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Turbine Construction Progress

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Boondocker:
Hello,

Attached are progress photos of my second wind turbine project under construction.   This turbine was inspired by the design posted by Chris Olson, 48dc MPPT.

http://www.fieldlines.com/index.php/topic,147278.0.html

http://dairylandwindpower.us/projects/Direct-Drive_3.2meter_MPPT/index.html

I built in some flexibility so adjustment can be made.  Some modifications are:
•   Magnet rotors are 14” instead of 13”, provide more room for possible stator winding changes.
•   The offset for the turbine shaft center line is adjustable, so it can be reposition with a change in blade length.
•    The prop hub, has jacking bolts behind support arms to better align the blade tracking.









The coils are made out of 65 turns of 14g wire



Coils are place in a jig to position them for soldiering and attaching them to one another.

Boondocker:
When making the stator mold, there is a relief pocket to provide extra space for the coil return wire.  This will prevent this wire getting hard press against the top portion of the coil .  Also, having this pocket in the mold allows the active area where the magnets over the stator to be thinner by a wire width.

Boondocker:
Hub
The prop hub design also originates from a Chris Olson project.

 http://www.fieldlines.com/index.php/topic,144577.54.html?PHPSESSID=bd86d441f62e40ca9df585aa8d6bf1a8


Machining the hub plate surface with resources available was found to be difficult.  Encounter much chatter due to plate flexing while surfacing.  A work around was to stiffen the plate by welding gussets to the back.

My machining lesson rigidity is paramount.

Just in case the 0.010” runout affects blade tracking, added fine thread jacking nuts and bolts behind the support arms for fine tuning if necessary.  There is also a kerf cut in the angle iron support arms to provide a deflection point.

Boondocker:
Alternator Testing

An air gap of 0.700” provides a comfortable magnets and stator clearance.   I tried a 0.600” gap and  the stator position just so right to avoid and contact.   

Testing the alternator obtained  2.14dcv/rpm at 0.700” gap, and 2.32dcv/rpm at a 0.800” gap  between magnets.

gww:
Don't stop now, want to see more. How much will it wheigh?  I'm having fun and thanks
gww

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