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$30 Vertical Axis Wind Turbine From Scrap Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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http://www.instructables.com/id/Vertial-Axis-Wind-Turbine-from-30-Of-Scrap-Materia/
Full power curves have yet to be calculated for this particular build, but according to Mr Ed Lenz's calculator (http://windstuff.org/calc/calc.php) a six vane at 0.93 meters
diameter and 1.1 meters high with a 90% efficient alternator should produce at least 135 watts of electricity in a 30 km/h wind, and 1.05 kilowatts at 60 km/h.
The materials listed in this tutorial are to make the three vane version. Double everything except the bike wheel for six vanes.
http://www.instructables.com/id/Vertial-Axis-Wind-Turbine-from-30-Of-Scrap-Materia/
http://www.instructables.com/id/Vertial-Axis-Wind-Turbine-from-30-Of-Scrap-Materia/
http://www.instructables.com/id/Vertial-Axis-Wind-Turbine-from-30-Of-Scrap-Materia/
Flip the vane, place the other former, and fold down the tabs. Place 2 bike spokes or thick wire in the fold of the former and bend it closed.
23:
Slice and remove the former's two outer corners. Cut the smaller triangle level with the edge of the other former half, but give the larger triangle a 2cm offset, so that it
overlaps.
Repeat for the other former.
24:
Take one of the offcuts left over from cutting a former. Cut out a strip which is 7cm wide and 52cm long. (This is assuming you're using a 56cm sheet, for any other size
just cut off 4cm. ie For a 75cm sheet cut the strip to 71cm).
25:
Draw lines from one edge at 2cm and 4cm, so that there are two 2cm strips and one 3cm strip.
Triangulate the strip as shown in the animation.
26:
Mark the middle of the ends of the 3cm wide face with lines a couple of centimeters long.
27:
Place the triangulated strut inside the vane so that the 3cm face sits on the row of drilled holes closer to the back edge. Sight the drawn lines through the top and bottom
holes to check that it's centered.
28:
Drill the strut through the holes in the vane and attach with rivets. Do the top and bottom holes first, then the two in the middle.
29:
Take a fresh sheet and cut in half. (This is assuming a 67cm wide sheet, for any other size just cut at 33.5cm).
Remove 4cm from one of the short edges.
30:
Repeat twice more so that you have three 33.5cm sheets. Align and peg all three together.
31:
From one of the long edges, draw three vertical lines at 1cm, 9cm, and 19cm.
Mark these lines in from both ends at 1cm and 17cm. If you're using other than 56cm high sheets then just mark so that the lines are divided into thirds, more or less.
Drill a 4mm hole at each of the twelve marks.
32:
Mark the sheet at 3cm and 5cm in from the opposite edge.
Triangulate the edge as shown.
33:
Place the half sheet inside the vane so that its un-triangulated edge is aligned with the vane's back tip.
34:
Drill and rivet the row of holes closest to the back edge. Keep the half sheet as flat and unbuckled as possible. It's ok to have a small gap or bowl at either end if it doesn't
fit perfectly in the vane.
35:
Stand the vane upright. Push the half sheet's triangulated edge in and forward so that it's against the other sheet and somewhat tight over the strut.
Drill through the row of holes on which the triangle is sitting and rivet in place.
36:
Drill through one of the middle holes in the half sheet's second row, making sure to keep the drill reasonably straight, and attach with a rivet and washer, so that the
washer is on the inside of the vane.
Repeat for the other three holes.
37:
Drill, rivet and washer the third row. The half sheet should be fairly tight across the strut.
38:
Fold up the overlap on both formers to 90 degrees.
39:
Drill through all the holes on the bottom former (the one which will be attached to the bike wheel). Drill into a small block of wood or similar so that the metal doesn't get
pushed in and so that you don't risk drilling your hand.
40:
Rivet each of the holes, except for the ones marked as in the animation, as these will be bolted to the wheel rim.
41:
Drill the holes in the top former and rivet all except the center one.
42:
Take your bike wheel. You may want to give the inside of the hub a clean, in which case use spanners to remove the axle from the hub and wipe everything down with
paper tissue or similar. Be careful not to lose any ball bearings.
Set the nuts so that as much length of axle as possible is on one side of the wheel (away from the sprockets if your wheel has them) and retighten so that the wheel runs
http://www.instructables.com/id/Vertial-Axis-Wind-Turbine-from-30-Of-Scrap-Materia/
smoothly and doesn't wobble. There are various videos on Youtube on how to do all this.
Drill three 4mm holes evenly spaced around the the rim, as close to the edge as possible. Your wheel should have 36 spokes, so drill a hole every 12 spokes.
43:
Poke an M4 bolt up through one of the holes and through the backmost unriveted hole in the bottom former of the vane. You may need to poke the former's bike spoke
out of the way, make sure it's on the outside of the bolt.
Place a washer, a spring washer, and a nut. Don't fully tighten yet.
Align the vane so that the other two unriveted holes sit on the edge of the wheel rim and mark with a pen through the hole.
44:
Rotate the vane away so that you can drill the two marks.
45:
Move the vane back and lock down with bolts, washers, spring washers, and nuts. Fully tighten all three.
You may need to drill out a part of the rim to allow the head of the bolt to sit close. If the bolt is poking out to much it may hit on the chain you'll probably be using to drive
your application.
46:
Assemble two more vanes from your remaining formers and sheets and attach them to the wheel.
47:
Take another sheet offcut and slice out a strip 9.5cm wide and 67cm long.
48:
Mark with lines so that you have widths of 3.5cm, 2cm, 3cm, and 1cm. Mark the 1cm width on both sides.
Flip the strip over and bend the 1cm width to 45 degrees. Flip back and triangulate as shown.
49:
Drill a 4mm hole 8mm in from each end of the strut on the 1cm flat area. Drill and rivet a hole at the midpoint.
Repeat twice more so you have three struts.
50:
Place an M4 bolt up through the unriveted center hole in the top of one of the vanes, and through the end holes in two of the struts. Add a washer, spring washer, and
nut.
Repeat with the other two vanes and the last strut. Lock all tight.
51:
The top of the vanes need to not be twisted relative to their base. Place the turbine on the ground so you can look down on it, stand over one of the vanes so that you can
see the long edge of both formers. Twist the top former so that it lines up with the bottom one, over correct a degree or two as it will slip back.
Drill a hole through one of the struts and the former 1-2cm from the edge. Add bolt, washer, spring washer, and nut. Recheck the alignment, drill the other strut and nut
bolt etc. Tighten all three.
Repeat for for the other two vanes.
You're done!
52:
Optionally, you can add an extra three vanes to the underside of the wheel.
http://www.instructables.com/id/Vertial-Axis-Wind-Turbine-from-30-Of-Scrap-Materia/
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Comments
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bethmwl says:
Very impressive. The construction video was so cool to watch as each piece came together.
SolarFlower_org says:
Thanks!
http://www.instructables.com/id/Vertial-Axis-Wind-Turbine-from-30-Of-Scrap-Materia/