Author Topic: My First 10 Footer  (Read 3490 times)

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luv2weld

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My First 10 Footer
« on: September 05, 2008, 03:34:29 PM »
In 2006, I wanted to increase my charging capability. When I compared the cost of

solar panels to the cost of wind generators for the same amount of power out,

wind power is looking good. Then bring in the fact that wind generators have

the ability to work 24 hours a day, while solar panels are limited to only several

hours each day, and there it is folks. We have a winner!!!


After a lot of reading on this site and several others, and 2 of Hugh Piggott's books,

I jumped in.


After looking at my stash of metal, I decided to go with Hugh's design for a 10 foot

diameter swept area. I didn't have the same bits that he called for in his plans, but I found

I had some heavy inch and a half angle that would substitute perfectly for his 3 inch

channel.





The next step was getting the rotors together. I used a half inch bandsaw blade (with the teeth

ground off) to make the surround to retain the magnets. Heated so it slips over the rotor

plate and allowed to cool and shrink to a tight fit. The magnets are potted in fiberglass

resin with talcum as a filler. You can see that the magnets stand proud of the resin, hopefully

to stir some air to help with cooling.





Then it was time to practice my counting. And after winding 9 coils, 17 Awg, 2 in hand,

75 turns, I was tired of counting.





This shot shows the stator freshly poured before the lid gets clamped on.





After curing for 24 hours, the stator came out of the mold very nicely.





This is the test fit for clearance before painting the stator.





Here, we're using the jacking screws to carefully assemble the generator head.





After all the metal and magnet work is finished, comes the part that most people seem

to be afraid of-----carving the blades. For me it is a quiet time. Lots of time to think, while

getting a good workout on the arms and shoulders. Here's the link to a previous posting

on carving blades.

http://www.fieldlines.com/story/2008/8/21/234112/976





For those who have never carved a set of 10 foot blades, the size is amazing when you

get them mounted. This shows a couple of my neighbors taking it down off the test stand.

They are both about 6 feet tall.

When the wind starts winding it up on the test stand, it reminds you

real quick to Be Careful. Those whirling blades can cause serious damage

to anyone that gets struck by one.




Here, it's being raised, in all it's glory. For those that know that I live in central Colorado,

you're probably wondering about the Texas flag on the tail. My girlfriend is from Texas,

and the flag seems to upset some city folks that have a cabin about 4 miles away. It's OK

for them to fly a German flag, (her mother is from Germany) but it upsets them that we don't

fly a Colorado flag. Some people's children!!!!!





This was completed and flying at the end of August 2006.


Ralph

« Last Edit: September 05, 2008, 03:34:29 PM by (unknown) »
The best way to "kill time" is to work it to death!

SparWeb

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Re: My First 10 Footer
« Reply #1 on: September 05, 2008, 09:46:46 AM »
So I take it the stator is wired in "Lone-Star"?

« Last Edit: September 05, 2008, 09:46:46 AM by SparWeb »
No one believes the theory except the one who developed it. Everyone believes the experiment except the one who ran it.
System spec: 135w BP multicrystalline panels, Xantrex C40, DIY 10ft (3m) diameter wind turbine, Tri-Star TS60, 800AH x 24V AGM Battery, Xantrex SW4024
www.sparweb.ca

Flux

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Re: My First 10 Footer
« Reply #2 on: September 05, 2008, 02:08:58 PM »
Nice work, well done.

Flux
« Last Edit: September 05, 2008, 02:08:58 PM by Flux »

TomW

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Re: My First 10 Footer
« Reply #3 on: September 05, 2008, 02:59:15 PM »
Another great story that would be on the Front Page if doing that didn't make it disappear from "Diaries".


Nicely done, indeed.


Thanks for the share.


Tom

« Last Edit: September 05, 2008, 02:59:15 PM by TomW »

blueyonder

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Re: My First 10 Footer
« Reply #4 on: September 05, 2008, 03:09:57 PM »
 you done sum nice work on that gen . very nice.

  reminds me i got to do better with my painting as yours looks so good.

  also a tip i can use from you is the bandsaw blade.

  that sure makes things more easy. cheers.
« Last Edit: September 05, 2008, 03:09:57 PM by blueyonder »

TheCasualTraveler

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Re: My First 10 Footer
« Reply #5 on: September 05, 2008, 04:19:33 PM »
     Couldn't you have thrown in some sloppy welds or a crooked magnet or something. OK so it's a quality, well built machine that probably puts out lots of power, but what else can it do?


     Just kidding...

« Last Edit: September 05, 2008, 04:19:33 PM by TheCasualTraveler »

tecker

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Re: My First 10 Footer
« Reply #6 on: September 05, 2008, 06:03:14 PM »
Nice that's hugh's machine to a tea .
« Last Edit: September 05, 2008, 06:03:14 PM by tecker »

oztules

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Re: My First 10 Footer
« Reply #7 on: September 06, 2008, 11:04:30 PM »
Beautiful work again Ralph, (Ya know, really, it wouldn't hurt to have a few flaws though... it would make us mortals feel better :-)  )


Ditto to Tomw's comment too.


Keep em cumming.... oztules

« Last Edit: September 06, 2008, 11:04:30 PM by oztules »
Flinders Island Australia

luv2weld

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Re: My First 10 Footer
« Reply #8 on: September 07, 2008, 05:58:21 PM »
I like it!!!!! Can I use that line??????


Ralph

« Last Edit: September 07, 2008, 05:58:21 PM by luv2weld »
The best way to "kill time" is to work it to death!

luv2weld

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Re: My First 10 Footer
« Reply #9 on: September 07, 2008, 06:03:03 PM »
Darn it!!!

You guys, handing out all them compliments!!!!!

Now you made my head so big I got to go get a new hat!!!!


But, let's not read too much into my handle.

Just because I like to weld doesn't mean I'm any good at it!!!!!


Ralph

 

« Last Edit: September 07, 2008, 06:03:03 PM by luv2weld »
The best way to "kill time" is to work it to death!

luv2weld

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Re: My First 10 Footer
« Reply #10 on: September 07, 2008, 06:07:22 PM »
That comment was in response to SparWeb.

Don't you just love Scoop!!!!


Ralph

« Last Edit: September 07, 2008, 06:07:22 PM by luv2weld »
The best way to "kill time" is to work it to death!

SparWeb

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Re: My First 10 Footer
« Reply #11 on: September 08, 2008, 12:01:44 PM »
Okay, it was just a quick turn of phase, anyway.


(....read that carefully)


;^)

« Last Edit: September 08, 2008, 12:01:44 PM by SparWeb »
No one believes the theory except the one who developed it. Everyone believes the experiment except the one who ran it.
System spec: 135w BP multicrystalline panels, Xantrex C40, DIY 10ft (3m) diameter wind turbine, Tri-Star TS60, 800AH x 24V AGM Battery, Xantrex SW4024
www.sparweb.ca