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

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.


I have 18 pieces of N50 magnets with the sizes 48mm&times;19mm&times;9.8mm which I want to use in making my homemade wind turbine. But I don't know the amount of power I will get when it is done. <br><br>But I'm sure I will gain experience as time goes on!
I know that every coil has two output wire. So how did you joined three coils with six output wires together to get just one output wire, please?
series, so there are two wires. one comes out of the machine, the other connects to the common of each of the other two series sets.
Thank you very much for your help, please.
<p>Good job on the generator!</p><p>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)?</p><p>Thanks MIke</p>
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.
Thank you for the explanations and pointers ... good harvest ;-)
<p>Do you have a materials list laying around?</p>
<p>Just wonderful. Your whole profile and ideas and ideals.</p>
<p>what kind of resin do you use to cover the stator and rotor?</p>
any fiberglass resin will work.
<p>hi sir please replay all of my 4 question because I am doing this as my college project.</p><p> 1. This my rough diagram arrangement of mag rotor,it is correct or any changes take place.(below)</p><p>2.i want to wind 14# 3parallel wires 35 turns to produce 1500w and how many rpms should rotate to get 1.5kv, can u estimate how many amps can I get.</p><p>3.and it can rotate 24hours, are any damage occurs.</p><p>4.i am buying 12v luminous inverter with 1000w*2batter ,how much time will take full the charging.</p><p>Please reply all of my 4questions because I am doing this as my college project. </p><p> Thanks,.</p>
<p>The request looks a bit wired: &quot;Sir ... answer my questions!&quot; </p><p>As far as I know student projects have to be designed and solved by the students not by asking other people how to solve ;)</p>
<p>thank q ,</p><p> which type of inverter and battery i should use for storing 1500watts</p>
1500 watts is a instantaneous amount of power. Batteries store amp hours or watt hours. Neither has anything to do with an inverter. clarify your question.
<p>Depends on your daily loads, and how much wind you get daily. Aren't they teaching you this in college? It's basic high school physics.</p>
<p>hi sir ,</p><p> i forgot to say we are implementing only your turbine planes,and we are not doing wind turbine (only we are doing magnet coil rotor),</p><p> please answer IF I GET 1500W AND 125AMPS FOR 1HOUR WHICH TYPE OF INVERTER AND BATTERY I SHOULD USE.</p>
<p>You have not specified your loads. What wattage are they, how many hours do they run, how much run time do you need when the alternator isn't running . This is what determines battery and inverter, not the alternator.</p>
1. correct<br>2. 650 rpm, 1500w / 12v = 125 amps, if you have 12' blades at 15mph, or 4' blades at 30 mph.<br>3. 24 hour operation only affects bearing life.<br>4. battery charge time is dependent on how low the batteries get (amp hours out), and the amount of charging available, (amp hours in). With wind, there's no way to forecast your daily ah production, as wind is too variable.
<p>How did you get 24 volts? Those magnets are about .38 teslas, and the coils are about 1 inch by 2 inch, just by my eyeballing it. </p><p>What frequency/rpm do you use as a basis?</p>
24v is based on the number of windings. 650 rpm is the target rpm.
<p>Thanks for the quick reply. Was just trying to do Faraday's Law to get a rough number. Since there are 3 coils in series, do you count it as 70 turns of wire, or as 210 turns? Also, what did you use as the magnet strength, and for the turn area? With a very strong magnet, I still only get 4 or 5 volts. I must be doing something very wrong. Since you stack magnets on each side, is that the same as having (approximately) double magnet strength?</p>
<p>yes, all 3 coils are counted. magnets are N45 minimum. yes, dual magnets double the strength. plus you have 3 phases being rectified into dc.</p>
Hello! I'm interested in building a wind turbine such as the one you made using your instructions for my high school project. I was wondering if this is achievable and not too difficult for someone at my age. Do I have to know a lot about physics or math in order to take on this project?
We did all the math for you, for this size alternator. If you want to make a different size unit, then there will be quite a bit of math. This unit will cost about $1500 or so to make.
<p>How much does is the output per hour.</p>
Depends on the wind, but it's capable of producing 1000 watts (as per the title). For one hour that would be 1 KWh. For 3 hours that would be 3KWh. For 12 hours, that would be 12 KWh, and so on ...
do the magnets all go the same way or alternate polarity?
<p>They alternate.</p>
thanks , also why do you need a rectifier before the charge controller? im just now really getting into this so i know it may be obvious... does the controller not regulate?
<p>The turbine produces ac, not dc. There is no controller between the turbine and the battery bank (controllers typically &quot;shut off&quot; when batteries are full, which would allow dangerous overspeeding.)/ You need a diversion control on the battery bank itself.</p>
<p>hi sir which type of inverter and battery r u using for storage 1000w ,80amps.</p>
Eight Trojan L16's in a 2x4 arrangement, for 800ah @ 24v. Outback 3600 watt 24v inverter.
<p>hi sir i am doing 1.5 kv turbine which winding is better 12v or 24v winding ,and why?</p>
24v winding allows smaller diameter wires in the coil, making it easier to wind the coils. 48v is even better. What voltage is your battery bank?
Would be nice to have more in-depth and complete instructions rather than just a basic overview. Any way to get full detailed instructions? That wouldnt include me to do another 5 hours of research? I'm more interested in the magnet coil generation and how to build it and acquire the parts.
<p>How much would this cost to make? I'm thinking of doing this for my senior project.</p>
$1500 or there abouts.
<p>Thank you</p><p>if the generator is kept constant producing about 800 watts, using an inverter, without using the battery,</p><p>I wonder if you could provide 800 watts to the load used</p><p>without battery</p>
Theoretically, but in practice, loads are rarely constant, and neither is generation.<br>
<p>very friendly and helpful</p><p>Axial Flux buy documents Alternator and Wind Turbine Plans</p><p>that good information and books provided in the same package, very affordable, so you can get valuable and interesting information and practice</p><p>any doubt what consultare</p><p>see you soon</p>
<p>Hello one question</p><p>the coils do not carry any core, the air is nucle</p>
This is an air core design. Reduces cogging.
<p>Is there any way i can see some more photos of the fan? </p>
At <a href="http://green-trust.org/products/" rel="nofollow">http://green-trust.org/products/</a> look for the axial flux wind turbine plans. there's a whole section on blade construction.
<p>can i use any glues</p>

About This Instructable




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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