Introduction: DIY 1000 Watt Wind Turbine

Picture of 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.

Update: DIY Amp Hour meter for monitoring charge!

All about homebrew wind and offgrid power systems, the complete reference!

Step 1: Build the Magnet Disks

Picture of 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.

Step 2: Build the Coil Disk

Picture of 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 (magnet) wire for 12 volts. Use 70 turns of single strand for 24 volts. # 3 phase diagram shown here shows 3 stator coils. each of those coils is actually 3 coils in series. coils 1,4, and 7 are series together, 2,5, and 8 are series together, and 3,6, and 9 are series together.

more details, see the following page 15 for the series star, 1-y diagram.

http://groups.yahoo.com/neo/groups/axialflux/files

AXIAL_FLUX_HowItWorks.pdf

Step 3: Build the Bearing Assembly

Picture of 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: Further Reading

Comments

AlexK212 (author)2017-07-24

Hello greetings

How do you control the battery charge

What device do you use to control the load

I would like to know the characteristics of the device for the charge control of 1000 watts

thanks for your attention

sspence (author)AlexK2122017-07-25

We use a diversion control. Basically, when the batteries hit a certain voltage, a load is attached, like water heating elements. The reason this is done is that if you were to disconnect the wind turbine, like you do with solar, it would self destruct.

DaceL2 (author)2017-12-14

green-trust.org appears to have been hacked

sspence (author)DaceL22017-12-15

not hacked. expired. it's gone.

RenatoS21 (author)2017-11-24

nice very helpful

01010011 01101001 (author)2017-11-14

Please Advise

Would you please provide the details of the coils individual weight and internal measurement or point me in the right direction?

Many thanks for creating this particular instructables.

Kind Regards Si

01010011 01101001 (author)2017-11-14

Please Advise

Would you please provide the details of the coils internal measurement or point me in the right direction?

Many thanks for creating this particular instructables.

Kind Gegards

ictinc (author)2017-11-07

Respect!!! I've come across this project many times. Now that I've finally decided to built my own windmill, I want mine based on this one.

I do however have some questions.

I would like my generator to output 230 volts AC with a minimum of 1000 watts. How would I need to change the windings on the coils to do so? Also, would there be any disadvantages by changing the output voltage to 230v AC?

The reason I would like the higher output is because I eventually want to connect it to the grid. I also don't like the hassle and expenses of charging batteries.

My actual design of the windmill would largely be the same, however I would like to try to attach the magnets to the tips of the blades instead of in the center.

sspence (author)ictinc2017-11-08

Outputting grid voltage means a synchronous design (fixed rpm / Hz), far beyond the goals and parameters of this design. magnets on the tips? you would need hundreds of tips and coils .....

RenatoS21 (author)2017-10-20

sir i think this kind of wind power can solve my problem i was amazed i am from philippines and i want to have complete kind of assembly please help me to build please i need very badly

trungl23 (author)2017-10-13

VERY GOOD


ahmedebeed555 made it! (author)2017-09-22

This instructable has always been an inspiration for me. Thank for sharing. I made this one from recycled stuff. Keep going good work.

https://www.instructables.com/id/TurbineOne-V2-Sup...

mostafaedrees95 (author)2017-09-12

Hi, I'm working on a graduation project exactly just Like the one you're working on, my project also has 1000 Watts output,

My point is I want u to help me by giving me a detailed report about the design and everything you used such as the Resistances and the wires
To help me on my project

my gmail : mostafaedrees95

Mostafaedrees2017 (author)2017-09-04

Hi, I'm working on a graduation project exactly just Like the one you're working on, my project also has 1000 Watts output,
My point is I want u to help me by giving me a detailed report about the design and everything you used such as the Resistances and the wires
To help me on my project

danijelg1 (author)2017-08-25

Hello,

You said that you made 2 parallel windings. What is benefit of it as compared of windings made of single wire?

Thank you for great tutorial

sspence (author)danijelg12017-08-25

Two smaller awg wires are easier to wind than one thicker one.

MuraliK37 (author)2017-08-03

Hi SS
If v rotate long time magnets will loss magnetism bcz of heat and no power develop ,wht shell v do,to gain loss magnetism for magnets

sspence (author)MuraliK372017-08-03

Don't let them overheat, and they won't lose magnetism.

ajayt7 (author)2017-07-05

Great project. Thank you for posting. If I may ask, can this same generator you built be used for A VAWT?

sspence (author)ajayt72017-07-06

It could, but VAWT's are so disappointing.

creektilghmank45 (author)2017-07-03

Go to inplix page if you'd like to know how to build it. Great solutions for everyone I think

Thanks for advice

Tonyobj (author)2017-06-26

Great job @SSpencer. I'm new on this platform but my project is very much in line with this. I need to know how to build different capacities from 1KW to 1MW (if possible) wind turbines for home/estate/industrial use. Simple solutions for everyday use.

mikecustalow (author)2017-06-17

Hey there! This is an awesome guide and I was wondering if I could use it as a reference on a site that I'm building? I would give proper attribution and provide links of course.

steele899 (author)2017-06-16

That's great but how do you hook up this electrical generator to AC circuit for powering domestic appliances?

sspence (author)steele8992017-06-16

Thank you for asking. This unit is designed for off grid applications, and uses a battery bank and inverter to make 120/240vac.

steele899 (author)sspence2017-06-16

I see. That's impressive work you're doing. Keep it up.

Poutsokavlis (author)2017-06-09

On magnet disks shown some kind of overheat under each magnet, can you tell me what is that?

sspence (author)Poutsokavlis2017-06-09

overheat? the magnets are held in place by superglue and epoxy.

MikeD50 (author)2016-10-13

Good job on the generator!

Could you elaborate a bit on the mechanics, e.g. how turbine rotates around vertical axis, are you taking any measures against cable twist, are you offsetting your turbine in strong wind in any way (mechanically or other)?

Thanks MIke

sspence (author)MikeD502016-10-13

I'm using harley wheel bearing on the vertical part. I manually untwist on occasion, but it hasn't been a big issue. there is an offset tail to point the turbine into the wind,and turn it out of the wind in winds above 30 mph. All that was beyond the scope of this instructable, but is documented in Dan Fink and Dan Bartmann's book.

John SeverinF (author)sspence2017-04-23

Slipring

MikeD50 (author)sspence2016-10-13

Thank you for the explanations and pointers ... good harvest ;-)

frisbrob (author)2017-04-14

Have a question? How do you run several wind generators at the same time to feed one battery bank without the charge controllers canceling each other out or can you run several generators in series some how and go through the one controller? I do not see how anybody goes off grid and runs their whole home using just one wind generator, even this 1000 w PMA will not put 1000 watts out unless the wind is blowing hard and constant all the time running it at full speed. It probably will only put out around 150- 350 watts bouncing up and down as the wind speed changes all day long. Can't keep a battery bank charged up and run your home on that little bit of power. Just wondering.

AlexK212 (author)2017-04-09

query

Each coil produces 4 volts

3 per phase connected in series give the 12 volts

it is right

anorris5 (author)2017-01-07

Hi nice project and impressed you made it all yourself. Was wondering would it be any easier and/or more cost effective to use a bike wheel motor? I can get a 1000w version for £150 in the UK. You say this project costs $1000 - $1500. How much of the time / cost is spent on the motor?

JohnS1343 (author)anorris52017-01-18

I was wondering the exact same thing too. Usually DIY (and especially non machined) things like this are extremely inefficient compared to a pre-made ones. I'd be very surprised if he got anywhere near 1000w. Does he list any electrical figures anywhere?

AFAIK you are better off getting a slower but more bulky generator rather than a small one that spins too easily and fast. So a bike one would not be the best.

anorris5 (author)JohnS13432017-03-02

I have seen a commercial wind turbine that uses bike motors and claims to be very efficient. Cost about £1000 and made 1000w watt max.

I have read that such motors are ideal for the job. No time to find links. Google it my friend.

Not sure about his home made one being inefficient. It looks good to me. It's only magnets and coils. Select quality ones. The bearings will only add a very small amount of extra drag, even low quality ones. My main issue with making your own is the effort and it's not much cheaper. Fun to make your own though if you like doing that. We are always going to depend on industry others to make the wires and magnets!

DanM6 (author)JohnS13432017-03-01

you be-d wrong!... this can put rated watts out easily & can be MORE affordable & can last for years!. Do the research! Why are you wasting time on Inscrutable just go buy one!

anorris5 (author)JohnS13432017-01-19

Hi John. Google it. Apparently they are perfect for the job. There's even some commercial home wind turbines using them that give 1000w in good wind.

Maybe sspence is not interested for other reasons, IDK, maybe it's more green if you make it entirely yourself. Nice work though designing and building it all yourself, must be pretty satisfying.

JohnS1343 (author)anorris52017-01-19

Interesting. Any chance you could link the £150 / 1000w one you meantion? Thanks.

sspence (author)anorris52017-01-07

About half was spent on the alternator, the other half on the tower. I'm not interested in bike wheel motors.

anorris5 (author)sspence2017-01-07

Thanks for the info. Half/half makes sense. I guess you must find it more interesting to make it all yourself? I have heard the bike wheel motors are perfect for the job. I will do some more research. Have a nice day.

8baller (author)2017-02-28

Yes for sure not enough info to bad looks like a fun build

MuraliK37 (author)2017-02-11

Hi SS
Which grade magnet is better N-32;50;52

sspence (author)MuraliK372017-02-24

52 is stronger.

Fred_tone (author)2017-02-19

"Is our Children Learning?"(infamous quote from G.Bush) I realize that many of the readers here may not have access to friends or library but those that DO have access; go to the library, take a friend or family member/neighbour that has attended a high school or college physics class or has professional experience. At the library, ask the librarian for books on basic electricity and magnetism. The principles outlined there may help you, with help from your partner, understand what is going on with the DIY generator and help you with other projects not to mention the realization that the public library is good for stuff besides free internet ...and you could even bring your new found understanding back here !

MuraliK37 (author)2016-12-21

Height of coil can increase magnet height.

sspence (author)MuraliK372016-12-22

coil height (depth) has nothing to do with magnet height. only the gap between the magnet and the coil is important. keep is as small as possible without interference. a 1" wide x 2" long x 1/2" deep magnet needs a coil that has a 1" x 2" whole in the center so that it only swipes one side of the coil at a time. The thicker (depth) the coil, the less flux on the further side of the coil. so pack them tight and thin as possible.

MuraliK37 (author)2016-12-20

Inside diameter of coil should be greater or less than magnet,and height of coil can increase mag height.

About This Instructable

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Bio: Professionally, I'm an IT Engineer (Executive Level) and Electronics Tech. I'm a Amateur Radio Operator (KK4HFJ). I lived off grid, with Solar (PV ... More »
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