept
area x wind speed³
(kg/m³, m², m/s)
The objective: Slow down the wind, and transfer

this energy into a spinning shaft

Wind quantity and quality are
both important

Most winds come to us at low
speeds

Tall towers are essential—you
wouldn't mount a solar panel
in the shade!

Turbulence is also a problem
HAWT vs. VAWT

1kw HAWT 
½ of a VAWTs rotor is moving in
the wrong direction

VAWT blades are also ½ as
efficient as HAWTs

Therefore VAWTs must be 4 times
as large as HAWTs to make the
same energy

VAWTs experience severe cyclical
stresses every rotation
1kw VAWT

VAWTs cannot be yawed out of the
wind to control them

VAWTs are not more quiet than
HAWTs, nor are they safer for birds

VAWTs do NOT perform better near
the ground, on turbulent sites, or in
low winds, than HAWTs—despite
the advertising hype
Comparison of wind turbine rotor design

efficiency and Tip Speed Ratios
Graph source: NREL

No wind turbine power
coefficient (cP) can exceed
the Betz Limit of 59.26%

Drag-based turbines are
very inefficient, suitable
only for grinding grain or
pumping water

High-solidity rotors have a
very high drag component,
and are also not suitable for
producing electricity
Before you try to think 
3-blade, low drag, lift-based
“outside the box,” find out turbines operating at TSRs
what's IN the box and why.
of 5-7 are the most
efficient, and are easiest
and cheapest to build.
Objective: produce electricity

POOR POOR

The lower the shaft RPM, the
heavier and more expensive the
alternator must be

Gearing to increase RPM is
undesirable due to friction,
which hurts low wind
performance
Waterpumper: 
Using electromagnets to
Savonious: Mostly Lift-based but produce magnetic flux hurts low-
drag based VAWT high solidity wind performance
with very low RPM and high drag
give low RPM 
Ferrous coil cores increase
FANTASY magnetic flux, but hurt low-wind
performance by cogging
There are many 
In winds of 7-28 mph that we
reasons this is a
graphic and not an want to capture, turbine RPM of
actual photo! 80-500 is ideal for TSR=5-7 and
therefore maximum cP
Wind turbine alternators


No effective commercial or surplus
products exist:
NO

Vehicle alternators need 1000 RPM plus;
too fast

Servo motors are wired wrong: very
inefficient, with high possibility of burnout
NO

Induction motors and surplus gasoline
generators need constant RPM
The only effective solution:

Build your own low-RPM
alternator.
Just like what all legitimate wind

turbine companies do!
Axial flux air gap alternator


Low RPM, specifically designed for
individual system voltage

Permanent magnets eliminate
parasitic losses from
electromagnets

Large mass of very powerful
magnetic material makes up for
large air gap and no ferrous coil
cores

Start-up cogging losses are
eliminated

Easy to build using standard
vehicle parts and/or flat steel
sheets, even in remote areas

Common in commercial wind
turbine designs
Furling Systems

Wind turbines must cope
with an exponential
increase in power from the
wind to survive

Alternators react to power
input on a mostly linear
curve

Matching the turbine rotor
to the alternator is critical

Reducing the swept area is
the best way to regulate
small wind turbine output

The most reliable, elegant,
easy to fabricate, and
effective solution is the
furling tail
Renewable energy systems


Hybrid solar/wind systems
produce the most energy, in kwh
per month, at most locations

Rated output is overrated

You cannot compare solar and
wind systems by “rated output”

Solar PV rated output assumes
full sun, fairly common

Wind rated output assumes 28
mph wind speeds, very rare

The critical figure is ENERGY
production in watt-hours, not
instantaneous POWER output in
watts. Instantaneous power
output does not matter much—
what matters is for how long you
gained or used it.
Local Manufacture and Training


Local manufacture is possible,
these photos from Bluefields,
Nicaragua, Blue Energy Group NGO

Skills and equipment needed
include welding, metalworking,
electrical wiring, resin casting,
wood carving
Frame Fabrication

Flat steel parts can be cut
with torch or hacksaw

Strong welding is
absolutely essential

Standard trailer bearings
are available worldwide
Stator Fabrication

The stator
must be a
solid resin
casting
Magnet Rotor Fabrication

Again, a
strong
casting is
needed
Blade Carving

Wood--the original
carbon-graphite
composite!

The main
advantage of
fiberglass is in
mass production
Towers

Towers must be both
tall and sturdy

Turbines must fly 30
feet above anything
within 300 feet in any
direction

Tower cost and time
to build it is at least
equal to that of the
turbine itself

Climb or tilt up—
depends on your skill
set and training
Regular Maintenance

A regular, yearly maintenance schedule
is essential with ALL wind turbines, not
just homebrew ones.

Maintenance training is critical with
inexperienced turbine owners

Climate affects the maintenance
schedule of turbines and towers
tremendously

Attention to detail is critical!
The “EVENT CASCADE” is the start of

almost all wind turbine failures.
For example, a $5 rectifier fails from a heat sink

that's too small. The turbine runs single phase,
and the stator overheats. The stator melts and
swells, causing magnets to rub it. Friction heating
brings the magnets past their Curie temperature.
The magnets no longer adhere to the rotors, and
fly out, hitting the blades. You are left with a pile
of junk!
Homebrew wind turbine books

Windpower Workshop
by Hugh Piggott

Axial Flux Wind
Turbine Plans by
Hugh Piggott

Homebrew Wind
Power by us
Wind turbine seminars


Hands-on experience for
educators is essential

Develop your own curriculum
to suit the ultimate location,
no matter how remote

Custom tailor the curriculum
to the skill level of your
students
Wind energy should be:
- Cost effective
- Reliable
- Silent
- Easy to live with
- Fun!

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Wind Generator Fabrication Pics

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Copyright 2008 by Otherpower.

Dan Bartmann and Dan Fink

Wind is the most difficult energy resource to harvest

The objective: Slow down the wind, and transfer

HAWT vs. VAWT

Comparison of wind turbine rotor design

Objective: produce electricity

Wind turbine alternators

The only effective solution:

Just like what all legitimate wind

Axial flux air gap alternator

Renewable energy systems

Local Manufacture and Training

Magnet Rotor Fabrication

The “EVENT CASCADE” is the start of

For example, a $5 rectifier fails from a heat sink

Homebrew wind turbine books

Wind turbine seminars

Wind energy should be:

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