(Remember all of this is still purely speculative at this stage)
OK thanks to reading many threads here in these forums and others for over a year I have pretty much settled on the design for my small generator of roughly 3KW it will be a home brew Axial based on Chris O's Fabricator's and Frans's 3 meter class turbines 15 coils 2 x 20 magnets geared up 1to 5 with a combination of mine and Frans's active / passive pitch control designs. I'm not concerned with the blades all that much since many years past I have helped make blades for competition air boats and after reading one of Hugh Piggott's books and seeing how 100s of blades are made those are just a matter of a lot of mind numbing labor unless I decide to buy or build a CNC router which is an option since I have other planned projects one of these could be used for Or I might simply hire them made. Something I rarely do for anything except for hiring a technician or laborer to help me.
For controllers such as Mppt and inverters will be determined when I decide on how much storage and solar I will have or need a lot will depend on if I am able to get grid in the area where I will be moving to or not If there is, or will be grid this is all moot since this will become little more than hobby experimentation or coupled with a stand by generator for back up in the advent of grid loss There will be no grid tie considered.
For my strictly experimental large turbine which may be used to power my shop should it work out I've narrowed my design down to a 90 coil 120 magnet radial 39 “ diameter at the separation point between the magnets and the coil cores 7 inches thick using 1â€x1†by 7†magnets and “T†shaped core laminations I'm estimating 150 turns of 15ga per coil with 30 coils per phase if connected in series that would be 4500 turns if connected 3 by 10 series parallel then it would be3 x 1500 turns 5x6 would be 900 turns 6x5 = 750 or 10x3 = 450 or finally 30x1=150. The higher turn count would mean much higher VOC @ lower amps the lower turn count configuration would be lower VOC with higher amps. One way has a higher susceptibility to total voltage loss with a shorted coil the other extreme is least susceptible to coil shorting. The transformer required to turn this into useable voltage suffers at both ends of the scale as well I am targeting for 60 RPM for the rotor controlling the RPMs with the pitch controller fine tuning the output voltage with a linear variable transformer moving the core VIA the pitch controller as well since this will be a 3 ph line voltage output it will need a transformer for each leg .
Due to the limited amount of magnet area I don't expect the output current will be anywhere near that of a wound rotor could be and I don't care since I have a Turkish made 30 KW gen set with a 4 cylinder Perkins
None of this can be made until I relocate because my home workshop is too small to do much more than a small amount of the machining and everythi9ng I was to build would just take up more space and weight for shipping