DIY 1000 watt wind turbine


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.
DIY 1000 watt wind turbine

step 1Build 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.

Build the magnet disks
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wind_class_008.jpgwind_class_022.jpgwind_class_049.jpgwind_class_060.jpg
wind_class_063.jpg

step 2Build 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.

Build the coil disk
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wind_class_021.jpgwind_class_026.jpgwind_class_048.jpgwind_class_082.jpg3phase.gif
af_wiring.png

step 3Build 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.

Build the bearing assembly
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bearing 2.jpgbearing.jpg

af_wiring.png

step 4construct 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 5Bolt it all together

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