Introduction
Building a vertical axis wind turbine (VAWT) can be a rewarding project for those interested in renewable energy. This guide covers two methods: using scrap materials like aluminum lithographic offset printing plates and a bicycle wheel, or repurposing parts from a front-load washing machine. Both methods are suitable for educational purposes or small-scale energy generation.
Materials and Tools
Scrap Materials Method
- Aluminum lithographic offset printing plates
- Bicycle wheel
- Basic hardware (bolts, nuts, washers)
- Hand drill
- Pop riveter
- Car alternator (optional for electricity generation)
Washing Machine Motor Method
- Front-load washing machine motor assembly
- Jigsaw
- Hacksaw
- Hole saw
- Strain gauge
- DAQ software
- Threaded rod
- PVC pipe
- Automotive brake rotor fixtures, wood, or plastic
- Screwdrivers, wrenches, hammer
Construction Steps
Scrap Materials Method
- Gather Materials: Collect aluminum printing plates and a bicycle wheel. Ensure you have access to basic hardware and tools.
- Design Selection: Choose between a three-vane or six-vane configuration. The six-vane version is more efficient in higher wind speeds.
- Assembly: Use a hand drill and pop riveter to attach the aluminum plates to the bicycle wheel. Follow the Lenz2 lift+drag design for optimal energy capture.
- Testing: Ensure the turbine can withstand winds up to 80 km/h for the three-vane version and 105 km/h for the six-vane version.
Washing Machine Motor Method
- Motor Removal: Extract the motor assembly from a front-load washing machine, preserving the coil, magnet, and shaft components. Use tools like screwdrivers, wrenches, and possibly a hammer to separate parts.
- Cleaning Components: Remove rust from coils and magnets. Apply a light coat of oil or clear sealant to prevent future corrosion.
- Hub Design: Create a hub to align coils with magnets and incorporate bearings. Use materials like automotive brake rotor fixtures, wood, or plastic. Ensure the hub allows for wiring access.
- Shaft Assembly: Retain the original washing machine drum shaft with bearings. Attach threaded rod to one end for blade assembly connection.
- Generator Assembly: Mount coils and magnets onto the hub and shaft. Test voltage and RPM output by spinning the assembly manually.
- Blade Construction: Use PVC pipe to create blades inspired by vertical-axis designs. Cut flat sections with a jigsaw and rounded edges with a hacksaw. Drill a central hole for the PVC post using a hole saw.
- Final Assembly: Attach blades to the threaded rod and mount the generator on a structure (e.g., porch, tree). Expect 50-100W output from a 400W-rated motor in optimal wind conditions.
- Testing: Measure torque using a strain gauge and DAQ software. No-load torque averages 0.39 ft-lbs, full-load torque is ~1.25 ft-lbs.
Electrical Generation
For electricity generation, attach a car alternator to the rotor. A car alternator has an efficiency of about 50%. The expected output is 158 watts at 50 km/h wind speed for the three-vane version and 649 watts at 80 km/h for the six-vane version. A six-vane setup with an efficient alternator can generate up to 1.05 kilowatts at 60 km/h.
Applications
The turbine can be used for educational projects, small-scale energy generation, or mechanical tasks like water pumping or flywheel spinning if electricity generation is not required.
Key Takeaways
Both methods offer cost-effective ways to generate renewable energy. The scrap materials method is simpler and uses readily available materials. The washing machine motor method requires more mechanical skill but offers higher efficiency. Proper testing and maintenance are crucial for long-term operation.
Summary
Building a vertical axis wind turbine using scrap materials or a washing machine motor is a practical way to generate renewable energy. Each method has its advantages, with the scrap materials method being simpler and the washing machine motor method offering higher efficiency. Proper assembly, testing, and maintenance ensure long-term operation and reliability.