DIY 1000 Watt Wind Turbine

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About: Professionally, I'm an IT Engineer (Executive Level) and Electronics Tech. I'm a Amateur Radio Operator (KK4HFJ). I lived off grid, with Solar (PV), Wind, and veggie oil fueled diesel generator power for 6 y...

We built a 1000 watt wind turbine to help charge the battery bank that powers our offgrid home. It's a permanent magnet alternator, generating 3 phase ac, rectified to dc, and fed to a charge controller. The magnets spin with the wind, the coils are fixed, so no brushes or slip rings necessary.

Update: DIY Amp Hour meter for monitoring charge!

All about homebrew wind and offgrid power systems, the complete reference!

Step 1: Build the Magnet Disks

We had 12" steel disks hydro cut. We cut a template for mounting the magnets. Then we mounted 12 grade n50 magnets around the outside edge. We then built a form, and poured the resin with hardner.

Step 2: Build the Coil Disk

We wound the nine individual coils, soldered them in a 3 phase wye configuration, and encased them in resin. We used 35 turns of 2 parallel strands of 14 gauge enameled (magnet) wire for 12 volts. Use 70 turns of single strand for 24 volts. # 3 phase diagram shown here shows 3 stator coils. each of those coils is actually 3 coils in series. coils 1,4, and 7 are series together, 2,5, and 8 are series together, and 3,6, and 9 are series together.

more details, see the following page 15 for the series star, 1-y diagram.

http://groups.yahoo.com/neo/groups/axialflux/files

AXIAL_FLUX_HowItWorks.pdf

Step 3: Build the Bearing Assembly

Two Harley Davidson wheel bearings are inserted into the pipe, with a smaller pipe locked between them to keep them in place.

Step 4: Construct the Blades

The blades are 2" x 6" pine, cut at 10 degrees on a table saw, and sanded into a rough airfoil. Not perfect, but close enough.

More can be found at

http://tech.groups.yahoo.com/group/axialflux/

http://www.green-trust.org

http://youtube.com/watch?v=o9EEHFKEckM

Step 5: Further Reading

2 People Made This Project!

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1,897 Discussions

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AlexK212

1 year ago

Hello greetings

How do you control the battery charge

What device do you use to control the load

I would like to know the characteristics of the device for the charge control of 1000 watts

thanks for your attention

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sspenceAlexK212

Reply 1 year ago

We use a diversion control. Basically, when the batteries hit a certain voltage, a load is attached, like water heating elements. The reason this is done is that if you were to disconnect the wind turbine, like you do with solar, it would self destruct.

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JasonA166

Question 5 weeks ago on Step 1

Good day, i have a question regarding your magnets. What direction is your magnetic field? Is it along the length or is it through the thickness? Secondly i just want to know, does it matter if the coils are inside or outside from the magnets? Thanks for this awesome build.

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tricooltransformers

Question 2 months ago on Step 2

Is there any advantage by using thinner wire, more turns, and generating a higher voltage? Is there an optimum winding /voltage for maximum power generation and minimum losses for this generator?

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MattB433

5 months ago

Hi, Im inquiring about the directions of the magnets. If i understand all of the magnets on one plate should point north and all the others point south so that they attract towards eachother and create a field through the windings. is this correct?

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sspenceMattB433

Reply 4 months ago

They alternate. one magnet is S up (away from coil), N down (towards coil), the next is N up, S down. It's mating magnet on the other plate is the reverse, S to the N of the magnet on the other side.

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AlejandroM228

Question 1 year ago

Hello greetings

I would like to know about the 12 "steel discs of how thick they are, and where they can be obtained

of steel shaft which diameter is and of what length

Thank you

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sspenceAlejandroM228

Answer 1 year ago

1/4" to 1/2" works fine. I got them built at a local metal shop.

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Kelyc

Question 1 year ago

It looks like this was originally posted almost 12 yrs ago. I was wondering how well this has held up over time.

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DaceL2

1 year ago

green-trust.org appears to have been hacked

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sspenceDaceL2

Reply 1 year ago

not hacked. expired. it's gone.

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RenatoS21

1 year ago

nice very helpful

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01010011 01101001

1 year ago

Please Advise

Would you please provide the details of the coils individual weight and internal measurement or point me in the right direction?

Many thanks for creating this particular instructables.

Kind Regards Si

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01010011 01101001

1 year ago

Please Advise

Would you please provide the details of the coils internal measurement or point me in the right direction?

Many thanks for creating this particular instructables.

Kind Gegards

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ictinc

1 year ago

Respect!!! I've come across this project many times. Now that I've finally decided to built my own windmill, I want mine based on this one.

I do however have some questions.

I would like my generator to output 230 volts AC with a minimum of 1000 watts. How would I need to change the windings on the coils to do so? Also, would there be any disadvantages by changing the output voltage to 230v AC?

The reason I would like the higher output is because I eventually want to connect it to the grid. I also don't like the hassle and expenses of charging batteries.

My actual design of the windmill would largely be the same, however I would like to try to attach the magnets to the tips of the blades instead of in the center.

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sspenceictinc

Reply 1 year ago

Outputting grid voltage means a synchronous design (fixed rpm / Hz), far beyond the goals and parameters of this design. magnets on the tips? you would need hundreds of tips and coils .....

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RenatoS21

1 year ago

sir i think this kind of wind power can solve my problem i was amazed i am from philippines and i want to have complete kind of assembly please help me to build please i need very badly

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trungl23

1 year ago

VERY GOOD