Author Topic: At long last she Flies!!  (Read 2195 times)

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alibro

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At long last she Flies!!
« on: October 17, 2007, 08:12:40 PM »
Hi everybody

It has been a long time since my last posting and a lot has happened, I was going great guns with my wind turbine project and hoped to get it finished and up during the summer so that I could test everything thoroughly before the winter sets in. Unfortunately my very close friend Gary was tragically killed in a road accident in July. Here is a pic of him helping with my first wind turbine a few years ago.





Needless to say I didn't have much heart in anything for a while, however Gary was a very supportive of my project and I know he would have wanted me to continue, so here is the latest update. If you want to see the first half of this build check out my Diary.





I first balanced the blades by hanging them from a thin wire. The amount of lead you can see on one blade shows how much wood can vary in weight even if all the blades come from the one plank. I guess I should have weighed them before I started carving! To rub salt in I actually made four blades from the one plank but ended up with two heavy and two light. Go figure!!!





I balanced them again when on the alternator as I was a bit concerned I might still get an imbalence when they spin but all seems ok so far.





This is a test raising of the tower. As you can see I made an 'A' frame which might have worked ok with a pulley at the top but was part of the problem which caused my first attempt to fail.





This was the other reason, the winch was not powerful enough.





For anyone out there who has not raised a tower before these turnbuckles are not recommended. On one test raising of the tower the cable slipped out of the open ended jaw and almost caused an accident. Thankfully no harm was done and I purchased turnbuckles with a bolt at either end for the live event. I also put another cable grip on each connection.





Up





Up





And away





The tower is around 26 feet high and yes I will cut down the hedge around it.





So far this project has taken the best part of a year to get this far, and I still have a good bit to do. I need to get batteries, make a shed for the batteries and inverter, sort out a charge controller and dump load, route the mains into the house and sort out which circuit in the house I will put onto the turbine and arrange a flip over switch so I can use grid power when the wind doesn't blow.

To get this far has been a lot of work but great fun, I will update again when I am using the power of the wind.

So far I have only briefly tested in light winds with a small battery bank and the voltage came up to 30V very easily. This doesn't mean much though as the batteries were small and already charged.


Cheers All

Alibro


PS I am undecided whether I should buy a charge controller (either a Xantrex C60 or Morningstar Prostar 30M) or try to build one. Does anybody have any experience of building a charge controller suitable for a 24V DanB 10 footer?

Also can anyone think of a household item which might be suitable for a dump load? What about a kettle element? Could it be connected to the ac three phase side of the rectifiers or am I being silly?

Any ideas appreciated.


Alibro



Sorry, I forgot to push this to the front page earlier. T

« Last Edit: October 17, 2007, 08:12:40 PM by (unknown) »

fungus

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Re: At long last she Flies!!
« Reply #1 on: October 17, 2007, 04:15:49 PM »
Looks pretty good! I would be interested to how it performs at a low level like that, what did you use for guy anchors?
« Last Edit: October 17, 2007, 04:15:49 PM by fungus »

jacquesm

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Re: At long last she Flies!!
« Reply #2 on: October 17, 2007, 04:44:27 PM »
Sorry to hear about Gary... too much death lately.


Congratulations on getting your windmill up, I hope the 3 day curse passed quickly for you.


Question, what is the diameter of the pipe you used for the tower ?


best regards,


 Jacques

« Last Edit: October 17, 2007, 04:44:27 PM by jacquesm »

TomW

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Re: At long last she Flies!!
« Reply #3 on: October 17, 2007, 05:13:05 PM »
Dalibro;


Sorry about the terrible loss of your friend. I am sure he would be proud to see it flying.


Nice looking bit of work. I do not like open hooks on turnbuckles, either but I think you could wire wrap them or something to keep it from dropping off. I picked thru a huge bin finding the ones with eyes on both ends to avoid the open hooks.


Cheers.


TomW

« Last Edit: October 17, 2007, 05:13:05 PM by TomW »

harrie

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Re: At long last she Flies!!
« Reply #4 on: October 17, 2007, 09:25:22 PM »
Sorry to hear about your friend Gary, IT seems like life hangs on a thread, which is good reason to be happy every day.


the project looks great, and thanks for sharing.

« Last Edit: October 17, 2007, 09:25:22 PM by harrie »

richhagen

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Re: At long last she Flies!!
« Reply #5 on: October 17, 2007, 09:33:52 PM »
Congratulations, I am also sorry to here about your friend, he looked too young, I bet he would be proud of you for getting it up and flying though.  You should be able to get eyebolts at a decent hardware store to retrofit to your turnbuckles.  You could also weld a piece of bar or other scrap across the opening to close it up.  It may be an optical illusion, but the pipe looked pretty bowed in the picture where it was half way up.  


Most of the setups I have seen, do not use a charge controller on the turbine, but rectify the 3 phase output to DC and run it directly to the battery.  Then a dump controller is used to dump the excess power once the battery voltage comes up.  I do not think that many charge controllers designed for solar will work that well with the wave form of the rectified output from a turbine in charge control mode.  


Looks great.  Rich

« Last Edit: October 17, 2007, 09:33:52 PM by richhagen »
A Joule saved is a Joule made!

snuffy

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Re: At long last she Flies!!
« Reply #6 on: October 17, 2007, 10:40:26 PM »
So sorry to hear about your friend Gary.  I'm sure he would be proud.  


I think you should check into ghurd's little controller.  I just got one for my 300w-400w 10 footer.  (not flying yet)  Using 3 power FETS and old clothes dryer elements for a dump load I'm pretty sure it will handle the load ok.  During bench testing it looks great but... like I said it's not flying yet.  Check ghurd's files for more info.

« Last Edit: October 17, 2007, 10:40:26 PM by snuffy »

Chagrin

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Re: At long last she Flies!!
« Reply #7 on: October 18, 2007, 12:30:38 AM »
A kettle element is designed to heat water. You'd assumedly shorten its life if you leave it to dump heat to open air. Also, some kettles use inductive heating elements -- they'll be designed for single phase AC and I don't think they'll work at all without water to heat.


Make sure the saddle of your cable clamps stays on the live end of the cable. http://www.gbgindustries.com/Clips2.htm

« Last Edit: October 18, 2007, 12:30:38 AM by Chagrin »

alibro

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Re: At long last she Flies!!
« Reply #8 on: October 18, 2007, 10:38:22 AM »
Thanks for the advice about the saddle, I will check that they are correct. Any other ideas for a dump load?


Alibro

« Last Edit: October 18, 2007, 10:38:22 AM by alibro »

alibro

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Re: At long last she Flies!!
« Reply #9 on: October 18, 2007, 10:41:16 AM »
it is around 2" diameter (the correct size to fit into the wheel strut) but has another pipe up the inside which is a nice tight fit.
« Last Edit: October 18, 2007, 10:41:16 AM by alibro »

alibro

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Re: At long last she Flies!!
« Reply #10 on: October 18, 2007, 10:50:15 AM »
Thanks for that Rich

I think it was a dump controller I was thinking of. I have contacted Ghurd regarding his.


Alibro

« Last Edit: October 18, 2007, 10:50:15 AM by alibro »

alibro

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Re: At long last she Flies!!
« Reply #11 on: October 18, 2007, 10:56:51 AM »
The anchors are 5 feet lengths of angle iron hammered into the ground then concrete poured around the top couple of feet. I am looking forward to getting some figures but unfortunately I don't have batteries yet or an anemometer to test wind speed.


Alibro

« Last Edit: October 18, 2007, 10:56:51 AM by alibro »

elt

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Re: At long last she Flies!!
« Reply #12 on: October 18, 2007, 12:03:53 PM »
Hi Alibro, you asked:


Does anybody have any experience of building a charge controller suitable for a 24V DanB 10 footer?


I built a 24v DanB 10 footer and a 50 amp dump load controller for it. I did have some problem at first with the FET driver (and smoked some FETs) but with the feedback and help of a lot folks here I think it has ended up being a very robust design. It has only be running for two months and I think that's a bit short for saying it's "proven." On the other hand, it has worked flawlessly for 2 months (knock on wood) and doesn't cost much more than the cost of your FETs.


http://www.otherpower.com/images/scimages/6527/dumper_5.jpg

http://www.otherpower.com/images/scimages/6527/DumpBoard_319as.gif


It all controlled by a $3 micro processor chip; if you wanted to build one I'd be happy to program one for you and as many spares as you might want. (I've only ever blown one Atmel uP and it wasn't on this board; spares are just for piece of mind.)


I've also, again with the help of this board, designed and built a "feature rich" dump controller that's completely analog. It's only been bench tested yet so I wouldn't recommend it unless you are particularly adventurous. (The first controller is working so well that I'm in no hurry to replace it.)


http://www.otherpower.com/images/scimages/6527/3_StageBuild_1.jpg


This one has switch selectable (manually selected) float, charge and equalize modes and is temperature compensated. It will handle 40 to 60 amps depending on the FETs and heat sinks. The charge mode can also be remotely selected and will eventually be controlled by my charge controller module but that's still in the works.


If you are interested, I'll help you however I can.


- Ed.

« Last Edit: October 18, 2007, 12:03:53 PM by elt »

alibro

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Re: At long last she Flies!!
« Reply #13 on: October 18, 2007, 03:24:31 PM »
Thanks for your reply, It looks great. I have been in touch with Ghurd and have agreed to buy his controller(s) so I think I will go that way for now but thank you for the offer.

By the way if you don't mind me asking where did you get the resistors? I have seen suitable ones on ebay but only from the USA


Cheers

Alibro

« Last Edit: October 18, 2007, 03:24:31 PM by alibro »

Kevin L

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Re: At long last she Flies!!
« Reply #14 on: October 18, 2007, 03:25:34 PM »
Just use a Baseboard Convection Heater for your dump load.  Can take A/C direct from the generator, and you can minimize losses associated with rectification.  Can pickup a unit for less the $40.00 at local hardware store.  Tea kettle Idea would work as long as you keep water in it all the time, with the benefit of adding humidity in winter if you're in a cold climate.  No water and the thermal fuse will blow, and they are not easily accessible to replace on most models.


Kevin L

« Last Edit: October 18, 2007, 03:25:34 PM by Kevin L »

elt

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Re: At long last she Flies!!
« Reply #15 on: October 18, 2007, 04:58:18 PM »
> where did you get the resistors?


ebay. Here's exactly what I'm using and it looks like he ships to you,

you'd just have to ask for a shipping quote...

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&rd=1&item=130075319196

Hope that helps,

- Ed.

« Last Edit: October 18, 2007, 04:58:18 PM by elt »

alibro

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Re: At long last she Flies!!
« Reply #16 on: October 19, 2007, 12:56:37 PM »
Hi Kevin

Thanks for your reply, I had thought of using the A/C side myself but I'm not sure how to connect it as it is a three phase alternator.

Would I connect each phase to one end of a heater element and short out the other end of the three elements?


Alibro

« Last Edit: October 19, 2007, 12:56:37 PM by alibro »

Kevin L

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Re: At long last she Flies!!
« Reply #17 on: October 19, 2007, 03:01:33 PM »
Ah, three phase, you would need two baseboard heaters connected together in a series circuit.  Just connect the third phase between the two heaters, and make sure the two heaters are properly wattage rated to handle anything the mills can output.  Light Bulbs could be used but a strong disadvantage to high wattage bulbs is that over speeding of the mill will occur if you lose the filaments.  When you buy the convection heaters, they are UL rated which is a plus compared to the power resistors.  As I am not familiar with your skill sets please use an abundance of caution and contact an electrician if you're unsure.


Kevin L

« Last Edit: October 19, 2007, 03:01:33 PM by Kevin L »