I have decided to build a wind turbine.
Since everything is always done on a large scale in Texas, it just doesn't seem right to start off building a small turbine....
So I have decided to just jump in with both feet and hope that when I get in too far over my head, you guys might throw me a lifeline before I go down in flames so to speak...
I want to build a 48 volt 20' machine. I know it is pushing the limit, but I am a firm believer that there is ALWAYS a workaround.
From what I gather, dissipating heat in the stator is the main concern in the larger machines.
I have run across a new epoxy system and was wondering if any of you guys have ever used it.
http://www.resintechgroup.com/casting.html
With this resin I was planning on designing a stator mold that would incorporate a heat sink design around the parameter.
Along with cooling fins around the outside of the stator, I was considering casting legs, coming off the main stator body that you would drill out for the SS all-thread. Instead of the current stator mounting brackets, I was considering welding a flange on the hub. Then bolting a thick, aluminum, roundish plate with a heat sink design machined into it's surface. The legs extending off the stator would contact the heat sink and further draw more heat away from the coils.
The magnets would mount in recessed pockets about .08" deep and be secured with one flat head SS cap screw through the center. Tapping a blind hole into the magnet.
Grinding a small notch and center punching a burr into the notch on the head of the screw, would stop it from ever backing out.
I was considering not even using epoxy on the rotors at all. This would cause the gaps between the magnets to move air as well.
Does this make any sense? or am I over engineering?
Murlin