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Off Grid 2 KW Axial Flux Wind Turbine And MPPT Dump Load Controler Build

Kris Harbour Natural Building・37 minutes read

A wind turbine is being rebuilt for a 24-volt system, with a focus on creating coils and optimizing voltage, turns, and air gap for efficiency. Additionally, a custom controller is being designed to optimize efficiency, manage excess power, and include fail-safe mechanisms for continuous operation.

Insights

  • The wind turbine underwent significant modifications, including rebuilding for a 24-volt system, coil winding with precise specifications, and resin casting for optimal performance.
  • A comprehensive system design for the wind turbine includes considerations for coil size, air gap, tail design, and a custom controller with fail-safe mechanisms, highlighting a holistic approach to efficiency and safety.

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Recent questions

  • How is a wind turbine coil wound?

    With even tension and 150 turns of wire.

  • What is the purpose of casting coils in resin?

    To fill voids and aid in heat conduction.

  • How is a wind turbine designed to prevent damage?

    With an offset angle and a tail for protection.

  • What is the purpose of a wind turbine's brake feature?

    To efficiently stop the turbine.

  • How is excess power managed in a wind turbine system?

    Delayed installation until a solution is found.

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Summary

00:00

"Rebuilding Wind Turbine for 24-Volt System"

  • Wind turbine being rebuilt due to initial version not being suitable for 24-volt system
  • Six months spent on and off working on the wind turbine
  • Creation of a coil winder for a wind turbine with 12 coils and 150 turns of wire
  • Use of chunky wire and big magnets necessitating a large hole in the center of the coils
  • Importance of coil size and air gap in relation to magnets for voltage and turns
  • Process of winding coils with even tension and 150 turns of wire
  • Template creation for casting coils in resin using 3D printed magnet template
  • Connection of three phases with four coils in each phase for electricity flow
  • Casting coils in resin with talcum powder for heat conduction and filling voids
  • Testing the stator for voltage output and successful charging of batteries at 60 RPMs

28:45

"Efficient wind turbine design and assembly"

  • The wind turbine is designed with an offset angle to prevent it from rotating out of the wind, with the tail keeping it in line until it furls to protect itself from damage.
  • The tail of the wind turbine is being worked on, with a slot cut out of an old scaffold tube to fit it properly.
  • The turbine is designed with a slight backward angle for better efficiency, with a plywood tail plate for flexibility in changing blade sizes.
  • A tube is being welded onto a flange plate to attach to the turbine's mast, ensuring a strong connection with sealed bearings.
  • The wind turbine assembly includes a magnet rotor and stator, with a total weight of about 80 kilos once fully assembled.
  • The wind turbine is designed for larger blades for increased efficiency, with plans to upgrade to 2.2 meter blades for higher energy output.
  • Due to excess energy from other sources, the wind turbine installation is delayed until a solution is found to manage the surplus power.
  • The blades of the wind turbine are mounted, with concerns about the pole's strength and potential future adjustments for efficiency.
  • The issue of wire twisting in wind turbines is addressed, with the explanation that occasional twists are not a significant concern.
  • A custom controller is being designed for the wind turbine to optimize efficiency and manage excess power, with detailed wiring diagrams and explanations of its functions.

51:38

"Relay activates light and buzzer with PWM"

  • When auxiliary one is triggered by auxiliary two feeding a PWM signal, a relay should be activated, causing a light to turn on and a buzzer to sound when two connections are made.
  • Diodes are placed between the connections to prevent backfeeding into the controller, ensuring a safe setup.
  • The PWM signal rapidly turns the heater on and off, sending small current pulses into it, effectively heating it up.
  • A fail-safe mechanism is in place where if power is lost, the relay trips out, shutting down the charge controller and diverting power to the heater.
  • The system includes a wind turbine with a brake feature triggered by shorting out terminals, allowing the turbine to stop efficiently.
  • Auxiliary one can be manually turned off, diverting all power to the heating coil, while turning it back on sends power back to the controller.
  • The system's weak point is identified as the solid-state relay, which may need a backup plan in case of failure to ensure continuous operation.
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