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Post by tjwilhelm on Jun 19, 2014 18:03:43 GMT -7
I spent the entirety of last week participating in one of the best, hands-on workshops EVER! Home Brew Wind -- the theory, design, and actual construction of very practical and very functional "small-wind" generators. Based on decades of personal experience, Dan Bartmann and Dan Fink have created one of the best educational experiences available. These photos are from just one small part of the process -- blade carving and assembly. More photos coming later. They have a book titled, Homebrew Wind; and, they have a very informative website: www.otherpower.comBy the end of the week, with the efforts of seven students and two instructors, we had a full sized wind genny built from scratch. We wound the stator coils. We built an dual, axial-flux rotor with neodymium magnets on steel plates, banded with stainless steel. We did loads of metal work (cutting, welding, and grinding) to build the furling mechanism and tower mount. What a total HOOT!  blade carving 02 by tjwilhelm148149, on Flickr  blade carving 03 by tjwilhelm148149, on Flickr  blade carving 04 by tjwilhelm148149, on Flickr  blade carving 05 by tjwilhelm148149, on Flickr  blade carving 06 by tjwilhelm148149, on Flickr  blade carving 08 by tjwilhelm148149, on Flickr |
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Post by USCGME2 on Jun 19, 2014 18:16:52 GMT -7
Awesome TJ. Keep the pics commin
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Post by thywar on Jun 19, 2014 18:40:05 GMT -7
That's amazing. Something simpler would be easier than carving but I'm more than impressed with the blade carving. The other pictures I'm looking forward to though
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Post by crashdive123 on Jun 20, 2014 3:12:41 GMT -7
Fantastic so far. Looking forward to the next installment.
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Post by hunter63 on Jun 22, 2014 8:38:58 GMT -7
Very cool......Thanks and keep us posted.
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Post by kutkota on Jun 22, 2014 9:36:01 GMT -7
I can't exit to spend some time looking aroundthat website. Thanks for the pictures. Looking forward to the rest.
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Post by tjwilhelm on Jun 28, 2014 8:53:13 GMT -7
Coils are wound on a jig powered by a drill motor...  Coils 02 by tjwilhelm148149, on Flickr  Coils 03 by tjwilhelm148149, on Flickr Finished coils are laid out on a pattern board. Precise positioning of the stator coils is important. This is a "wild ac" three-phase stator...  Coils 05 by tjwilhelm148149, on Flickr  Coils 06 by tjwilhelm148149, on Flickr After all the coils are positioned, soldered, and fixed together with fiberglass patches and super glue, they are laid into the stator mold to check fit...  Coils 07 by tjwilhelm148149, on Flickr Then, the stator is poured from automotive epoxy...  Coils 08 by tjwilhelm148149, on Flickr  Coils 09 by tjwilhelm148149, on Flickr  Coils 10 by tjwilhelm148149, on Flickr  Coils 11 by tjwilhelm148149, on Flickr  Coils 12 by tjwilhelm148149, on Flickr |
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Post by cajunlady87 on Jun 28, 2014 12:05:53 GMT -7
Check you out TJ, what an awesome and beneficial project you and your friend put together. I can't wait to see it working. Looking forward to an update.  |
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Post by USCGME2 on Jun 28, 2014 21:16:15 GMT -7
Thats like wow, datgum, and gee-whiz all rolled up in one!  |
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Post by tjwilhelm on Jun 30, 2014 18:47:57 GMT -7
This generator (wild-ac alternator) has a stationary, wound armature; and, a revolving, permanent magnet field. It's configured as an axial-flux alternator. This means there are field magnets on both sides of the armature coils with the flux from one field plate to the other running through the coils, parallel with the axle. I have almost 1,000 pics from the project-build; but, I've selected the most significant parts of the process for this thread. I'll post three more set of pics (is that OK, mods?) -- building the revolving field plates; assembling the alternator; and, final assembly. FYI, the mechanical heart of this thing is a standard trailer hub! Here are some pics from the field plate assembly: Neodymium magnets...  Field 01 by tjwilhelm148149, on Flickr The steel plates for the front and rear fields, and the stainless steel banding that wraps the edge of each...  Field 03 by tjwilhelm148149, on Flickr Cutting the SS bands to length prior to welding them into rings...  Field 05 by tjwilhelm148149, on Flickr An aluminum template is used to position the magnets on the steel plates. These neodymium magnets are SUPER strong, and thus dangerous. One of them jumped a full 12" across the table and crushed one of the team's fingers while he was holding another one in his hand...OUCH!  Field 06 by tjwilhelm148149, on Flickr Super Glue is applied next to the magnets. The Super Glue gets wicked under the magnets via capillary action...  Field 07 by tjwilhelm148149, on Flickr Heating the SS band in a pizza oven and then quickly fitting it over the O.D. of the field plates...  field 08 by tjwilhelm148149, on Flickr  Field 09 by tjwilhelm148149, on Flickr Hub holes are covered and sealed. Then the magnets are potted with epoxy...  Field 10 by tjwilhelm148149, on Flickr A finished revolving field plate...  Field 11 by tjwilhelm148149, on Flickr |
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Post by tjwilhelm on Jun 30, 2014 18:55:49 GMT -7
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Post by tjwilhelm on Jun 30, 2014 18:59:13 GMT -7
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Post by thywar on Jun 30, 2014 20:39:16 GMT -7
That is absolutely fantastic!!!!! What a great project and learning experience. It's also very artsy! Love those blades. I hope this gets written up in numerous magazines. I hope you write the article for numerous magazines and periodicals. You should publish this SOMEWHERE!!!!!
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Post by tjwilhelm on Jun 30, 2014 21:28:18 GMT -7
Thywar...thanks, bro; but, it's not my design. I was just a student in the workshop! I will be teaching this at school in the fall -- my students will be building one like this. There's a book and a website all about this. The book is titled Homebrew Wind Power by Dan Bartmann and Dan Fink. Their website is: www.otherpower.com |
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Post by Cwi555 on Jul 1, 2014 9:18:51 GMT -7
TJ,
Great pictures. How are they preventing over speed? I don't see any furling or pitch mechanism?
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