Instructables
Picture of Small Wind Powered Generator
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As far back as I can remember, I've all ways wanted to make a wind generators.
My 1st and only attempt was back in high school, when I had built one using wooden blades and turning a bicycle generator.

So after getting hooked on Instructables .com and viewing other members wind mill projects, I've been on the lookout for DC motors and thinking of some ideas.

Then one night it hit me.... I had an old cordless drill that I was no longer using.
So after finding and disassembling the drill, is when the brainstorming began :)

Through the months I've added several steps about the 2 different wind generators and the modifications made to both of them as problems arose. 

 
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Step 1: Step(s) after intro.....

The chuck tightens down perfectly on the gear that is attached to the motor, which this in turn provides a "hub" for a larger disk for the blades to be attached too . The
blades will have to spin in a clockwise direction to keep the chuck tight.
I cut in half a section of pipe that is slightly larger than the outside diameter of the friction bearings that are between the hub and the chuck. I then used an water hose
repair connector to hold the cut pipe halves around the friction bearings which also will provide support.
I attached the assembly to a plastic peg board.
After getting the unit assemble/attached to the peg board, it fit perfectly inside an 10 oz coffee can

After attaching the blades and hooking up a voltage meter, I took it outside in a very light wind.

The completed unit spins freely and the small DC motor does create a small amount of DC current.
I can/could install a bigger motor using the "chuck".

The day I mounted it atop a pole, a thunderstorm came up with high winds and the wind turbine handle it just fine.

Step 2: Mounting the unit

I found an adjustable closet rod that I'll mount the assembled unit on to.

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ddavis662 (author) 4 months ago

04/22/2014

For recent updates please visit this other instructables site

http://www.instructables.com/id/Small-Wind-Generator-Rebulid-Relocate-and-Repla/

ddavis662 (author) 6 months ago

For an old update on the WG

Copy and paste this link

http://www.instructables.com/id/Small-Wind-Generator-Rebulid-Relocate-and-Repla/

rwarwick128 days ago
Awesome gearing tactic! Got my gears spinning.
dannyb1233 months ago

how do you stop the battery over charging and also do you need ac or dc current to charge a car battery?

ddavis662 (author)  dannyb1231 month ago

over charging wasn't an issue since at the max it would only produce around 13 volts (DC).

You need DC current to charge automobile batteries.

ogremills2 months ago

Doesn't the furling take away a lot of the potential energy being created? It may be the safer way to go on that slender pole you have the turbine attached to, but I'd think a more substantial pole cemented into the ground could take the higher wind gusts and provide better energy conversion.

ddavis662 (author)  ogremills1 month ago

I had the tension set on the furling mechanism to where it would only furl in high winds or heavy gust during thunderstoms.

felohidalgo10 months ago
With that amount of wind which is the total voltage pruduced ?
ddavis662 (author)  felohidalgo4 months ago

with those steady high winds, it would put out around 12 volts

Thanks Davis

Yes. What voltage will it hit in good wind. How many amps or watts does it make? What voltage cordless drill did you use?

Your windgen looks great! Thanks for taking the time to document it.
ddavis662 (author)  pbickwermert4 months ago

In the highest gust before it would furl would be around 13 volts.

I have no idea as to how many amps or watts.

The drill was a cheap cordless drill that was given to me years ago.

ddavis662 (author)  pbickwermert6 months ago

Thanks for the compliments and sorry for the very late reply!!!

It would produce around 12 volts during the high gust of wind.

Not sure about the amps or the watts.

The friction bearing housing finally gave up after a series of heavy thunderstorms.

jeidins5 months ago
you should have left gears from drill attached that way it would hit 12-18 volts on 10m/s wind.
ddavis662 (author)  jeidins4 months ago

Yea, your right about that! All I would have had to do was cut the handle off and mount the drill to the base and attach the blade assembly.

13010284 months ago

What do you do when it rains?

ddavis662 (author)  13010284 months ago

Nothing, it was all incased in the PVC pipe with caps

MacOSJoey2 years ago
You really did a beautiful job with this machine. It's such a simple yet very effective looking design. You're furling system is the first DIY attempt at this style. I'm personally working on my own turbine, but I haven't been able to find a good way to connect the shaft on the blades to the generator. I think I will use your idea, as it seems to work very well. Only two things I would recommend: See about making the generator housing a little more weatherproof. I'm not sure where you are but where I am ice, snow, rain, dust, etc. can wreck havoc on anything. Also you should really see into connecting this turbine to a charge controller and batteries or a grid tie inverter. For how much it spins, it shows potential for a decent power yield.

Great job!!
ddavis662 (author)  MacOSJoey2 years ago
Thanks for the compliment on my work! In connecting the chuck to a shaft, be it the generator or a blade hub, I use a pair of channel lock pliers and vise grips to tighten the chuck as tight as possible. The PVC housing seems OK and I have the wind generator hooked up to a regulator that is part of a solar charge system with 3 dry cell 12 volt batteries at my mom and dads country home.
Check out this instructable,
http://www.instructables.com/id/Small-Wind-Generator-Rebulid-Relocate-and-Repla/
When I get a chance I'm going to delete it and add it as a step to this instructable.
As you can see the gearing has worn very little and the interior seems fairly clean.
On the housing cover, you can see that the gearing has spun so fast, that it has slung Teflon grease onto the cover.
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Also, does the turbine make as much noise as there is in the video? Is it bothering?
ddavis662 (author)  MacOSJoey2 years ago
yea, the gearing hums that loud. Not bothering at all, it's kind of cool to hear.
How do you keep the wires coming from the motor from tangling up when the turbine spins around? Is there some kind of stop attached so it cant rotate freely? And also, do you have any ideas on how to make a homemade charge controller for a wind turbine? , do you buy your charge controllers? If so what brand do you recommend?
ddavis662 (author)  Electronics Man2 years ago
Sorry for the late reply, I've been on vacation. I just have an old phone line running through the pipe/tower to the generator. If it does twist up, I have to untwist the wire. As for controllers... I don't use a charge controller since the power that is being generated is normally less than 12 volts.
Check this guys site out for a lot technical information that mine lacks...
http://www.mdpub.com/Wind_Turbine/
ddavis662 (author)  ddavis6622 years ago
7/15/12 I took my windmill down to relocate it. This is how twisted the phone line was. Doesn't look to bad to me.?
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Wow, that looks really good. I thought it would be worse than that.
ddavis662 (author) 2 years ago
the furling mechanism being put to the test!
I love the furling mechanism you made. At what wind speed does it start to lift up, and how could you adjust it to lift at different speeds?
ddavis662 (author)  Electronics Man2 years ago
Not sure about the wind speeds. I guess somewhere between 20 and 30 mph winds. The furling mechanism can be adjusted by raising or lowering the nuts on the bolts that the springs are attached to.
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wow thats great! I never thought of making it that way but now i really want to try
ddavis662 (author) 2 years ago
here is a good video of the wind generator steadily spinning and steering in the winds as a storm approached.
harsat2 years ago
I do not understand why you are thinking so Small,
how about this, a Gas powered Generator, One where the gas motor does not work,
why can you not take the generator and make a wind turbin out of it?

I mean come on, a drill is fine and dandy for a small school project, but lets get serious, we want to produce electricity, and there are alot of generators that dont work or need to have the gas motor repaired that would make a good
Wind Turbin Generator, I was also thinking what if you hooked up a solar powered battery with a super gear setup to power the generator at night. just an Idea.

ddavis662 (author) 2 years ago
1/8/2012
Step 9 is about a furling mechanism that I made after the wind generator blades came loose after a day of high winds.
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ddavis662 (author)  ddavis6622 years ago
Check out the furling mechanism at work in 20-30 mph gust.
ddavis662 (author) 2 years ago
Update 1/2/12
Our area experienced high gusty winds, some at over 30 MPH for about 2days.
My four bladed wind generator made it through most of the high winds, then the blade assembly finally spun loose and then was spinning freely on the bolt that was being held by the chuck.
Then the blades wildly spinning wobbling and were striking the mast and ripped off the cover to the gearing and motor.
Only a minor chip on one of the blades.There was times I thought the mast was going to bend, as the generator was spinning wildly in the high gusts.

I should have the wind generator back up and spining in just a matter of days.
ddavis662 (author) 2 years ago
Wind generator in the back ground, with the solar panel mounted to the deck railing, the Night Watch Man mounted on the right/center post and the LED lights hanging down behind both center post.
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ddavis662 (author) 2 years ago
An idea that I'm working on using the chuck from #1, but reversed.
The gearing on the small 12 volt motor and the "hub" match.
Then it will be easy to experiment with different blade designs by using the "chuck" to hold the blades.
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ddavis662 (author)  ddavis6622 years ago
Check out step #8
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ddavis662 (author) 2 years ago
I've got #2 up and generating power at my parents farm.
Brought #1 back to my house for future experiments.
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ddavis662 (author) 3 years ago
Step #7 starts my plans for test model #2
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ddavis662 (author)  ddavis6623 years ago
Test model #2 up and spinning (step #7)
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