The Basics:
Normally, I try to discourage folks from building their own wind generator from
scratch. My reasoning? The failure rate of home-built wind
systems is extraordinarily high. The principle reason for these
failures is a lack of understanding of the two major laws of
physics concerning wind power. In simple terms, the first law
states that the power available in the wind is proportional to
the cube of the wind speed. This means that if the wind speed
doubles, say from 5 to 10 miles per hour, the power available at
the wind generator blades increases by a factor of eight! Even
small increases in wind speed yield major gains in power. An
increase in wind speed from 10 to 11 miles per hour results in a
33% increase in the power of the wind.
Some Wind-system Basics:
Normally, I try to discourage folks from building their own wind
generator from scratch. My reasoning? The failure rate of
home-built wind systems is extraordinarily high. The principle
reason for these failures is a lack of understanding of the two
major laws of physics concerning wind power. In simple terms,
the first law states that the power available in the wind is
proportional to the cube of the wind speed. This means that if
the wind speed doubles, say from 5 to 10 miles per hour, the
power available at the wind generator blades increases by a
factor of eight! Even small increases in wind speed yield major
gains in power. An increase in wind speed from 10 to 11 miles
per hour results in a 33% increase in the power of the wind.
The second law states that the power available to the blades is
proportional to the square of the diameter of the rotor. In
other words, if you double the diameter of the rotor by making
the blades twice as long, you increase the power by a factor of
four.
Many folks think, "As long as I'm building by own blades, why
not make them twice as long as I think I need them?" You will
get more power when the wind is blowing lightly, but unless
everything in the windmachine is designed to support the larger
blades, it will be destroyed by the first violent windstorm.
The purpose of this discussion is to warn the prudent to err on
the side of caution. We all know what happens to weak links.
Something flimsy or underbuilt will probably be the downfall of
the project. Remember that you are dealing with machinery that
may weigh as much as an automobile engine, mounted high in the
air, with extremities that are rotating at several hundred
rpm.
Generally speaking, it can be said that the more advanced the
design, the longer the components will last. "Advanced" does
not mean complicated. (Remember the KISS rule: "keep it
simple, stupid".) The wind systems that have lasted through the
decades almost always have simple designs. Stay away from
complex electronics, hydraulics, and mechanical systems on the
tower. While lots of levers and springs and gizmos may look
neat, they will consistently come back to haunt you.
Wind-system Plans
These plans for wind systems have been gleaned from the hundreds
of designs published over the last six decades. Only the best,
most workable designs, and only those plans that are still
readily available to the public are listed.
The plans are categorized in three classes based on the
following criteria: Beginner: relatively simple designs that
can be fabricated with the use of hand tools.
Intermediate: more complicated designs that require the use of
such tools as a drill press, band saw, sheet metal brake, or
welder. Advanced: the most sophisticated designs requiring
skilled use of such machine tools as a metal lathe or milling
machine.
The "intermediate" and "advanced" projects listed are, for the
most part, tried and true designs with the bugs worked out of
them. Those categorized as "beginner" may need some
modifications and refinement. While it is unlikely that your
local library will have many of the books or periodicals listed
below, a good library should be able to get them for you through
their interlibrary loan program. Be sure to give the library
all of the information listed.
Beginner
Home Six-Volt Wind-Electric Plans, by H.F. McColly and Foster
Buck, published by the North Dakota Agricultural College
Extension Service, Fargo, ND, January, 1939. Reprinted by the
Mother Earth News in 1975 as Stock #81005. This 19 page booklet
describes a very simple direct-drive design that can use any
automotive generator, not just 6 volt, for generating up to
several hundred watts. Included is a section for carving a 5'
wooden blade.
Wind and Windspinners, by Michael Hackleman, Peace Press, 1974.
This classic walks you through the design and construction of a
Sovonious rotor coupled to an automotive alternator. S-rotors
are low-speed drag devices more suited to pumping water. They
are low tech and easily fabricated. Good beginner projects for
low budget, low wattage applications.
"Recycled Wind Generator", Energy Primer, by the Portola
Institute, 1974 (ISBN #00-914774-00-x), pages 86 and 87. This
article details the building of a tilt-up, 300 watt generator
similar in design to the old Parris-Dunn machines (now used by
Southwest Windpower in their Windseeker II). Included is
information on rewinding the automotive generator for slow
speed. No details on blade construction. "Transformation of an
1880's Wind Pump to a Wind Generator at King School", by John
McGeorge, Alternate Sources of Energy Magazine, #24, 1976 (ISBN
#0-917328-14-0), pages 18-22. A simple design using an
automotive alternator. Details included for carving a good 10',
3-blade rotor from wood.
"The Flight of the 'Red Baron'", Mother Earth News, #92,
March/April, 1985, pages 96-102. Very low-tech sailwing type of
wind generator using plumbing fittings for the mainframe and
fabric for the "blades". Output is about 70 watts.
"The Blue Max: Affordable Wind", Mother Earth News, #93,
May/June, 1985, pages 100-105; with an update in MEN, #94, page
101. The second generation of the "Red Baron", and considerably
larger at 350 watts. Like its predecessor, the "Blue Max" is
also constructed of pipe fittings and fabric.
"The Wind Blows Free", by John McGeorge, John's Workshop,
Alternate Sources of Energy Magazine, #43, May/June, 1980 (ISBN
#0-917328-33-7), pages 34-38; with an update in ASE, #47,
January/February, 1981 (ISBN #0-917328-37-x), page 53.
Construction of a complete micro-wind system using a 3 watt
bicycle generator and a model airplane prop. Schematics for a
voltage doubling control panel are included. This is for the
tinkerer with very modest needs.
Three others should be mentioned. While not complete plans,
there is enough information in the citations for the clever
person to work with.
"Build Your Own Budget Windcharger", by Harry Kolbe, Mechanix
Illustrated, February, 1978, pages 56-60. Diagrams illustrate
the basics for building a downwind sailwing generator using an
automotive alternator with step up sprockets and chains.
"Here's How I Built A Wind Generator", by Winnie Red Rocker,
Handbook Of Homemade Power, published by Mother Earth News,
1974, pages 198-203. This same article was also published under
the title "Build A Wind Generator", in Alternative Sources of
Energy -Book One, edited by Sandy Eccli, 1974 (ISBN #0-8164-
9247-6), pages 70-71. Describes a system using an automotive
generator, with tips on constructing a 7' wooden blade.
"I Built A Wind Charger For $400", by Jim Sencenbaugh, Handbook
Of Homemade Power, published by The Mother Earth News, 1974,
pages 186-197. Also published under the same title in Mother
Earth News, #20, March, 1973, pages 32-36. Still another plan
using chains, sprockets, and an automotive alternator.
Intermediate
"Do-It-Yourself Wind Generators", by Jim DeKorne, Producing Your
Own Power, Rodale Press, 1974 (ISBN #0-87857-088-8), pages
43-60. While not complete plans, this excellent article
describes a copy of the old Jacobs Twin Motor, a wind generator
utilizing two aircraft generators, to produce up to 4800 watts.
Contains a lot of good tips, and a few details on rotor
construction.
Design and Construction of a Propeller Type Wind Electric
Generator, by Jack N. Krueger, Bulletin #76-01-EE- 02, The
Engineering Experiment Station, University of North Dakota,
Grand Forks, ND, January, 1976. This 61 page bulletin walks you
through the construction of up to a 3kw wind generator.
Included is a section on building fiberglass-coated wooden
blades.
"The Noble Windgenerator" by Haven Nobel, Alternate Sources of
Energy Magazine, #24, 1976 (ISBN #0- 917328-14-0), pages 4-10.
Very good plans for a timing belt driven automotive alternator.
Construction techniques for fiberglass-over-foam blades, details
for a governor, and data on rewinding an alternator for 120
VDC.
Plans for Construction of a Small Wind-Electric Plant for
Oklahoma Farms (Publication #33), by Arnold Benson, Oklahoma
Agricultural and Mechanical College, Stillwater OK; June, 1937.
This 34 page bulletin contains details for rewinding small
generators, and a good section on blade building including an
excellent set of blade templates. Portions of this bulletin
were reprinted in Wind Power Digest, #4, March, 1976, pages
42-55, under the title "A Small Wind-Electric Plant", by the
same author.
"A 1000 Watt Windplant You Can Build", by John Shelley, Wind
Power Digest, #16, Summer, 1979, pages 38-49. Another gear
driven automotive alternator. Contains details for a governor
and unique set of sheet metal blades.
The LeJay Manual, by Lawrence D. Leach, copyright 1945 by LeJay
Mfg. Co. This 32 page book belongs on every tinkerers
bookshelf. It has recently been republished by Lindsey
Publications, P.O. Box 12, Bradley, IL, 660915-0012, and is
available for $6.70, postpaid. Included in the many projects
are several small wind generators, generator rewinding data, and
the wooden blade plans that most of the above citations
employ.
High-Speed Windgenerator Propeller Plans, by Kucharik Wind
Electric, copyright 1980. Available from American Performance
Products, P.O. Box 1351, Island Heights, NJ, 08732-1351.
Details the construction of a workable 2-blade airfoil for wind
generators. While Kucharik Wind Electric is out of business,
Jim Kucharik has agreed to make the plans available for $12,
postpaid.
Advanced
Building 3-Phase Alternators From 3-Phase AC Motors, copyright
1977 by Norbert Klemp. Seven intense pages of data describing
how to rewind an ordinary 3-phase motor into a permanent magnet,
direct-drive, slow speed alternator for wind applications.
Available for $15, postpaid, from Norb Klemp, 4806 W. Cedar
Creek Rd., Grafton, WI, 53024.
"Concentrated Alternator Design", by Edwin R. Fitzpatrick,
Alternate Sources of Energy Magazine, #38, July/August, 1979
(ISBN #0-917328-28-0), pages 18-19. Enough information is
available in this short article to rewind a 3-phase AC motor to
a wire-wound field, direct drive, slow speed DC generator. All
of the following plans are well drawn sets of blueprints that
any machinist should be able to follow. Postpaid prices are
listed in parenthesis.
Available from Tom Hill, RD #3, Box 806, Boyertown, PA, 19512.
Plans To Build Your Own 3 Bladed, Blade Activated Governor,
13'8" Diameter Rotor ($8.00).
Plans To Build Your Own 2 Bladed, Blade Activated Governor,
13'8" Diameter Rotor ($8.00).
Plans To Build Your Own 2 Bladed, Blade Activated Governor, 9'
Maximum Diameter Rotor ($8.00).
Plans To Build Your Own 6'6" Jacobs Type Blades for the Blade
Activated Governor ($4.00).
Access Any feedback is appreciated. If anyone knows of any
other notable designs, send the details to "Letters to Home
Power". Mick Sagrillo, Lake Michigan Wind & Sun, 3971 E
Bluebird RD., Forestville, WI 54213 ¥ 414-837-2267.