It's going on 3 years now since dismantling the semi successful wind generator #3.

Now living in central Texas with a constant wind blowing and seeing all of the famous Texas windmills for pumping water scattered all throughout the country side.

I decided I wanted another generator, so I was going to buy a "ready to use" generator from Amazon, but didn't find any that had any good reviews.

There are several of those high dollar "ready to use" generators in the Austin area that have failed and no longer spin.

So 1st off from Amazon.com, I bought a $20 low RPM DC motor, a 10mm spindle adapter for an 8MM shaft and a set of 8MM pillow block bearings.

Dug out of storage all of the "stuff" that I had kept from my previous wind generators and so now it begins.

This latest attempt will be for a more durable and lasting generator, with higher voltage output.

For the design of the windmill and furling mechanism, you'll need to go to my older instructables. I will not cover that in this Instructable.

Also, I'll be letting the images do more of the explaining by putting captions to most of the images per each step

Step 1: The Blades

Using a 4" PVC pipe 2' long, mark it into 1/4s, then into the actual shape of the blade using masking tape.

The handsaw worked perfect for the task of cutting the PVC pipe.

<p>My 1st wind generator Instructable </p><p><a href="https://www.instructables.com/id/Small-Wind-Powered-Generator/" rel="nofollow">https://www.instructables.com/id/Small-Wind-Powered...</a></p><p>My 2nd wind generator Instructable </p><p><a href="https://www.instructables.com/id/Small-Wind-Generator-Rebulid-Relocate-and-Repla/" rel="nofollow">https://www.instructables.com/id/Small-Wind-Generat...</a></p><p>The 10MM spindle adapter for the 8MM motor shaft</p><p><a href="http://www.amazon.com/gp/product/B00N9VMOHE?psc=1&redirect=true&ref_=oh_aui_detailpage_o00_s00" rel="nofollow">http://www.amazon.com/gp/product/B00N9VMOHE?psc=1&amp;...</a></p><p>The Pillar Bearing for an 8MM shaft</p><p><a href="http://www.amazon.com/gp/product/B00YINI3RW?psc=1&redirect=true&ref_=oh_aui_detailpage_o03_s00" rel="nofollow">http://www.amazon.com/gp/product/B00YINI3RW?psc=1&amp;...</a></p><p>The adapter/bushing set for the saw blade</p><p><a href="http://www.amazon.com/gp/product/B004EGC16C?psc=1&redirect=true&ref_=oh_aui_detailpage_o02_s00" rel="nofollow">http://www.amazon.com/gp/product/B004EGC16C?psc=1&amp;...</a></p><p>The low RPM DC motor</p><p><a href="http://www.amazon.com/gp/product/B00YG5Z9NI?psc=1&redirect=true&ref_=oh_aui_detailpage_o06_s00" rel="nofollow">http://www.amazon.com/gp/product/B00YG5Z9NI?psc=1&amp;...</a></p>
<p>Hi ,i work for the windturbine company we have left over Neodymium Rare Earth Magnets from old design if u interested i will sale 30$ per piece,size 70mm 44mm 32mm 18mm</p><p>contact northtechteam@gmail.com</p>
cool and thanks!!
<p>I bought a 440 amp controller from EBay seller Windengineering </p><p><a href="http://stores.ebay.com/windgeneering/">http://stores.ebay.com/windgeneering/</a></p><p>Here is a video showing the controller cutting out at 14.5 volts</p><p><iframe allowfullscreen="" frameborder="0" height="281" src="//www.youtube.com/embed/D8AtZ1B3ymQ" width="500"></iframe></p>
12 volt LED Christmas lights attached to the tower's guide wires
<p>Furling mechanism being put to work during an aproaching rain storm with 30+ MPH gusts</p><p><iframe allowfullscreen="" frameborder="0" height="281" src="//www.youtube.com/embed/ut2SYXDWRz4" width="500"></iframe></p>
<p><a href="http://science.howstuffworks.com/environmental/green-science/wind-power3.htm">http://science.howstuffworks.com/environmental/gre...</a></p><p>This might help with the stalling that your design seems to have in direct gusts.</p>
a study has been done and the PVC pipe design/angle is the most aerodynamic for wind generation
the blades are not stalling. that is the shutter speed and the spinning of the blades. Like in a western movie where the wagon wheels appear to be spinning backwards.
several images showing ideas on hopefully very sturdy and weather proof ideas
<p>How many watts does it generate per hour?</p>
don't know. it pegged out my 10 amp meter
I still don't believe this is correct. but at 5 volts , 20 amps = 100 watts.<br>I just don't believe it's putting out that many watts
<p>This is an excellent 'able and project. Very easy to follow and good links - congratulations! I have built a few of these myself with varying degrees of success!lol I am using this as the model for my next generator right now. Thanks for sharing this.</p>
Thanks and good luck with your build.<br>in the last few weeks we have been hit by some very high winds. some ranging from 48-60 mph. both wind generators have held up. can't say as much for the metal pipe that was used to join to pieces of conduit.
<p>I believe that a turbine produces AC current, and a generator produces DC current. Many people like to use AC producing devices because they can save money on the lower cost of the cable to bring in the power. With AC, smaller wire can be used to provide the power. The AC is then converted to DC at the point of usage, using diodes. If a DC producing motor is used, then the size of the cable diameter has to be larger, to minimize the resistive power loss of the wire. </p>
<p>A turbine is a machine (think a jet engine) and a generator is a device that generates electrical power (AC or DC). A generator can usually be used as a motor and vice versa.</p>
<p>right, but a &quot;wind turbine&quot; is a machine that wind powers. a &quot;wind generator&quot; is really a misnomer sounding more like it generates wind, ie a breeze making fan. so to be accurate it is a &quot;wind (based) turbine, electricity generator&quot;.</p>
in USA terms they both mean the same thing
<p>In automotive:<br>Generator = DC<br>Alternator = AC<br>Though an alternator may be just an AC generator?</p>
<p>The blue part is the turbine and the grey part to the left is the generator - if you want to generate power, but you can also power the generator as a motor to use the turbine to compress/decompress air. (dependant on the direction of travel)</p><p>I always find it interesting how different disciplines (Automotive, Aviation, Electrical) have their own words/meanings for &quot;in principal&quot; the same item and how the use determines the name.</p>
<p>Cool pic and Thanks! . The TVA in Chattanooga TN at Raccoon Mtn, use <br>something similar but on a much larger scale. The motors/turbines pump <br>water to the top of the mountain when electricity is at a low demand, <br>then release the water and generate power when there is a higher demand for electricity.</p>
<p>&quot;...pump water to the top of the mountain when electricity is at a low demand, <br>then release the water and generate power when there is a higher demand for electricity.&quot;<br><br>Storing potential energy. Nice.</p>
<p>I wonder just how many of the readers remember (or even drove) the old cars with generators (NOT alternators). I'm 66 years old, so I remember well, but the funny thing is, I had forgotten until reading your post. :) </p>
<p>I had a couple of VW beetles... they had generators into the 1970's</p>
<p>Yes, a DC motor can run as a generator and a DC generator can run as a motor, but neither can be as efficiently run as the other. This is because the brush offset between a generator and motor is different. With a motor, the brushes lead the coil so that you have better torque. With a generator, the brushes are in sync with the coil so you get maximum output.</p>
<p>turbine</p> <br><p>ˈtərˌbīn,ˈtərˌbin/</p><p><em>noun</em></p><p>noun: <strong>turbine</strong>; plural noun: <strong>turbines</strong></p><ol><li><div><div><div><div>a <br> machine for producing continuous power in which a wheel or rotor, <br>typically fitted with vanes, is made to revolve by a fast-moving flow of <br> water, steam, gas, air, or other fluid.</div></div></div></div></ol>
<p>What determines the required wire size is the current to be passed through the wire, not whether it is AC or DC. The main benefit of AC in electricity distribution is the ease with which it is transformed into different voltages. As the power must remain the same, transforming an AC current into a higher voltage means that a proportionally lower current is transmitted and a smaller diameter wire may be used.</p>
well y'all are going way over my head with my rural west Alabama highschool education on the wiring size and resistance :-\ all I know is that the voltage meter shows plenty of DC voltage going to the regulator.
I do see something wrong with your logic here. I think you aren't giving yourself enough credit here. Anyone can memorize words in a book, but it takes a different mindset, skill set, and observation set to see a wind generator in a PVC pipe, and other associated materials. There is something very brilliant in simple machine logic and simple principles that are not over engineered. Not all engineering happens on paper, and some of the best projects are made of recycled parts other engineers decided where not viable for their project. So I will leave this at; brilliant thanks for the share, and you should give yourself more credit for your inter engineer.
Thanks for the great encouragment. It's not a matter of how many volts/watts/amps does my generator produce, but more of a matter will it work and survive the extreme conditions. Will the idea of the male and female connection spin but yet stay connected. Will the pillow bearing releave pressure
part #2 :-\<br>and keep it off the bearings in the motor? could it be used in a much larger scale?
<p>Doesn't A/C travel on the outside of the wire, or something like that, which makes stranded wire desirable for A/C?</p>
<p>The skin depth in copper at 60 Hz is 8mm, and varies inversely as the square root of frequency.</p>
<p>That's a function of frequency. At higher frequencies, there is a tendency for the electrons to flow along the perimeter of wires, called the skin effect, so in radio applications, coils are often wound with Litz wire (individually insulated multi-strand wires). <br>At 60Hz, multi-stranded wire is often used because it is more flexible. You will note that the strands in such wire are not individually insulated. House wiring is usually solid core until you get to larger gauges.</p>
<p>The skin effect is also a function of voltage because both frequency and voltage affect rise time. Current travels over the skin of overhead high voltage lines even though the frequency is only 60 Hz.<br><br>Skin effect will not happen with this wind turbine because neither the frequency or voltage are high enough.</p>
<p>I've done some reading on the skin effect and it seems that voltage does not play a role in the effect. The skin effect is produced by back EMF and eddy currents in the conductor which &quot;push&quot; the electrons to the surface of the conductor. The skin depth in copper at 60Hz is 8.5 mm. High voltage power lines may have a steel core surrounded by aluminum conductors. Though the steel is not a great conductor, it adds strength to the cable and the current stays in the more conductive aluminum due to the skin effect.<br><br>What high voltage does do is cause electrostatic distortion in the insulator (air) between the lines and ground.</p>
<p>True, the forces interact to produce the effect. The skin effect will be present in any AC line, it becomes more pronounced at higher frequencies and voltages.</p>
<p>Actually, the wires don't care whether you are carrying AC or DC, they are sized ONLY on the total Amperage they are required to carry. With long runs, there will also be voltage drop so the wires will need to be upsized for that as well.</p><p>Since your total Power (Watts) is simply VoltsXAmps, Ideally, you want the generator to produce the highest voltage it can with little amperage for smaller wires and smaller voltage drop. That high voltage/low amperage can then be transformed to just the right voltage for your battery bank and the much higher amperage with a MPPT controller</p><p>While there is a small amount of loss in the MPPT controller's conversion, it more than made up for with the efficient charging of your batteries and MUCH smaller wires required on a long run from a turbine to the house.</p><p>As an aside, a 3-phase AC generator is more efficient at extracting the total power coming from the blades and transmitting it down the wires. Most decent commercial wind generators use a 3-phase AC alternator which is then rectified into DC before going into your battery pack.</p>
<p>An alternator produces alternating current which can be rectified to supply a pulsating dc voltage and current. A generator produces direct current without the use of rectifiers. A turbine is used like a motor and is made to spin with it's output shaft connected to whatever you want to spin. AC is commonly used nowdays for power distribution because it's easy to step up in voltage or step down in voltage using transformers. DC is used for long distance power feed in some places due to the high loss that would be incurred if AC was used, odd as that sounds. It avoids losses due to cable capacitance and inductance as well as maybe magneticly induced losses that AC would incur. DC can also link power grids that are not in phase as well as those operating on different frequencies.</p>
Thanks for that info! I was at 1st worried that the the TV satellite coaxial would have to much resistance, but it appears to be perfect. I guess since the TV/satellite work on a low voltage too?
<p>As an electrical engineer, using coax type cable is a great idea! It is weatherproof and sturdy. Try to keep the cable run less than 100 feet to reduce losses, that may be small anyway.</p>
That's great to know! I can't believe I found that 50' of coxail and satalitte dish tripod at the dumpster to the campground! it saved me lots of time and money.
TV satellite signals are very weak. In order to perform, the signals have to be amplified. Those high frequency signals operate on the outside layer of the wires. It is not the same as using a cable to provide power to run objects. For power cables, the larger the diameter of a wire, the least resistance (and losses in the form of heat) it presents to the travel path of the current.
<p>....unless something changed drastically since I left Engineering school - I think you got it exactly opposite.</p><p>You can easily step up/down voltage on the DC (DIRECT Current).</p><p>AC (ALTERNATING Current) is your solution for long distance travel as in DC you quickly loose most of your power to resistance - which doesn't show in AC in the same form as it does in DC.</p><p>Eddison was screwed with his DC-power-grid plans - he hardly could leave a village before crashing the circuit.</p><p>It wasn't until Tesla came up with AC and showed the world, that you can transmit AC basically without distance limits - too bad for Tesla that Westinghouse scooped up his AC patent....</p><p>Cheers all,</p><p>thjakits</p>
I watch a program on PBS about that exact situation. Telsa (sp) was a genius. They said he had a 3D type visionary mind.
<p>well somehow inverters use diodes to get AC out of DC batteries.</p>
<p>No, you have the wrong end of the stick. The losses for AC and DC will be as far comparable as far as basic wire resistance is involved. But, if you use EITHER at a huge voltage, then the losses over long distances will be proportionately lower. And I mean huge: 50 to 100,000V. That's why over-head power lines are overhead, a long way overhead.</p><p>However, only AC can be easily down-converted to a useable domestic voltage ( by a transformer ). With DC you're stuffed.</p><p>Just my $0.02 worth</p><p>Bruce</p>
<p>Actually I think you are both partially right and partially wrong. The determining factor for line loss, ( the voltage lost to the carrying cable) is determined by the amount of current being carried, as in the formula E=I*R, voltage (drop) equals the line current times the line resistance. The higher voltage used for power transmission lines means the same amount of useable power can be carried at a lower current, P=I*E (power(watts) equls I(current in amps) * E(voltage). </p><p>What screwed Mr. Edison was the fact that DC voltage is not easily changed up or down, where AC voltage can be easily changed through the use of a transformer. This meant that the farther that Mr. Edison's wires stretched, OR the higher the load that was put on them, the larger the wires had to be, since he was effectively limited to the voltage that the end user needed. </p>

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