Step 8: Design #3 using a 3 to 1 gearing and a furling design

This unit is using the chuck and geared hub from #1, just reversed.
The gear on the motor matched the gearing from the chuck/hub.
I mounted the motor and chuck/hub to a thin metal plate, then bolted the plate to the windmill.
I used 4" PVC pipe and caps to enclose the motor and chuck/hub.
I'll experiment with blade designs for both speed and torque.

I installed 4 larger blades made from 4" x 2' PVC pipe.

<p>Design #4</p><p><a href="http://www.instructables.com/id/Wind-Generator-Design-4/" rel="nofollow">http://www.instructables.com/id/Wind-Generator-Des...</a></p>
<p>8/4/2015</p><p>Well, has anyone been successful in building their wind generators?</p><p>Any better ideas and improvements? So far, _CrashA_'s idea of the power/audio jack has been the best.</p><p>It's been about over 3 yrs since my 1st try. I now live in central Texas where this is a constant wind. I was going to buy a &quot;residental/commercial&quot; windmill, but just reading the reviews alone was enough to forget that idea. So I'm back at it and working up a parts list.</p><p>For me, finding a good motor is the biggest problem without spending hundreds of dollars that you'd never get back.</p><p>So today I bought this motor and 10/8MM spindle adapter and will go from there. I'm planning to also use some form of a mounted bearing to keep pressure off the motor bearings and adsorb so of the forces from the vertical furling.</p>
Great project! <br><br>I also use the drill chuck idea on my Wind Turbine, I have a 1/2 UNF 4&quot; Bolt going through a bicycle wheel and into the drill chuck - the threads match perfectly.<br><br>One idea to stop your wires from getting twisted is to use an audio or power jack connector to act as the slip ring. If you plug in your headphones to your computer or phone, you can spin that jack all day long without it affecting the sound. Same principle for when the turbine is spinning into the wind, the female audio connector will stay stationary on the pole, and the jack to connect into it will spin with the generator etc. <br>I'm going to be embedding this idea on mine when I can. <br><br>Hope it helps! :)
Like the idea of the power jack. Thanks.
<p>Great idea!!!</p>
<p>Thanks and awesome idea about the audio/power jack!!!!!</p><p>I one day soon hope to rebuild/built another wind generator!</p>
<p>04/22/2014 </p><p>For recent updates please visit this other instructables site </p><p>http://www.instructables.com/id/Small-Wind-Generator-Rebulid-Relocate-and-Repla/</p>
<p>For an old update on the WG</p><p>Copy and paste this link </p><p>http://www.instructables.com/id/Small-Wind-Generator-Rebulid-Relocate-and-Repla/</p>
I'm also busy building a wind generator. The Nema 23 24Vdc stepper motor is a great choice for small wind turbines. It will produce about 20watts of power that you can charge batteries with.
<p>that's cool! Good luck and keep us updated!</p>
do you thing a 24v motor at 300rpm is a good idea? I mean..wouldn't it somehow burn?
<p>does the wires twist? if so, how do you manage twisting wires?</p>
Awesome gearing tactic! Got my gears spinning.
<p>how do you stop the battery over charging and also do you need ac or dc current to charge a car battery?</p>
<p>over charging wasn't an issue since at the max it would only produce around 13 volts (DC).</p><p>You need DC current to charge automobile batteries.</p>
<p>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.</p>
<p>I had the tension set on the furling mechanism to where it would only furl in high winds or heavy gust during thunderstoms.</p>
With that amount of wind which is the total voltage pruduced ?
<p>with those steady high winds, it would put out around 12 volts</p>
<p>Thanks Davis</p>
Yes. What voltage will it hit in good wind. How many amps or watts does it make? What voltage cordless drill did you use? <br><br>Your windgen looks great! Thanks for taking the time to document it.
<p>In the highest gust before it would furl would be around 13 volts.</p><p>I have no idea as to how many amps or watts.</p><p>The drill was a cheap cordless drill that was given to me years ago.</p>
<p>Thanks for the compliments and sorry for the very late reply!!!</p><p>It would produce around 12 volts during the high gust of wind.</p><p>Not sure about the amps or the watts.</p><p>The friction bearing housing finally gave up after a series of heavy thunderstorms.</p>
you should have left gears from drill attached that way it would hit 12-18 volts on 10m/s wind.
<p>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.</p>
<p>What do you do when it rains?</p>
<p>Nothing, it was all incased in the PVC pipe with caps</p>
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. <br> <br>Great job!!
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.<br> Check out this instructable,<br> <a href="http://www.instructables.com/id/Small-Wind-Generator-Rebulid-Relocate-and-Repla/" rel="nofollow">http://www.instructables.com/id/Small-Wind-Generator-Rebulid-Relocate-and-Repla/</a><br> When I get a chance I'm going to delete it and add it as a step to this instructable.<br> As you can see the gearing has worn very little and the interior seems fairly clean.<br> On the housing cover, you can see that the gearing has spun so fast, that it has slung Teflon grease onto the cover.<br>
Also, does the turbine make as much noise as there is in the video? Is it bothering?
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?
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.<br> Check this guys site out for a lot technical information that mine lacks...<br> <a href="http://www.mdpub.com/Wind_Turbine/" rel="nofollow">http://www.mdpub.com/Wind_Turbine/</a>
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.?
Wow, that looks really good. I thought it would be worse than that.
the furling mechanism being put to the test!<br> <div class="media_embed"> <iframe frameborder="0" height="315" src="http://www.youtube.com/embed/fMmkK88Jok4" width="560"></iframe></div>
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?
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.
wow thats great! I never thought of making it that way but now i really want to try
here is a good video of the wind generator steadily spinning and steering in the winds as a storm approached.<br> <div class="media_embed"> <iframe frameborder="0" height="315" src="http://www.youtube.com/embed/AgRyUNDl4to" width="560"></iframe></div>
I do not understand why you are thinking so Small, <br>how about this, a Gas powered Generator, One where the gas motor does not work, <br>why can you not take the generator and make a wind turbin out of it?<br><br>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 <br>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.<br><br>
hello sir <br>see web page love information thing build much power off want run the battery power run love hear from you soon write me at spiritwild09@hotmail.com or find face book at http://www.facebook.com/wolfthunder68
1/8/2012<br>Step 9 is about a furling mechanism that I made after the wind generator blades came loose after a day of high winds.
Check out the furling mechanism at work in 20-30 mph gust.<br> <div class="media_embed"> <iframe frameborder="0" height="315" src="http://www.youtube.com/embed/R3lu3KmNdD8" width="420"></iframe></div>
Hi! sir '<br>want know you this run small place in of thing all? <br>write back at my wolfthunder68@yahoo.com
Update 1/2/12<br>Our area experienced high gusty winds, some at over 30 MPH for about 2days.<br>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.<br>Then the blades wildly spinning wobbling and were striking the mast and ripped off the cover to the gearing and motor.<br>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.<br><br>I should have the wind generator back up and spining in just a matter of days.<br>
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.
want know this work small place all?
hello sir <br>want do this work not he;p on your power yes or on look all information get on this write me at e-mail or send information to me in the mail <br>look in thing help power all ? thank you for your time <br>1748 Jack turner cave city ,Ky 42127 <br>espiritwild09@aol.com
An idea that I'm working on using the chuck from #1, but reversed.<br>The gearing on the small 12 volt motor and the &quot;hub&quot; match.<br>Then it will be easy to experiment with different blade designs by using the &quot;chuck&quot; to hold the blades.

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