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Step 2Simple Furling Device for the Wind Generator:
After a series of tests with the Air-X Airfoil blades, I then mounted the generator to a National brand spring hinge (Model# N190-736 V122), to serve as a furling device. With the weight of the generator too heavy to act as a vertical-furling device, the lightweight spring hinge worked quite well as a side-furling device.
The generator was mounted on a block of varnished wood, with the axis of the generator offset 1-5/8" from the axis (or pivot-point) of the hinge. The 1-5/8" offset provides the necessary leverage for the furling to properly engage when the wind speed reaches 9-10 mph (= 4.0 - 4.5 m/s). A wind speed of 9-10 mph creates a pressure of about 2 pounds on the spinning blades, initiating the furling process, and keeping the DC voltage output, from the generator, at a manageable level.
A 1-1/2" diameter hard nylon wheel was also mounted (with a large, long woodscrew, as the axle) to support the 5" swing of the furling generator. A rubber bumper was also added to the rear end of the generator to provide a soft-stop @ 90 degrees to the wind.
Some sort of furling device is required, when using Air-X blades, as they are quite capable of speeds of over 2,000 rpm, and, at that rate, require a generator with a much more thicker shaft, and also require a OEM diecast Air-X hub. My simple ABS hub (and tiny 5/16 inch diameter generator shaft) is only suitable for speeds up to about 750 rpm. Also, automatic furling eliminates the higher generator rpm's that cause premature wear on the relative small generator bearings, not to mention the possibility of burning out the electronic charge controller, which is usually rated with an upper voltage limit, as well as the strain on the lightweight portable mast and rigging.
Here are the results of the generator, with three Air-X blades, and furling device (but before the parabolic nose was added) under actual wind conditions (before the automatic furling kicks in):
3.0 mph (1.34 m/s) wind speed, generator spins @ 186 rpm, producing 5 VDC, 0.15 Amps, 0.80 Watts.
3.8 mph (1.70 m/s) wind speed, generator spins @ 269 rpm, producing 8 VDC, 0.31 Amps, 2.50 Watts.
4.4 mph (1.97 m/s) wind speed, generator spins @ 325 rpm, producing 10 VDC, 0.42 Amps, 4.20 Watts.
5.7 mph (2.55 m/s) wind speed, generator spins @ 533 rpm, producing 15 VDC, 0.83 Amps, 12.5 Watts.
6.0 mph (2.68 m/s) wind speed, generator spins @ 553 rpm, producing 16 VDC, 0.87 Amps, 13.9 Watts.
6.8 mph (3.04 m/s) wind speed, generator spins @ 573 rpm, producing 17 VDC, 0.90 Amps, 15.3 Watts.
9.0 mph (4.02 m/s) wind speed, generator spins @ 634 rpm, producing 20 VDC, 1.02 Amps, 20.4 Watts.
The wind generator maxes out at 24VDC, with the furling kicking in -no matter how fast the wind blows, although sudden gusts will sometimes generate short bursts of up to 34VDC, before the tail properly orients the wind generator and enables the automatic furling to take effect. The electronic charge controller is rated up to 25VDC (but takes the occasional 34VDC bursts in stride) and process it into a safe 14VDC - 16VDC for the sealed lead acid battery pack.
The generator was mounted on a block of varnished wood, with the axis of the generator offset 1-5/8" from the axis (or pivot-point) of the hinge. The 1-5/8" offset provides the necessary leverage for the furling to properly engage when the wind speed reaches 9-10 mph (= 4.0 - 4.5 m/s). A wind speed of 9-10 mph creates a pressure of about 2 pounds on the spinning blades, initiating the furling process, and keeping the DC voltage output, from the generator, at a manageable level.
A 1-1/2" diameter hard nylon wheel was also mounted (with a large, long woodscrew, as the axle) to support the 5" swing of the furling generator. A rubber bumper was also added to the rear end of the generator to provide a soft-stop @ 90 degrees to the wind.
Some sort of furling device is required, when using Air-X blades, as they are quite capable of speeds of over 2,000 rpm, and, at that rate, require a generator with a much more thicker shaft, and also require a OEM diecast Air-X hub. My simple ABS hub (and tiny 5/16 inch diameter generator shaft) is only suitable for speeds up to about 750 rpm. Also, automatic furling eliminates the higher generator rpm's that cause premature wear on the relative small generator bearings, not to mention the possibility of burning out the electronic charge controller, which is usually rated with an upper voltage limit, as well as the strain on the lightweight portable mast and rigging.
Here are the results of the generator, with three Air-X blades, and furling device (but before the parabolic nose was added) under actual wind conditions (before the automatic furling kicks in):
3.0 mph (1.34 m/s) wind speed, generator spins @ 186 rpm, producing 5 VDC, 0.15 Amps, 0.80 Watts.
3.8 mph (1.70 m/s) wind speed, generator spins @ 269 rpm, producing 8 VDC, 0.31 Amps, 2.50 Watts.
4.4 mph (1.97 m/s) wind speed, generator spins @ 325 rpm, producing 10 VDC, 0.42 Amps, 4.20 Watts.
5.7 mph (2.55 m/s) wind speed, generator spins @ 533 rpm, producing 15 VDC, 0.83 Amps, 12.5 Watts.
6.0 mph (2.68 m/s) wind speed, generator spins @ 553 rpm, producing 16 VDC, 0.87 Amps, 13.9 Watts.
6.8 mph (3.04 m/s) wind speed, generator spins @ 573 rpm, producing 17 VDC, 0.90 Amps, 15.3 Watts.
9.0 mph (4.02 m/s) wind speed, generator spins @ 634 rpm, producing 20 VDC, 1.02 Amps, 20.4 Watts.
The wind generator maxes out at 24VDC, with the furling kicking in -no matter how fast the wind blows, although sudden gusts will sometimes generate short bursts of up to 34VDC, before the tail properly orients the wind generator and enables the automatic furling to take effect. The electronic charge controller is rated up to 25VDC (but takes the occasional 34VDC bursts in stride) and process it into a safe 14VDC - 16VDC for the sealed lead acid battery pack.
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