so i am taking that chllange to create my own style of Savonius wind generator.
in this Instructable i will include the steps that will achieve my Faroun Savonius Wind Mill.
the size over all will be approx 6 feet high and 2.5 feet wide
split into 3 main steps and each main step will split into mini steps.
Note:: that the sound that you hear in the movie is the leaf blower that is producing air to turn the wind turbine.
3 main steps are:
-Turbine assembly =TA
-Cage assembly =CA
*top, bottom and sides frame
*mount on a fixed roof or tower
-generator and battery assembly =GBA
*Rectifiers and battery connection
sure things may change a bit along the way but you will be the first to know.
bellow is the semi-final product for Faroun Savonius
so lets start.
Step 1: Turbine Assembly / Blades
in my Project i decided to use Aluminum for Material but u can use steel, Puck Board, or even a simple 5gal pale cut into 2 or 45gal drum cut into 2, so many options you have for the blades.
the size for my blade is 12.5 width, 6.25 depth, .125"thick, 20" circumference and 18" high.
i did not cut or roll the blades i bought them that way, yes i am lazy..lol... i was going to do it with 5gal pale cut into 2 but i figured i want to spend a bit of money just to see the max i can get.
so i have 9 blades, 3 in each section. each blade takes a third of the disc area. so each 3 blades sandwiched between 2 discs (discs are my step2).
Step 2: Turbine Assembly / Discs
mine are made of Aluminum and you can use steel wood plexglass and all kinds of options, it all depends on what metarial are the blades so you can match to disc.
the size is 24" in dia. and .25" thick with 1 inch hole in the centre for the shaft (step3 will talk about shaft).
we need 4 discs nice and round with not to much "wabole" in them.
Step 3: Turbine Assembly / Shaft and Bearings
for a shaft you can use other than solid steel, you can use plumung pipe, that you find any where, wood also but the the best choice and so on...
i hope so far i am clear with my instructions.
Step 4: Turbine Assembly / Howto Put Together
i welded the blades insted of using angle brakets to hold them to disc, but you can use weld,steel brackets, wood brackets or grouve and glue them to disc and so on...
so after mounting the blades to discs into 3 sections and each section has 3 blades offset on top of each other by 60 degree, i then inserted the shaft into the center and adjusted for my setup distance, 4" away from bottom and the rest of the room left on top fpr my generator(later step).
after the shaft is in the desired spot i then used the pluming flange to fix the shaft to the blades.
I then placed the Bearings at the end of each end and voila it is assembled.
you noticed that it is in the cage (we will talk about the cage in aNOTHER STEP)
i dont think i miised anything.
Step 5: Cage Assembly/ Frame
bottom base is holding the bottom of shaft.
the top is holding the top of the shaft also in the future
it will hold the coils(in a later step)
the walls are assambled in a way that half of the turbine is showing
to mount the wind deflection(in next step).
the cage is simple, the trick is to keep it square and croocked.
Step 6: Cage Assembly/ Wind Deflection
i simply biult the cage and then covered half the turbine where the blades are comming backwards, the reson to cover them is to eleminate the drage that the back of the blade create, also i am in the middle of adjusting the deflection method to be more productive in tunneling the wind twards the desiered area.
take a look at the rendering that i have created.
Step 7: Generator
i have 3 ideas, one is to pully a pm alternator to shaft, 2nd is to mount the pm alternator to the disc diameter using v belt or timming belt, 3rd is to make my own generator using the top aluminum disc to hold the neo magnets and be the Rotor and place another disc on top facing the magnets and on it will be the Coils and that will be the Stator
Step 8: Generator/ Alternator
i am trying the alternator using the disc itself,
i placed a timming belt to the diameter of disc using strong epoxy glue.
and then i mounted the pm alternator to the edge of the belt spring loaded to it. very simple no pully and it is 10 to 1 ratio.
it works but i need over 10MPH wind to make it worth while.
there are many other options for already made dc generator out there at this stage you can choose your generator and mount it and see what you get. otherwise you will have to move to the next step witch is custom PMG, it is in the testing stages and there is no one like it so i am going to waste few dollars figuring the coil out.
Step 9: Generator/ Neo Earth Magnets and Coils
the plan is to place 24 n50 2"x1"x.5" magnets on the top disc and 21 20 AWG 150 winds coils on bottom of another disc that faces the magnets.
i am planing to sptill the coil output into 2 feeds, again it is in the testing mode and if you have anything to add now is the time to do it.
my hope that i can make 500 watts.
some said i will get more and others said less.
testing is fun.
Step 10: Coil Winding
-20AWG magnet wire
i made my coil winder from a simple plan, i included a video to show what it is.
it took a good 4 hours to wind 18 X 150 winds. it is a hard job but not as bad as the placment of magnets....wow..
3 phase connection as per the STAR connection diagram.
Step 11: Magnet PLacement
it took me 2 days to place 24 mags on the disk, some said if it was steel disck it would have been esier.
anyway, i used GB weld to glue them down and then i put 2 part epoxy all arround for extra hold. and later in the project i will cover them HALF way in bostik or resin.
Step 12: Faroun-3-phase-coil-test-20awg-150-winds
thanks T for the help you are providing, i am a slow student.
Step 13: Faroun-3-phase-coil-test-20awg-50-winds-Final
i decided to lay the coils, all 3 Phases conected and rectified produced 20volts dc at 60RPM 5mph wind
-16 N42mags 2 discs
-50winds per coil .125 thick very thin
-3 phase STAR configuration
-rectifed to dc using 2 bridge rectifires
-.2" gap in bettween the magnets an dthe coils.
-spining at 60RPM 5mph wind(using floor)
-produced 20volts DC
you are going to relize that my coils are very thin, but in order for me to get the mags close together i had to thin the coils to improove the flux passing through the coils,
the mags are only .5" far from each other and between them the sitt the coils.
you will see in the movie that i am getting 50 watts at 100 rpm again i had to rev it up to get the power cause i have no wind where i have it, any way with all my calculation., i am confidet to say it can get 200watt at 20mph wind.
note:maybe my calculation are a bit low but my expectaions are also low.
i am going to go back and use a treadmill dc motor because it did give me more power. I hope next step i will show the dc motor and who it works.
and place it outside in the real world. (outside will be in the next steps)
Step 14: PM DC Motor Generator Mount
i simplified 2 ways as you will see in the photos and the movie.
one way is to use a V belt with 5 to 1 pullies.
the other way is to get timming belt and a wooden disk 3/4" and place portion of the belt arround the cirunfrence glued on, place it on the turbine and the smaller pully that you can get at the junk yad too mount it to the dc motor, you will see in the pics and movie what i meam.
i liked the timming belt better it was less drag and qiuter.
they both produced about 12.25 volts at 80 rmp witch is i am assuming 10mph wind. i know i know soon i will be taking the beast outside, finally sring is here and the snow is gone i hope for few month...lol..