让咱们创建一个直径为10英尺的风力发电机。本机是计划简略，重要是基于休皮哥特的设计。它的特色为3相发机电。
This page serves as an index of pages that detail how we build a10'diameter wind turbine.The machine is of asimple design,largely based on Hugh Piggott's designs.It features and axial flux 3phase alternator.It should be fairly efficient in low winds(producing perhaps in the ballpark of 100watts in low 10mph winds)and it should produce around 700watts in winds of 25mph,at which time the machine should begin to furl.Peak power we see from this machine is about twice that(1500watts)although Idon't believe the alternator can withstand that for long.It makes for anice,quiet low wind machine.Below are links to different stages of the project.
第一部份：主机箱制作(金属加工).
This chapter will describe how we build the'frame'for the wind turbine.This involves afair bit of metal work.To do this you'll need to have the ability to cut/grind and weld steel.If you're new to this type of work it might pay to practice your skills on some scraps.The tolerances with this are not terribly,again-the design is very forgiving.But some of the welds are critical so you need to be abit careful.Also keep in mind the dangers of metal work.This is the most dangerous work you'll do to build the wind turbine.Metal is often sharp when you cut it.Grinding can be fairly dangerous-lots of shards flying around and I've seen grind stones explode before,so be sure to wear aface shield.Cutting with atorch or welding has it's obvious hazards(molten hot steel and sparks flying).Just follow proper safety proceedures and odds are you'll live through it.
Materials List 1/4"thick steel plate,15"square(stator bracket发电机组,tail bracket,disk to support the back of the spindle)
1"sched 40pipe,6'long(tail boom,tail pivot)
1.25"sched 40pipe,9"long(tail bearing)
2"sched 40pipe,4"long(to attach alternator to yaw bearing)
2.5"sched 40pipe,12"long(yaw bearing)3"sched 40pipe,3.625"long(pipe to support wheel spindle and stator bracket)1.25"x 1/4"bar stock,5'6"long(tail boom gusse t,tail vane bracket)
Pictured above are all the parts you'll need to make(or have made)before you start.Not pictured above are the parts of the tail itself which we can discuss later,because it is aseperate part.
1-Stator bracket.The stator bracket is cut from 1/4"thick steel plate.It serves to support the front of the wheel spindle(on which the main wheel hub/bearings go)and it supports the stator.To lay it out柴油机发电机组,find center and draw two circles.The inner circle is 4"diameter,the outer circle is 15"diameter.Lay out 3'spokes'120deg apart.The spokes are 1.5"wide at the outer diameter and 2"wide where they meet the inner 4"dia circle.Centered on each spoke at 13.75"diameter is a1/2"hole(these accept the studs that will mount the stator).In the center of the bracket is a1.25"diameter hole.This fits the wheel spindle.You can cut this out with atorch,or aplasma cutter easily.If those tools are not available,you can simplify the design keeping in mind that the critical measurements are the locati*of the 1/2"and 1.25"holes.Some folks will make the inside 4"dia circle with ahole saw and then make the spokes with bar stock.While it doesn't look quite as neat,it works just as well.The spokes should be fairly rigid so if you do use bar stock use at least 1.5"x 1/4",any thinner might bend under the torque that the stator will impose upon it.
2-Yaw bearing cap.The yaw bearing cap is simply adisk of 1/4"steel with a3/4"dia hole drilled in its center.It will be welded to the top of the yaw bearing and the hole will accept the cord from the alternator which will run down the center of the tower.When making the magnet rotors you cut a2.75"diameter hole in their center.Use the scrap from one of the magnet rotors for this-it's the perfect diameter,all you need to do is drill the hole in the center.
3-Spindle发电机,part#BT-88.This is the spindle that our wheel hub(Dexter part#81-9A)fits.It's probably the most common spindle in use for 1000pound trailer axel sand it's widely available.There are other slightly cheaper spindle/hub setups but Iprefer this one.It's the best choice because it's widely availabe and it's machined on both sides which makes life much easier for us.You can certainly modify the design to accept other brands of spindle/hub assemblies but Ithink it's easier to stick with the Dexter parts here.Check out the appendix for suppliers.
4-This is the 3"dia sched 40pipe that supports all the parts of the alternator.It's 3.625"long and we cut a2.5"hole in it with ahole saw.