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A Wind Turbine Recipe Book, The Axial Flux Windmill Plans 2009 Version

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A Wind Turbine Recipe Book (2009 English Units edition) This is the latest edition of my 'axial flux windmill plans' as used in the courses I teach worldwide. The Recipe Book replaces my older plans 'How to Build a Wind Turbine' (2005). The Recipe Book is a much better structured document than the older 2005 plans. Rather than evolving 'organically' it is carefully planned to include six different sizes of turbines. Each section offers general advice combined with specific dimensions and diagrams for each of these six sizes and a range of operating voltages. During 2008 the Recipe book was only available in metric units, but in 2009 a new 'English Units' edition is also available (written specifically for North American readers who prefer to use Inches and AWG sizes for wire. It is based on the use of neodymium magnets sized 2”; x 1”; x 1/2”; as available widely in North America.) Make sure you get the book that suits you best.


1. Choosing what to do

A. Be safe! 

B. How big?

C. Diagram of a small wind system

D. What can the wind turbine do?

4 a. Load controllers

5 b. Choosing battery voltage

5 c. Battery types

6 E. Why some popular ideas are not good ideas 6 a. Car alternators

6 b. Steel cores in the stator coils

7 c. Multiple rotors and stators

7 d. Vertical axis wind turbines (VAWTs)

7 e. Multi blade rotors

8 f. Rooftop mounting

8 g. Saving money off the electricity bill

8 h. Mounting a wind turbine on a car to charge the battery

8 i. Using a centrifugal clutch or brake to limit speed

9 j. Building a duct 9 F. What goes wrong with homebuilt wind turbines?

9 G. Useful web pages for more information:

9 2. Tools 10 A. Safety etc 10 B. All-purpose tools

10 C. For marking and measuring

10 D. Electrical 10 E. Resin preparation

10 F. Steelwork

10 G. Woodworking tools

10 3. Using the tools

11 A. Cordless drill

11 B. Screwdriver bits

11 C. Measurements

11 D. Vernier calipers

11 E. Levels 11 F. Compasses

11 G. Multimeters

12 H. Soldering technique

12 I. Electric Arc welding

12 J. Cutting steel

13 K. Drilling

13 L. Tapping a thread

13 M. Wood saws

13 N. Other wood cutting tools

14 O. Sandpaper

14 P. Power tools 14 4. Blades

15 A. Parts of the blade

15 B. Selecting the wood

15 C. The blank shapes

16 D. The trailing edge line

17 a. Mark out the shape of the blade at each of six stations along its length .

17 b. Carve away wood above the trailing edge line to create a new face

18 E. Blade thickness

18 F. Airfoil shape

19 G. Hub assembly

20 a. Cutting the 120 degree angles at the roots

20 b. The plywood pieces that sandwich the blades.

20 c. Marking out the holes in the plywood

20 H. Assembling the blades

21 I. Balancing

22 a. Balancing in situ

22 b. Fine balancing

22 c. Alternative ways to balance the blades

22 d. Balancing on a spike

23 e. Dynamic balance

23 J. Painting and finishing

 23 5. Mechanics

24 A. The yaw bearing

 24 B. The alternator

24 a. Choosing a hub

24 b. The magnet rotor disks 25 c. Alternator frame 26 d. Mounting the alternator to the yaw bearing 27 e. 3600 and 4200 turbines

29 C. The tail 30 a. The inclined hinge 30 b. Tail boom

 31 c. Tail stops

 32 Electrics

34 Energy conversion

34 Choosing wire size and number of turns per coil 34 Stator wiring connections 35 Three-phase stators

35 Battery charging with DC

36 The coils

36 12-volt stators marked *

36 Making the coil winder

37 Winding the coils

38 Connecting the coils

38 12-volt stators

39 The moulds

 39 The stator mould

39 The 1200 stator mould

41 The magnet rotor mould

 41 The magnet positioning jig 42 Resin casting

43 Casting the stator 43 Casting the magnet rotor(s) 45 Alternator assembly and testing

46 Rotor mounting options

46 Rotor mounting studs

 47 Assembly

 47 12-volt turbine rectifiers

48 Testing the alternator

 48 Installation

49 Wiring the batteries

49 The rectifier and brake

 49 Meters

 50 Controller

50 Inverter

50 Commissioning the turbine

50 Guyed towers

 51 Wiring the tower

 51 Guyed tower pipe sizes

51 Guy anchors

52 Lifting the tower

 53 Taller towers

53 Adjusting the guys

53 Alternator design

54 Matching the blades

54 Tip speed ratio (lambda l)

54 Calculating the blade rotor rpm

54 Blade power

54 Calculating the output voltage vs. speed

54 Wire sizes and power losses

55 Size of wire to use

55 Coil resistance 56 Stator resistance

56 Current and power loss

57 Rectifier loss

57 Efficiency

57 Windspeed

 57 Stator cooling

57 Estimating the rpm

57 Blade speed at full power

58 Exploring some design factors

59 Magnet spacing

59 The effects of speed

59 The effects of system voltage on efficiency

 59 Varying the voltage with the speed

59 High voltage transmission

 59 Glossary




There are 1 review(s) for A Wind Turbine Recipe Book, The Axial Flux Windmill Plans 2009 Version

  • Good read that really breaks it down

    by Handi – 14th Dec 2014

    I have this book and really enjoy it - its soft cover and about 60 pages but has loads of pictures and is full of helpful hints and formulas

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