Faroun Savonius Wind Turbine




http://www.vawt.tk Alternative energy is a must in the future and all of us would like to challange the idea that we can not change and be efficeint.

so i am taking that chllange to create my own style of Savonius wind generator.

in this Instructable i will include the steps that will achieve my Faroun Savonius Wind Mill.

the size over all will be approx 6 feet high and 2.5 feet wide
split into 3 main steps and each main step will split into mini steps.

Note:: that the sound that you hear in the movie is the leaf blower that is producing air to turn the wind turbine.

3 main steps are:

-Turbine assembly =TA
*assembly howto

-Cage assembly =CA
*top, bottom and sides frame
*wind deflection
*mount on a fixed roof or tower

-generator and battery assembly =GBA
*Rectifiers and battery connection

sure things may change a bit along the way but you will be the first to know.

bellow is the semi-final product for Faroun Savonius
so lets start.


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Step 1: Turbine Assembly / Blades

here we will disscuss the blade:

in my Project i decided to use Aluminum for Material but u can use steel, Puck Board, or even a simple 5gal pale cut into 2 or 45gal drum cut into 2, so many options you have for the blades.

the size for my blade is 12.5 width, 6.25 depth, .125"thick, 20" circumference and 18" high.

i did not cut or roll the blades i bought them that way, yes i am lazy..lol... i was going to do it with 5gal pale cut into 2 but i figured i want to spend a bit of money just to see the max i can get.

so i have 9 blades, 3 in each section. each blade takes a third of the disc area. so each 3 blades sandwiched between 2 discs (discs are my step2).


Step 2: Turbine Assembly / Discs

the disc is very simple.

mine are made of Aluminum and you can use steel wood plexglass and all kinds of options, it all depends on what metarial are the blades so you can match to disc.

the size is 24" in dia. and .25" thick with 1 inch hole in the centre for the shaft (step3 will talk about shaft).

we need 4 discs nice and round with not to much "wabole" in them.


Step 3: Turbine Assembly / Shaft and Bearings

i am using 1" steel shaft 80" high mounted bettween 2 ballbearings and attched to the blades with 2 pluming flange.

for a shaft you can use other than solid steel, you can use plumung pipe, that you find any where, wood also but the the best choice and so on...

i hope so far i am clear with my instructions.


Step 4: Turbine Assembly / Howto Put Together

well this one goes like this:

i welded the blades insted of using angle brakets to hold them to disc, but you can use weld,steel brackets, wood brackets or grouve and glue them to disc and so on...

so after mounting the blades to discs into 3 sections and each section has 3 blades offset on top of each other by 60 degree, i then inserted the shaft into the center and adjusted for my setup distance, 4" away from bottom and the rest of the room left on top fpr my generator(later step).

after the shaft is in the desired spot i then used the pluming flange to fix the shaft to the blades.

I then placed the Bearings at the end of each end and voila it is assembled.

you noticed that it is in the cage (we will talk about the cage in aNOTHER STEP)

i dont think i miised anything.


Step 5: Cage Assembly/ Frame

the frame is a box made of 2"x4"

bottom base is holding the bottom of shaft.
the top is holding the top of the shaft also in the future
it will hold the coils(in a later step)

the walls are assambled in a way that half of the turbine is showing
to mount the wind deflection(in next step).

the cage is simple, the trick is to keep it square and croocked.


Step 6: Cage Assembly/ Wind Deflection

the wind deflection idea has been arround for ever but i did not see it with the Savonius so i dicided to be diffrent and combine my Faroun Savonius with the deflection method.

i simply biult the cage and then covered half the turbine where the blades are comming backwards, the reson to cover them is to eleminate the drage that the back of the blade create, also i am in the middle of adjusting the deflection method to be more productive in tunneling the wind twards the desiered area.

take a look at the rendering that i have created.


Step 7: Generator

this is the tricky part.

i have 3 ideas, one is to pully a pm alternator to shaft, 2nd is to mount the pm alternator to the disc diameter using v belt or timming belt, 3rd is to make my own generator using the top aluminum disc to hold the neo magnets and be the Rotor and place another disc on top facing the magnets and on it will be the Coils and that will be the Stator

Step 8: Generator/ Alternator

i did not try the pull driven alternator yet.

i am trying the alternator using the disc itself,

i placed a timming belt to the diameter of disc using strong epoxy glue.

and then i mounted the pm alternator to the edge of the belt spring loaded to it. very simple no pully and it is 10 to 1 ratio.

it works but i need over 10MPH wind to make it worth while.
there are many other options for already made dc generator out there at this stage you can choose your generator and mount it and see what you get. otherwise you will have to move to the next step witch is custom PMG, it is in the testing stages and there is no one like it so i am going to waste few dollars figuring the coil out.


Step 9: Generator/ Neo Earth Magnets and Coils

this is where you guys met me head to head, all i have for this step are the plans, i am in the mist of buying the Mag and Wire.

the plan is to place 24 n50 2"x1"x.5" magnets on the top disc and 21 20 AWG 150 winds coils on bottom of another disc that faces the magnets.

i am planing to sptill the coil output into 2 feeds, again it is in the testing mode and if you have anything to add now is the time to do it.

my hope that i can make 500 watts.

some said i will get more and others said less.

testing is fun.

faroun "revised:01-19-2008"

Step 10: Coil Winding

after a long research i decided to go with 150 winds.
-20AWG magnet wire
i made my coil winder from a simple plan, i included a video to show what it is.
it took a good 4 hours to wind 18 X 150 winds. it is a hard job but not as bad as the placment of magnets....wow..

3 phase connection as per the STAR connection diagram.

faroun "revised:01-26-2008"

Step 11: Magnet PLacement

Wooow...what a job!! ....that was the most tough thing to do.. with N50 mags...all i can say be carefull and patient.

it took me 2 days to place 24 mags on the disk, some said if it was steel disck it would have been esier.

anyway, i used GB weld to glue them down and then i put 2 part epoxy all arround for extra hold. and later in the project i will cover them HALF way in bostik or resin.


Step 12: Faroun-3-phase-coil-test-20awg-150-winds

here you will see each phase tested resistance and voltage i do not have an amp meter.

thanks T for the help you are providing, i am a slow student.


Step 13: Faroun-3-phase-coil-test-20awg-50-winds-Final

this step will show the 12 coils and 16 mags alternator testing

i decided to lay the coils, all 3 Phases conected and rectified produced 20volts dc at 60RPM 5mph wind

-12 coils
-16 N42mags 2 discs
-50winds per coil .125 thick very thin
-3 phase STAR configuration
-rectifed to dc using 2 bridge rectifires
-.2" gap in bettween the magnets an dthe coils.
-spining at 60RPM 5mph wind(using floor)
-produced 20volts DC

you are going to relize that my coils are very thin, but in order for me to get the mags close together i had to thin the coils to improove the flux passing through the coils,

the mags are only .5" far from each other and between them the sitt the coils.
you will see in the movie that i am getting 50 watts at 100 rpm again i had to rev it up to get the power cause i have no wind where i have it, any way with all my calculation., i am confidet to say it can get 200watt at 20mph wind.
note:maybe my calculation are a bit low but my expectaions are also low.

i am going to go back and use a treadmill dc motor because it did give me more power. I hope next step i will show the dc motor and who it works.

and place it outside in the real world. (outside will be in the next steps)


Step 14: PM DC Motor Generator Mount

in this step i was looking to show the diffrent ways to harnees the winds energy using pm dc motor,

i simplified 2 ways as you will see in the photos and the movie.

one way is to use a V belt with 5 to 1 pullies.

the other way is to get timming belt and a wooden disk 3/4" and place portion of the belt arround the cirunfrence glued on, place it on the turbine and the smaller pully that you can get at the junk yad too mount it to the dc motor, you will see in the pics and movie what i meam.

i liked the timming belt better it was less drag and qiuter.

they both produced about 12.25 volts at 80 rmp witch is i am assuming 10mph wind. i know i know soon i will be taking the beast outside, finally sring is here and the snow is gone i hope for few month...lol..


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    127 Discussions


    7 years ago on Introduction

    http://www(DOT)vawt(DOT)tk come up as a "phishing attempt" on the network I am on currently. Does anybody else have this problem?

    2 replies

    Reply 7 years ago on Introduction

    i am not sure what you mean, however, the http://www(DOT)vawt(DOT)tk site is under my name.


    Asad Kumar

    5 years ago

    Great stuff.... you can find more detail about the above topic (alternator/Generator)

    Asad Kumar

    5 years ago

    Great...but i want to know that .... does the output of this ALternator/Generator would be according to the EMF Equation of Alternator ?...Plz reply
    Ref: http://www.electricaltechnology.org/2012/11/emf-equation-of-alternator-or-ac.html


    6 years ago on Step 9

    To whom is ever building this turbine, you may want to use 2 high out put transistors to amplify the wattage out put


    Reply 9 years ago on Step 13

    lol...I am so sorry to say that I spelled it wrong, it is the "Gauge" size of wire.


    Glenn Burrow

    8 years ago on Step 14

    I have a few suggestions:
    Not to be rude, but your knowledge on the subject of electromagnetism is a bit thin to be building a generator. All your logic is sound, but a deeper understanding will take you very far. It is mostly mind-numbing stuff but a long grind through it all is worth your time.

    You may also want to use Word or some other program to double check your typing. Sometimes in a complex explanation, a single wrong word can really change the entire idea of the sentence. And being someone who is annoying enough to correct people often - I recognized many spelling errors. You will be appreciated greater if you convey your ideas in a more professional manner.

    Design wise, a Savonius turbine, like other vertical axis wind turbines (VAWT) are designed for simplicity, reliability, and not having to change to face the wind. By adding wind "funnels" you do increase efficiency in several directions, but you also end up greatly decreasing efficiency in other directions.

    Also, one thing to remember with belt drive systems. They rely on FRICTION to operate. And as I am sure you are aware, friction is the greatest enemy to efficiency. Well lubricated gear systems or a chain and sprocket system end up more efficient and more reliable, making up for the added difficulty in construction.

    One last thing to this now lengthy comment. I have always designed things with a thought left in my mind by an old high school teacher: KISS (Keep-It-Simple-Stupid). Oddly enough, the SIMPLER the design ends up, the better they seem to work. If it is not necessary to the end goal, remove it.

    I may be only 16 but hopefully I will soon be the possessor of several patents for various things I have designed. I wish you the best of luck and happy building.

    1 reply
    farounGlenn Burrow

    Reply 8 years ago on Step 14

    Great comment and highly welcomed.
    you are correct, I do have a problem spelling and not explain my design correctly.
    since this design a I have moved on and have invented few different vawts and hawts.
    also, I have built 12 serpentine axial flux, not traditional coils.
    please check me out at youtube my name is emagnets.




    8 years ago on Introduction

    Great work man. I have played with some of the N50 magnet generator designs all over the web and was trying to establish the most efficient coil design. I was playing with number of coils vs. gauge of wire vs. thickness of the overall coil vs. saturation of coil in magnetic field. All of these variables seemed to play a role in the Power (voltage vs current) output of each individual coil.

    You mentioned you had to have a 10 mph wind to produce anything worthwhile... I found that If you use smaller gauge wire in your coil the magnet can travel slower by the coil while still producing (almost) the same power output....

    I'm sure someone out there has already worked out the math on all of this but from experimenting I found the thinner gauge wire to produce better results at lower RPM as well has higher RPM.

    Again, great work, thanks for posting!

    1 reply

    Reply 8 years ago on Introduction

    it is great to figure things out on your own, i have uploaded few videos on youtube to show coils vs magnet results.



    8 years ago on Introduction

    Love this, helping my son look for energy saving ideas for his school project,, would love to incorporate this..Great Instructable!!!

    1 reply

    Reply 8 years ago on Introduction

    you welcome, you can make as small as you want it to be, from tin cans or pop bottels..



    farounmr thrifty

    Reply 9 years ago on Step 10

    if you mean the video link then go to youtube and search for emagnets user

    you will find all my video. you should check out my latest "Column turbine"




    9 years ago on Step 14

    There was one design that used a older tape drive motor it was dc as well like your tread mill motor and you could mount it directly to the shaft. once you have it then you have an on board source to feed the alternator you started with more then one something will gell. likely develop wings and fly.


    9 years ago on Step 7

    There is a company call AIR that makes the countrys best selling small wind turbuine there neodenium generator is designed to produce electricity from the wind. it has proven track record and is available seperately from the HAWT the one i'm speaking of costs five hundred fifty dollar of turbine complete how much the generator cost seperately i'm not shure. Designing the generator into the turbine eliminates the loses due to gear reduction or transfeer through belts or chains so direct drive is the solution. One fan type HAWT has the generator built into the tips of the fan turbine. In addition to your existing bearings on both ends of the shafting one might look at reducing friction further by the inclusion of sapphire bearing points. this or other hard materials could greatly reduce friction. Every one really wants a levatating savanious rotor so if we can get one thats made foam core protected like a surfboard with firberglass and levitated and so lightweight a slight breese with turn it then it's a go


    9 years ago on Step 6

    keep the (A-Vas-E-A) idea design a better frame support . I think he was trying to suggest the avasay might rotate out side the support frame so maybe it ought to be round like a small trampoline frame some how it also has to move 360 degrees freely in the wind maybe intergral to the cental axel shaft on seperate set bearings. It would have to be guided by a wind vane not into the wind as HAWT tail does but ninety degrees to the wind to creayte an avasay effect. We need get the science on this avasay effect percentage gain vs expense and effeciency it's actually not about effeciency or design but what works well for the masses a desig made for common recycable materials that anyone can build or buy cheaply will produce more watts then a corporate build turbine that un affordable and produces electricty for only those that can afford it. In a disaster having a source for fresh charged up batteries may make hugh difference just having lights and communications. So charging a cell phone battery or couple AA is worthy goal as well and there so many out there they are almost free if not free.