First, I wanted the device to run self-contained, outdoors, for a week. Second, I wanted it to be able to record very small gusts of wind, several of the designs here required rather strong winds to get going. Lastly, I wanted to record the data.
I decided to go for a really lightweight rotor design with as little inertia and resistance as possible. To accomplish this, I used all plastic parts (including threaded vinyl rods), ball bearing linkages, and optical sensors. Other designs used magnetic sensors or actual DC motors, but both of those slow the rotor down, optics use a little more power but offer no mechanical resistance.
The data logger is simply an Atmega328P with an 8 mbit flash chip. I thought about going SD, but I wanted to keep the cost, power consumption, and complexity low. I wrote a simple program that logged two-byte rotation counts every second. With 8 megabits I figured I could collect about a week's worth of data. In my original design, I figured I would need 4 C cells, but after a week they were still fully charged so I must have been off by an order of magnitude in the power consumption. I didn't use linear regulators, I drove all voltage rails to 6V (even though some of the parts were rated 3.3V. Yay overdesign!).
To download the data, I had a complex system that read the flash and dumped it to the arduino serial monitor, and I cut and pasted into Excel. I didn't spend time trying to figure out how to write a command line USB app to dump the flash to standard out, but at some point I will need to figure this out.
The result was rather surprising, I was able to observe some very interesting trends, which I am saving for another report.
Step 1: Build the Rotor
I tried a few different shaft lengths, small, medium and large (about 1" to about 6") and found that the larger sizes torqued too much and didn't respond well to low wind speeds, so I went with the small size shafts. Since everything was clear plastic, I made a handy little printout to help alight the three blades.
The ornaments came from the Oriental Trading Company, item "48/6300 DYO CLEAR ORNAMENT", $6 plus $3 shipping. The plastic shafts and the structural disk came from a local TAP Plastics store, about $4 more in parts.
Step 2: Build the Upper Base
I planned to attach an optical sensor to the bottom of the shaft, so I mounted the CPVC coupling into a larger base. Home Depot is a fun place to mix and match CPVC/PVC fittings. Ultimately I was able to stuff the 3/4" threaded CPVC coupling into a PVC 3/4" to 1-1/2" reducer. It took a lot of playing around to make everything fit, but it left enough room for electronics.
98743A235 -- Black Threaded Nylon Rod (5/16"-18 thread)
94900A030 -- Black Nylon Hex Nuts (5/16"-18 thread)
Cheap skateboard bearings
3/4" threaded CPVC adapter
3/4" to 1-1/2" PVC reducer to threaded 3/4" pipe
Note: PVC and CPVC coupling dimensions are not the same, probably to prevent accidental misuse; so swapping in a plain PVC 3/4" regular adapter won't work, however, the THREADS of a threaded adapter are the same, which is totally weird. The CPVC coupling threads into the PVC adapter bushing. Adapter... bushing... coupling... I'm probably mixing up all of these terms, but 15 minutes in the Home Depot plumbing aisle will set you straight.
Step 3: Optical Interrupter
I glued the painted cup to a nut and fastened it to the end of the shaft.
Chair leg protector cup thing from the Home Depot
Step 4: Attach the Rotor!
Step 5: Build the Lower Base
I used a PVC mate to the upper PVC bushing. This lower base mate is just a threaded 1-1/2" PVC coupling. The upper rotor base pressure fits into the lower base via this coupling. As you'll see later, I didn't glue these pieces together because I wanted to be able to open it up and make adjustments if necessary, plus the assembly is easier when attaching the circuit boards.
Waterproof box from Polycase, item # WP-23F, $12.50
Threaded 1-1/2" PVC coupling
Step 6: Build the Optical Sensor
The idea is that this circuit mounts underneath the rotor cup, which interrupts the beam as it turns, generating logical transitions for each edge. I don't have a good picture of how this was mounted. I basically glued two plastic offsets into the lower base PVC coupling, and screwed it into them from above. I had to grind down the edges of the board to make it fit neatly.
I don't even have a schematic for this, it is really easy: just run a 1k resistor from Vin and wire it up so that the LED Is always on and the output of the detector is on its on pin.
1 940nm LED
1 OPTEK OPL550 sensor
1 three-pin plug (female)
1 1.5"x1.5" circuit board
Various lengths of wire
Heat-shrink tubing if you like your wires bundled
Step 7: Build the Data Logger
The Arduino prototyping board was way to big to fit into the chassis. I used EagleCAD to lay out a smaller circuit board, and lost pulled off a single layer ... there are four ugly wires I needed to bridge a few gaps.
(I thought I measured this at ~50mW operating power, and based on the Watt-Hours of the batteries, I thought i would drop below 5V in a week, but either my power measurement or my math was wrong because 4 C-cells kept going for a long time.)
Fairly straightforward layout: just a resonator, the ATmega328, a flash chip, a debug jumper, a debug LED, power supply cap, and that's about it. There's something called DorkBoard which I could have used too, it's basically everything needed for an ATMega328 dev board in the size of DIP socket. I considered buying one but my discrete approach was about 50% cheaper. Here is the dorkboard link: http://dorkbotpdx.org/dorkboard_assembly_tutorial
Here's the basic idea (source code will be included later on) how the board operates:
Jumper set to "debug" mode: attach a change-value interrupt to the optical sensor output, and flash the test LED in unison with the detector. This was very helpful for debugging.
Jumper set to "record" mode: attach the same interrupt to a counter, and in the main loop, delay 1000 msec. At the end of the 1000 msec, write the # of edge counts to a 256-byte flash page, and when the page is full, write it out and reset the count.
Simple, right? Pretty much. I really like the Winbond flash devices, I used to design flash back in the 90's, so it was fun to program them again. The SPI interface is brilliant. So simple to use. I'll let the schematics and source code speak for themselves.
Did I mention EagleCAD is awesome? It really is. There are some great tutorials on YouTube.
Step 8: Attach the Electronics
Step 9: Calibration
Yes, that is a 2x4. I attached the anemometer to one end, and a debug Arduio to the other. The LCD displayed the rotor counts.
The process went like this:
1) Find a long straight road with no traffic.
2) Hold the 2x4 so that it pokes as far out the window as possible
3) Turn on voice recording on your iPhone or Android
4) Turn on a digital GPS speedometer on your handheld device of choice
5) Drive steadily at several speeds and announce to your recorder the speed and average rotor counts
6) Don't crash
8) Later on, when not driving, replay your phone message and enter the data into excel and hope a linear or an exponential or a polynomial fits with an R-squared value greater than 99%
This conversion # will be used later on. The device only captures raw data, I post-processed it to MPH (or KPH) in Excel.
(Did I mention I applied a badass coat of olive drab paint? I would have called this a "Tactical Data Logging Anemometer", but then I remembered that "Tactical" means "black".)
Step 10: Go Collect Some Wind Data!
That's pretty much it. I think a few pictures are missing, e.g. not shown are the four C-cells crammed into the lower base. I couldn't fit a spring-loaded holder so I ended up soldering leads to the batteries themselves. I'm writing this instructable a year after I built it, and in revision #2, I used AA batteries because I grossly overestimated the power consumption. Using AA allowed me to add an on-off switch and really freed up some space inside, otherwise it was pretty tight.
In all I was pretty satisfied with the design.
The graph below shows one week's worth of averaged data. The batteries started to die on day seven. I could have improved battery life by running the LED at a lower duty cycle at about 1kHz and I wouldn't have lost any edges due to the comparatively low the angular velocity of the rotor.
Have fun! Let me know if you see any room for improvement!
Step 11: Source Code
Attached is a single Arduino source file. I GPL'd it because, hey, GPL.
EDIT: I'd like to point out that my implementation of using a 1s delay() is a terrible idea! The amount of time required to write to the flash and read the sensor may seem small, but over the course of 7-10s it adds up to some significant drift. Instead, use 1Hz timer interrupt (Timer #1 on the 328P can be calibrated to 1Hz perfectly). To be safe you should code in a fence in case the page write & sensor read for some reason takes longer than 1 second (handle dropped samples), but a timer interrupt is THE way to do stuff that needs to be, well, time-accurate. Cheers!