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Picture of Faroun Savonius Wind Turbine
http://www.vawt.tk Alternative energy is a must in the future and all of us would like to challange the idea that we can not change and be efficeint.

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
*blades
*discs
*shaft
*bearings
*assembly howto

-Cage assembly =CA
*top, bottom and sides frame
*wind deflection
*mount on a fixed roof or tower

-generator and battery assembly =GBA
*generator
*Rectifiers and battery connection
*testing

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.

Faroun

 
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Step 1: Turbine Assembly / Blades

Picture of Turbine Assembly / Blades
blade-acuall.jpg
here we will disscuss the blade:
material,Size,shape.

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).

faroun

Step 2: Turbine Assembly / Discs

Picture of Turbine Assembly / Discs
top-disc.jpg
the disc is very simple.

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.

faroun

Step 3: Turbine Assembly / shaft and bearings

Picture of Turbine Assembly / shaft and bearings
falange02.jpg
falange01.jpg
bearing.jpg
i am using 1" steel shaft 80" high mounted bettween 2 ballbearings and attched to the blades with 2 pluming flange.

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.


faroun

Step 4: Turbine Assembly / howto put together

Picture of Turbine Assembly / howto put together
blades-weld01.jpg
full-turbine02.jpg
full-turbine04.jpg
full-turbine03.jpg
well this one goes like this:

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.

faroun

Step 5: Cage Assembly/ Frame

Picture of Cage Assembly/ Frame
top-brase.jpg
bottom-disc-belt.jpg
cage-assembly.jpg
the frame is a box made of 2"x4"

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.

faroun

Step 6: Cage Assembly/ Wind Deflection

Picture of Cage Assembly/ Wind Deflection
full-turbine05.JPG
top-view-layers-1-2-3.jpg
wind-direction-angle-board.jpg
winddirection-curved.jpg
the wind deflection idea has been arround for ever but i did not see it with the Savonius so i dicided to be diffrent and combine my Faroun Savonius with the deflection method.

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.

faroun

Step 7: Generator

this is the tricky part.

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

Picture of Generator/ Alternator
elternator02.jpg
elternator01.jpg
elternator00.jpg
i did not try the pull driven alternator yet.

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.


faroun

Step 9: Generator/ Neo earth Magnets and coils

Picture of Generator/ Neo earth Magnets and coils
magnet-coil-path.jpg
magnet-disc-layout.jpg
this is where you guys met me head to head, all i have for this step are the plans, i am in the mist of buying the Mag and Wire.

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.

faroun "revised:01-19-2008"

Step 10: Coil Winding

Picture of Coil Winding
Jan_12_08 025.jpg
Jan_12_08 026.jpg
Jan_12_08 027.jpg
Jan_12_08 033.jpg
after a long research i decided to go with 150 winds.
-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.

faroun "revised:01-26-2008"

Step 11: Magnet PLacement

Wooow...what a job!! ....that was the most tough thing to do.. with N50 mags...all i can say be carefull and patient.

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.

faroun

Step 12: Faroun-3-phase-coil-test-20awg-150-winds

here you will see each phase tested resistance and voltage i do not have an amp meter.

thanks T for the help you are providing, i am a slow student.

Faroun

Step 13: Faroun-3-phase-coil-test-20awg-50-winds-Final

this step will show the 12 coils and 16 mags alternator testing

i decided to lay the coils, all 3 Phases conected and rectified produced 20volts dc at 60RPM 5mph wind

-12 coils
-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)

Faroun

Step 14: PM DC motor generator mount

in this step i was looking to show the diffrent ways to harnees the winds energy using pm dc motor,

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..

regards
mr thrifty4 years ago
faroun's link is dead.
faroun (author)  mr thrifty4 years ago
if you mean the video link then go to youtube and search for emagnets user

you will find all my video. you should check out my latest "Column turbine"

regards

sam
MY MCAFEE SITE ADVISOR SAYS THE LINK TO "HOW IT WORKS" CONTAINS ADWARE, SPYWARE, OR OTHER BAD SOFTWARE THAT DISTRIBUTES MALWARE
DanFord6 years ago
You say "after much research" i'm trying to make a very similar one, but smaller, and i'm struggling to find any concrete info about size of wire, coils, strenght and numbr of magnets. Could you suggest any sites, or books or anything that would be helpful??? Thanks heaps!
faroun (author)  DanFord6 years ago