Blades
.......................................................................
Alternator
.................................................................
Grid connection
........................................................
Furling system
..........................................................
Units
.........................................................................
.................
esign decision: where to fit the rectifier4Some rules for adapting the design
..........................
8'
I2Aml machine conmction -materials 1Notes
on
workshop safety 10
BLADE THEORY
11
Blade power
.............................................................
1
Blade speed
..............................................................
1
Blade number
..........................................................
1
Blade shape
..............................................................
11
Cawing the blades 12
STEP ONE is to create the tapered shape
...............
12
......
TEP TWO carving the twisted windward face
12
...............................................
hecking the drop 13
.......................
TEP THREE carving the thickness13STEP FOUR Carve the curved shape on the back ofthe blade
.................................................................
4STEP FIVE Assembling the rotor hub
....................
15
.........................
utting the roots to
120
degrees15
.............
arking and drilling the plywood disks15
.............................
lamping the blades together 15Drilling holes for the mounting bolts
..................
16
....
TEP SIX Cutting out and gluing on the wedges 16
ALTERNATOR
THEORY
n
Preparing he bearing hub 18
....
rilling out the
112'
[12 mm] holes in the flange18
Fabricating he alternator mounts 19
The Yaw Bearing
.....................................................
19Alternator mounting bracket
..................................
19Stator mounting brackets
.......................................
0
Mounting the stub shaft/axle
.................................
21
Vauxhall
/
Ope1 hub
........................................
1
Trailer hub and stub axle
....................................
1
USA GM hub
.......................................................
1
~rllllnghe magnet rotor plates22Making the stator mould 23
Mark out the shape of the stator
.............................
3
.......................
ut out the stator shape in plywood24
....................................
crew the mould to its base24
Making the coil winder 25
ELECTRICAL THEORY
26Winding the coils 26Connecting the calls 27
Hints for soldering
..................................................
7Soldering the coil tails
........................................
27The ring neutral
......................................................
8The output wiring
...................................................
8
casting the stator 29
Putting it together
...................................................
9Removing the casting from the mould
...................
0
The magnet-positioning ig 30Making the two rotor moulds32
Parts of the moulds
.................................................
2
Casting the rotors 33
Handling the magnets
............................................
3Gluing the magnets to the disks
.............................
33Dry run
...................................................................
3Checking for magnet polarity
.................................
33Preparation for casting the rotors
..........................
33
..................................................
utting it together 33
FURLING SYSTEM THEORY
34
Why furl?
...............................................................
4How the furling tail works
.....................................
34Controlling the thrust force
....................................
5
Fabricatlng he tall hinge 16
The tail itself
...........................................................
7
Cutting out the tallvane 38Mounting herectlfier bAssembling the alternator 40
Preparation
............................................................
0Hub and shaft
........................................................
0Stator mounting holes
........................................
0Back magnet rotor
..................................................
40
................................................................
he stator 41Front magnet rotor
.................................................
1
Connecting the rectifier 42Testing the alternator 42
Short circuit tests
...................................................
2AC voltage tests
......................................................
2DC voltage tests
......................................................
2Connecting to the battery
.................................
3
~annectinghe battery 43
Fuses or circuit breakers
........................................
3
...........................................................
onnections 43
...........................................................
rake switch 43Safety
......................................................................
3
Choosing soltable wire slzes
44
Wire type
................................................................
44
Fitting and balanclng he blades 45
............................................
hecking the tracking 45Balancing the rotor
................................................
5
.............................................................
ine tuning 46
Guyed tower ideas 47Controlling he battery charge rate48
Shunt regulator circuit
...........................................
48
10 foot 13 metre1wind tubne9
Wiring connections
............................................
9
12foot 13.6ml wind turbine 50
...............................................................
he stator 50Winding details
..................................................
0Wiring and connections
......................................
1Magnet rotors (2 in number)
..................................
2Alternator Mounts
..................................................
2Blade Dimensions
..................................................
4Making the plywood triangle
..............................
4Tail hinge design
.....................................................
5
.......................
he moment of weight of the tail56
4 foot n.2ml diameter wind turbine57
Blades
......................................................................
7Bearing hub
.............................................................
7The shaft
................................................................
8
......................................................
otor moulding 58
..........................................................
tator mould 60Assembly of the stator
............................................
60
......................................................
he yaw bearing 61The tail bearing and tail
........................................
1
.............................................
iring up the battery 62
Using polyester resin
63
.................................................
ould preparation 63
Workshop toole 64
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