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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
<p>Hi, I have a question, let's say that I have a turbine that for 30 mph would output maximum 1kw. How does the generator come into the equation? Would it matter if use a 48 magnet generator instead of a 24?</p>
The number of coils, the number of windings, the number and size of the magnets, the size of the wire in the coils, the length of the blades, all determine the power output at a given wind speed.
<p>Thank you for the answer, this is exactly what's puzzling me. If I go online and check power calculators I have to enter the wind speed and the blade length then I can have the maximum power that can be extracted, e.g. for a 15 mph,a 3 ft blade turbine can extract 111W, that's all.</p><p>So for this wind speed and length blade there's no way you can get 200W, 1000W or 5000W no matter how many magnets, coils, windings you use.</p><p>Please correct me if I am wrong, I still live under the impression that the more magnets you add, the more power you get.</p>
<p>You are correct, 3ft blades at 15mph can only produce a maximum of 111w. You need longer blades. Ours are 8-10ft. http://www.green-trust.org/windpowercalc/eindex.html</p>
<p>blimey the magnets in the uk are &pound;14 each x 24 =&pound;336 !</p>
<p>found some on e-bay for &pound;3.49 each</p>
<p> if you took apart a hard drive you find various sizes in something somebody else throws away</p>
But not big enough for a machine this size.
Yes they are pricey. This unit costs over $1000 to build.
<p>I make my own. INPLIX plans helped me a lot</p>
<p>ive been working on something similar and have yet to complete it..i use around 30 or so KW a day...and was looking to figure a way to make free energy with a magnate powered turbine or generator...do you think its plausable to make something like this to power what i use daily?</p>
Well, it's not &quot;free energy&quot; (a mythical device that makes power from nothing), but it's free in the sense that the energy input (fuel) doesn't cost anything. This unit can make anywhere from 0 to 24kWh per day depending on how much wind you have. just add more units to make more power, or make a bigger unit. If used in a hydro generator, it could easily produce 24kWh daily. Magnets don't make power, magnets converter rotary power to electrical power, at a loss.
<p>also was wondering if it would be possible to have the directions sent to my email?!</p>
<p>each magnet has a holding force against mild steel of 40-50kgs, with the two rotors mounted very close to each other I guess the structure has to be real rigid to deal with that force</p>
hence the steel plates and threaded rods.
my project is a 500watt waterwheel. how do you calculate the required magnet strength to produce this output?<br>This project has 24 40-50kg strong magnets. would half this power produce half the electrical output?
<p>Here is a 500 watt design. the magnets are much smaller disk versions - http://www.axflux.us/HBPBAXL412.htm</p>
<p>real quality, shame it's not a DIY design tho, perfect for my application, just have to see if I can justify the cost as this is an experiment I'm undertaking</p>
<p>One magnet N42 of 1&quot; x 2&quot; x .5&quot; size costs how much? approximately ?</p>
What is the size of the magnets
1&quot; x 2&quot; x .5&quot;
<p>What kind of cost can I expect for this project? My mother has been interested in getting some off-grid power setup at her house and I would love to go DIY with the project as money is a concern. </p>
Around $1500 or so depending on where you get your materials, and how much of the work you do yourself.
<p>Where am I able to see the complete instructable of this entire wind turbine project from start to finish?</p>
<p>check utube</p>
<p>check utube</p>
There are many builders who have posted their information in the discussion group, and the files section. Others have posted at otherpower.com. A project like this is difficult to reproduce in this medium, it really takes video or hands on, which is why various groups give hands on classes. It's a very technical project.
<p>Resins are sold in specialized chemical supply stores in my country, and they are far away from my location.<br><br>I'm wondering if I could use <em><strong>other materials for casting the stator</strong></em>. Would it work if I've cast the stator in say mastic of marble putty with hardener, gypsum plaster, or concrete cement.<br>Will that affect magnetic flux intensity between the opposite poles through coils?</p>
Have you tried marine or automotive places? Both use fiberglass and hardeners. Bondo used in body repair could work.
<p>Thank you for the quick reply!</p><p>I'll visit auto body workshops who use fiberglass. but for curiosity, do I need specific electrical properties for the material used for casting the stator ? anything in materials I mentioned may affect the produced power efficiency ?</p>
<p>alll Resins are none conductors fiber glass! only if you put conducting material in it ,but the resin alone is fine.</p>
<p>Make sure there is no metal. other than that, you are good.</p>
<p> Resins are sold in a lot of stores for auto repair Walmart has them.</p>
Love this .. and I really want to make one but not wind mill bycycle based generator can you please tell me how much power it can produce at 500 rpm <br>
It's designed for 650 rpm, you would have to add more windings for a lower rpm. The human body tops out at about 100 watts or so.
<p>nice project! good job!</p>
No way, no how , will that wire generate 1000 watts. I think you misplaced a decimal point.
You would be wrong. It's only 41 amps at 24v. Don't forget, it's 3 phase.
I Read Hugh piggots plans and he quotes 100 watts not 1000.<br>You don't give much information on wind, rpm, etc. Where can I find that information?<br>Am I right in thinking each coil is putting out 24v @15 amps?
<p>This is a bigger unit than Hugh Piggott's. 8' blades, 30 mph wind, 650 rpm</p><p>each coil puts out 8v @ 13 amps. 3 coils in series makes 24v @ 13 amps per phase. </p>
<p>In Power calculations series connected coils will produce 8+8+8 volts= 24 volts but the current will remain at 13 amps. because of phase angle shift, all three phases together will produce 24 volts 13 amps. correct?</p>
<p>Correct. In a star configuration we get a higher voltage, but fewer amps. In a delta configuration we get a lower voltage, but higher amps. This unit produces 41 amps at 24v at full power, not 13 amps as I previously posted. I mistakenly divided the amps by the number of phases. For more details, see http://www.windstuffnow.com/main/3_phase_basics</p>
<p>I've always been a fan of &quot;green energy&quot; however the area I live in does not have optimal wind speeds to make this a viable alternative. I'm aware that the principal has been applied to a human powered device such as a stationary bike with varied outcomes. My question is, could a more efficient manual device to top off batteries be done using some true hillbilly engineering along with the principal of the propeller turbine? If so I'd like to hear any thoughts on it, such as wheel size, wire gauge, etc..</p>
There have been smaller 100-200 watt devices built that would be appropriate for your application. I suggest you join the discussion group, as you will be able to chat with those that have built the smaller units.
<p>This sounds great! </p><p>Too technical for me though...I'm not an educated man so I only understand about 1/3 of what you presented here...if that much.</p><p>Give me a wind mill, a alternator from a semi truck, &amp; I'll my own system a whole lot easier. </p><p>My way of building a wind generator is what I understand &amp; know how to do...I'm not saying this is a bad instructable, just saying I do not understand it.</p>
a alternator from a truck will make a lousy wind turbine. too lossy, and requires too high rpm.
<p>I wish you uploaded the full tutorial here :/</p>
<p>Hey! Did you do the same for magnetic motor generator, or I am wrong. Can't find this project here anymore. Thank you.</p>
Magnetic motor generator? All generators / alternators use magnetism to help generate electricity. Please elucidate.
<p>what is the rpm needed for this generator to make 1.000 watt</p>

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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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