How I built an electricity producing wind turbine

Several years ago I bought some remote property in Arizona. I am an astronomer and wanted a place to practice my hobby far away from the terrible light pollution found near cities of any real size. I found a great piece of property. The problem is, it's so remote that there is no electric service available. That's not really a problem. No electricity equals no light pollution. However, it would be nice to have at least a little electricity, since so much of life in the 21st century is dependent on it.

One thing I noticed right away about my property is that most of the time, the wind is blowing. Almost from the moment I bought it, I had the idea of putting up a wind turbine and making some electricity, and later adding some solar panels. This is the story of how I did it. Not with an expensive, store-bought turbine, but with a home-built one that cost hardly anything. If you have some fabricating skills and some electronic know-how, you can build one too.

More details on this project and my other alternative energy projects including my home-built solar panels, and my home-built biomass gasifier can be found on my web site.

Step 1: Acquiring a generator

I started by Googling for information on home-built wind turbines. There are a lot of them out there in an amazing variety of designs and complexities. All of them had five things in common though:

1. A generator
2. Blades
3. A mounting that keeps it turned into the wind
4. A tower to get it up into the wind
5. Batteries and an electronic control system

I reduced the project to just five little systems. If attacked one at a time, the project didn't seem too terribly difficult. I decided to start with the generator. My online research showed that a lot of people were building their own generators. That seemed a bit too complicated, at least for a first effort. Others were using surplus permanent magnet DC motors as generators in their projects. This looked like a simpler way to go. So I began looking into what motors were best for the job.

A lot of people seemed to like to use old computer tape drive motors (surplus relics from the days when computers had big reel to reel tape drives). The best apparently are a couple of models of motor made by Ametek. The best motor made by Ametek is a 99 volt DC motor that works great as a generator. Unfortunately, they are almost impossible to locate these days. There are a lot of other Ametek motors around though. A couple of their other models make decent generators and can still be found on places like Ebay. This web site talks about the virtues and vices of various Ametek motors when used as generators. http://www.tlgwindpower.com/ametek.htm

I managed to score one of the good 30 volt Ametek motors off of Ebay for only $26. They don't go that cheap these days. People are catching on to the fact that they make great wind generators. Other brands will work, so don't fret about the price Ameteks are going for. Shop wisely. Anyway, The motor I got was in good shape and worked great. Even just giving the shaft a quick turn with my fingers would light a 12 volt bulb quite brightly. I gave it a real test by chucking it up in my drill press and connecting it to a dummy load. It works great as a generator, putting out easily a couple hundred Watts with this setup. I knew then that if I could make a decent set of blades to drive it, it would produce plenty of power.

There is more information on how to choose a motor for use as a generator on my web site at http://www.mdpub.com/Wind_Turbine/

Comments

[AmateurGus]

Fisrt, I take my hat off, your project is amazing. I'm building one right now, i'm done with the main part of the charge controller. Have 2 questions for you.
1.- What total resistance and wattage should use for dummy load. whats a minimum safe, supposing i'm using a generator just like yours?
2.- i want to connect a wind turbine and 2 solar panels, how many amps should have the blocking diodes to be on the safe side?

Hope you have the the time to answer and i appreciate that you share these things, hopefully we can make this kind of energy affordable for more people (i live in a third world country, buying this stuff new costs a literally a fortune).

[AnAnalyst]

While your charge controller will charge batteries, it has no topping charge circuitry. Because of that, your batteries will not last as long as they could. Given that they are a major expense, it may be worth while to buy a commercial one or add the necessary circuity.

[robb91]

can we buil the wind turbine without the charge controller

[4lifenerdfighter]

That depends. Can we destroy whatever we connecct the turbine to?

[acicalla]

I have a question regarding the 99v ametek motor and charge controllers. So far I have only been able to find charge controllers that accept 12, 24 and 48v dc as input from either a wind turbine or solar panel. So what if anything needs to be done to step down the voltage from 99v to 48v dc to the charge controller? Or do I even need to change anything? Can I just wire the 99v ametek dc output to the 48v charge controller?

[zogworth]

Unless you gear it up, your 99v Ametek will only be producing 30v MAX at wind turbine speeds. A 12v charge controller will handle this easily.,

[aeszok]

Just a quick question, it didn't look to me like you had any sort of battery on there. I don't know a lot about this stuff, but as consistent as the wind is, wouldn't you have issues with not having any power being fed to your laptop and other stuff when the wind isn't blowing? Even with the controller, did it still make lights and things flicker and have periods of no power?
Fantastic instructable though, very in-depth and easy to understand.

[tesladude123]

I have a 180v 4000rpm dc motor from a treadmill.
will this work better?

Thanks.

[MacOSJoey]

Well if you were to do the math, 180/4000=12/266.

Yes. That will make a fantastic wind generator.

Seriously people, the algebra's not that hard.

[tesladude123]

Thanks, I was just in a rush.

[resinpsa1]

do it yourself - http://www.umeluieruki.ru/

[mcronnie]

For an extra power source during calm weather, could you cover the blades/tail in solar panels?? :)

[seraine]

You probably could, but they wouldn't really be worth it. For one thing, most cheap solar panels are flat, which doesn't work for catching the wind. For another, if you put leads on the solar panels, they would become tangled and cut really fast. Also, when they are placed vertically (such as on a blade), they catch sunlight for only a short period of time. In fact, the extra weight on the blades would probably lessen the power produced. You would be much better off by putting them on a flat surface or in a panel.

[TheGreatS]

Here is an easy yes or no question. Will the char controller work for any motor of any voltage rating? Mine is a 120 volt DC motor salvaged from a blender (If that helps any).

[MOMJE9]

i can used motro ca,?

[LIS10114344]

hi i can get hold of a pillar drill easily, it is rated 1420 rpm and 240 volts,
so 1420 divided by 240 =5.92 rpm - per volt
would this be a good motor/generator for a wind turbine?

[LIS10114344]

hi just wondering, if a motor is producing a DC current to charge a battery then is there any need for a rectifier/bridge rectifier to stop the charge from the battery reverting to powering the motor?
thanks.

[mdavis19]

Hello,

If you look closely at the captions in the photo of the charge controller, there is a blocking diode to prevent the battery from back-feeding the motor. There are also rectifier diodes in the schematic of the charge controller.

[Da Person who plays paintball.]

Great idea, great project, great description, great everything.

Although, a little idea popped into my head, if you could make turbines with inbuilt solar panels, would that increase the power available.

Her`s a great `ible for DIY scrap solar panels.

http://www.instructables.com/id/DIY-Solar-Panel/

[harveylo]

The drive (propeller) is an important part of this project. I made a two bladed prop of mahogany, light and easily worked. I was on my sailboat at the time so shaping the airfoil was less than exact. I could balance it statically but not dynamically very well. The airfoil shape is a must if you want to have it work. The airfoil pulls the propellar around. The outer third of the blade produces 2/3rds of the power so I've read. Also there are companies that make blades but that's no fun. I have a car generator which if I don't decide to play some more will be available.
I used a diode to prevent the battery from driving the blade. Because of the inaccesability to reach it on the boat, I bypassed it to start the blade turning in light breezes and it would then continue to generate. When at anchor on a boat the boat usually heads into the wind unless you have strong tides.

[edvannatta68]

hi! how are you want can get information this you build me hear or at [e-mail] or [e-mail]

[shadow68]

want know get more information on this hope help me OK?

[nbwriter]

The Mdavis WindTubine Tutorial is by far the best practical build I've seen online. Thankyou for posting!

Finding a solution for blade propellers that's both durable and efficient amounts to a fascinating engineering challenge. From my research, PVC blades (while cheap and easy to make) do not have the basic strength necessary to survive high wind speeds. (As Mdavis discovered).

Curiously, commericially made blades (for HAWT turbines) do feature connecting "tabs" that are placed centrally, rather than at the sides. Two main differences are apparent:

1. Carbon fibre is favoured over PVC as the blade material
2. A lamination process is used during blade manufacture (possibly strengthening the finished blade propellers and tabs).

Aerodynamically, the blades need to bulge at one side, then taper at the other. (A basic aerofoil). This reduces drag, as does a cambered blade. Since lift is produced once your aerofoil blade is in operation, this must be a contributory factor leading to blade failure (because the turbine is literally trying to "take off"!)

Personally, I think this "take off" factor amounts to a design flaw in HAWT turbines, since the primary objective is to capture wind energy and transfer it to the DC motor. I'd like to do testing on VAWT systems (Savonius) to see if the "lift" problem is minimized.

It's unlikely any comparison data (between HAWT propeller and VAWT savonius efficiency) exists. But you never know, the Internet is a big place... Any feedback welcomed.

NB

[pantaz]

The charge controller has been redesigned by the original designer. Reduced part count, and easier to find components! 

http://www.mdpub.com/555Controller

 He also has kits and assembled units available (see link on his website). 

[sbob1]

why not choose dynamo?

[Barrettkg]

I have the chance to buy a 1/2 hp motor. The specs are: Voltage is 115/230. rpm 1725. I am waiting to hear back on the amperage. Would this be a decent motor to use?
I know the rpm is really high but I was wondering if the high Voltage would make up for it.
Thanks for the help

[WV_Kokamo_Joe]

I have a 1000 watt generator and the engine leaks oil when it is started or running. I was thinking of removing the generator portion and using it with some sort of a turbine setup.

I have not thoroughly inspected the current setup on this generator and do not know if it is a DC or AC generator although it has ports for accessing DC along with the AC outlets.

How hard would it be to utilize everything already included in the parts on this generator?

[spylock]

I have a question,I was going to try to make one with a 12 volt power wheels motor,I plan to use a charge control,but whats going to keep my battery from running the moter,the control?How will I solve that problem ?Ive herd reverseing the motor wires,but dont understand.

[A flyin muffin]

Read the first paragraph on step 8. The blocking diode.

[spylock]

Wil that be true if I happen to get hold of one of the old computer moters,I forget the name of them at the moment but Im sure you know the one Im talking about,Ive seen other sites that says the diode isnt needed with those.Thanks and Im sorry to keep bothering you.

[Tobita]

CRT monitor?

[rtaznita]

can i use 60 v ametek motor?

[itri45]

could i use an old 6 inch fan motor as a generator.
great job on the generator.

[jchowarth]

won't the wires twist up inside the tower over time?

[GrapeApe226]

Well your vacuum cleaner cord winds up over time and you have to pull it out and unwind it. It's not that hard to unplug your long extension cord from the charger end and give it a few twists in the needed direction. I live in an area where the wind blows180 degrees from morning to evening; about 30 miles inland from the Pacific Ocean. This is something I will keep an eye on,

[spylock]

You can pu a stop on the turbine so it wont spin all the way around,it will go as far as the stop both ways though still allowing the turbine the full 180.

[Ole bally]

HI There, I live in a country where we cannot just send funds outta the country...(a dictatorship) so very sadly I can't become a Pro Member!
Have you or would you please have a look at the Henry Moray website and the Tesla website. Both these guys were pioneers in the energy field and a Tesla generator offers FREE electricity! Apparently from the 'cosmic' energy field!
I'd love one of the members to get one of the kits offered, build it and then give us all the heads up as to it's reality!

[BuildHomeSolarPanel]

Great videos there. It is very informative and persuasive. Thats a great way to build a wind turbine. It could give you a lot of benefits and advantages.
Keep it up. Great post too.

[Tushar Max]

When i see the picture showing the the aluminum plate, toothed pulley and the blades assembly, it set me thinking "could one not use a similar looking ceiling fan assembly"?

[Sciniro]

Great work, compliment. Bravo