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.
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.
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.
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.
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
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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