axial generator with lamination core

[mbouwer]

Due to low weight ( but in mind the necessary stiffness ) I assembled the spokes and the ring of the stator bracket out of thin steel sheet.

[mbouwer]

The composition can now be mounted on the yaw bearing.
First I want to make the blade pitch mechanism.

[mbouwer]

Bracket for mounting the stator bracket ( and bolted to it the main bearing ) on the yaw bearing.
My intention is to shape all parts in a way that scaling up and reinforcing is easy to do.

[MattM]

Did you bend a c-channel into a nice bow shape?  Impressive.

[mbouwer]

@MattM,
It is for the connection of the nacelle hood to the statorbracket.

[MattM]

Stretching metal is an art.  Unless someone has tried it, its hard to appreciate the skill.  I know it is not easy to keep it in a nice uniform shape.

[Ungrounded Lightning Rod]

Bracket for mounting the stator bracket ( and bolted to it the main bearing ) on the yaw bearing.
My intention is to shape all parts in a way that scaling up and reinforcing is easy to do.

I'd expect enormous bending forces on those side braces.  Have you considered making them about twice as wide (continuing up and back twice as far)?  I'd think that would at least quadruple the strength.

(Adding a diagonal from the top to the rear would also add a lot of strength, but it looks like
it would get in the way of something - at least the rear bolts..)

[mbouwer]

A new lighter and wider version of the driven yaw bearing. Made of 1 and 2 mm sheet steel.

[MattM]

For U.S. folks its 18 gauge for 1mm and 12 gauge for 2mm.

[mbouwer]

As the basis for the yaw bearing the top 16.69 inches of the mast.

[mbouwer]

A layer of polyester around the mast and yaw bearing also provides protection against the weather.
I want a tilting mast, so I aim for lightweight above the tilting point.

[mbouwer]

My axial version of Reply # 524 is too small.
On this new shaft I want to mount magnet rings with a diameter of 150 mm.

[Bruce S]

Is it me? or does the latest picture look like the axial is broken?

Bruce S

[mbouwer]

@ Bruce S,
The shaft and hub are still in raw condition here, and I still have to weld the mounting for the magnet rings on it.


I am now making a mold for assembling the 2 magnet rings.

[mbouwer]

The magnet rings must become 20 mm wide and 170 mm outer diameter.
It's about making them identical, tight and lightweight, and that's why this mold.

[mbouwer]

Each assembled magnet ring tube will consist of 3 rings of 1 mm thick
and 1 ring of 2 mm thick. Against that ring I want to glue the 5 mm thick magnets.

[mbouwer]

The new stator will have a nominal diameter of about 150 mm

I want to stick to Felix Niessen's Bavaria Winding Scheme Calculator.

27 coils with iron core and 30 magnets ( 20 x 5 x 5 )

[brandnewb]

Inspired by the professional windmills around, the idea is that I first need to create test setups,
 
to, together with windmill builders on this forum, search for a design of a light direct drive generator with operational reliability.

In doing so we must be able to build that generator with stuff that is common and easy available for me and windmill friends on the forum.

It seems to me that the generator is the most difficult component.

I am also on a mission to create a working turbine that actually does something.
In my, now more than 1 year, oddesy I am left to believe the first step is to focus on the turbine. And then match the aternator to go with it.

I made the blunder of first spending time on designing the sickest alternator ever. Only to learn later that there is no turbine that can deal with it

But since you and I both are from the low lands. May I please ask what is your typical wind speed where you want to harvest from?

Here it is in the 3m/s range. But since I have a somewhat large lake adjacent to my lawn and if winds are from the north then things can get a bit brutal.

[mbouwer]

@ Brandnewb,

Since the beginning I've been following your thread.
I have an average of 5 m/sec here, but you can also harvest energy from 3 m/sec.

Let's talk about the possibilities.

[mbouwer]

Magnet rings and main bearing.

[mbouwer]

In between a setup for a smaller driven yaw bearing for a profile work piece.
The hub with hardened steel rings and an outer diameter of 72 mm

[mbouwer]

On the right the 1 degree conical mast top part of 20 cm long.
On the left the yaw bearing with the cuff that fits on this top part.
I'm going to cover the outside with polyester.

[brandnewb]

@ Brandnewb,

Since the beginning I've been following your thread.
I have an average of 5 m/sec here, but you can also harvest energy from 3 m/sec.

Let's talk about the possibilities.

(Attachment Link)

Sorry @mbouwer, I have missed the email notifying me of your response.

I am ready to talk more details once I have my prototype turbine spinning for some time. earlier tests have been done but not too confidently yet.

THe image you posted is of a rather large / high turbine. That is something my municipality will never allow for though.

I'll keep one updated once more trustworthy results come in after my holiday.

[mbouwer]

Small main bearing for the new set up.
Largest diameter is 80 mm

[mbouwer]

The blade suspension pitch bearings:
I think they should be part of the blade root.
And no moisture should get in.
I want to start with hardened steel rings ( 55 mm inner diameter ) of a scrapped bearing.

[mbouwer]

Components for the blade shafts.
The blade must be able to make about 90 degrees of rotation suspended in the slide bearing and the ball bearing.

[mbouwer]

The blade shafts. A layer of slidingbearing material is welded on the cuffs.
The right cuff jhas already been turned to 55 mm diameter with the correct fit in the hardened bearing rings.

[mbouwer]

Basically for the blade suspension I am making large diameter light versions of a king shaft.

[mbouwer]

My intention is to cover the blade suspension completely and to shield it as much as possible from the weather conditions.

[mbouwer]

Scalable lightweight blade shafts.
I will now make a smaller version for the profile workpiece.

[mbouwer]

To keep the moisture out, I want two O - rings per axle in the slide bearings.

[mbouwer]

For the workpiece a light version of a main bearing.

[MattM]

The quality of your casts has gone up considerably from the beginning.  Very nice looking.