An AC Delco alternator Windmill for wind power generation
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README.md

README.md

AC-Delco Alternator Windmill

An AC Delco alternator Windmill for wind power generation

Release 2017.12.10-beta ( Pictures Below ) INCOMPLETE PROJECT - Use for experimental only Tested in 40mph winds found that gear slippage and destruction occurs Need to Refactor the design for more stability However, Project has demonstrated the ability to charge @ ~ 20mph winds This includes self-excitement ( Actual power gained )

Windmill Picture

Current Work INCOMPLETE PROJECT - Use for experimental only Current Work still needs to be built and tested. This is the 5-blade design updated to handle high winds better by moving the alternator to behind the post and creating a 5-Gear system in which the miter gears will transfer to straight gears appropriately. This also creates a 20:1 Ratio versus Version 2017.12.10-beta which created a 15:1 Ration.

Windmill

Introduction

Windmill Picture

Specification

  • Takes 18-mph winds to barely start charging the battery
  • Which doesn't take into account the ( 4V @ 0.85A = 3.4W ) Idle waste
  • Can also run ( 3.7Vdc @ 0.62A = 2.294W )

Alternator Excitement Regulation

In order to be efficient an Arduino ( Micro-controller ) must be used to adjust the alternators excitement level on the fly. This was accomplished by designing a custom circuit detailed in the 'AltRegulator' folder. The folder includes the Arduino Sketch last used to control excitement as well as KiCad design files. The board was designed with the LinkSprite T8 CNC router using trace isolation.

Regulator-Circuit

Raw Materials Needed

Electrical Materials

  • 14 AWG Wire; Enough for Excitement ( pole 1 ) and Regulator ( pole 2 )
  • 10 AWG Wire; Alternator ( Batt. ) to Batterry
  • 40 Amp Diode?
  • (2) Female Solderless Connectors for Alternator ( pole 1 & pole 2 )
  • (2) O-Ring Solderless Connectors for Alternator ( Batt. & Ground )
  • Incomplete list; check back later

Bolts Needed

- (1) 5/16" x 5" Coarse Bolt    Hub-Mount Cross Bolt
- (1) 5/16" x 2" Bolt           For Hub Center
- (2) 5/16" Nuts                For Double Nuts on Hub Bolt
- (1) 5/16" x ?" Bolt           For Alternator Top Mount ( Alt Threaded Hole )
- (1) 3/8" x ?" Bolt            For Alternator Bottom Mount
- (1) 3/8" Nut                  For Alternator Bottom Mount
- (4) #10-24 x 2" Screws        For 4-Rail Gears ( 9.1x Step Up )
- (8) #10 Nuts                  For Double nuts on each Gear screw
- (8) #10 x 3/4" Wide Washers   For each side of Rail Gears
- (9) #10-24 x 1/2" Screws      For Vinyl Siding to DIN / 3-per-blade
- (9) #10 Standard Washers      For Vinyl Siding to DIN / 3-per-blade
- (9) #10 Nuts                  For Vinyl Siding to DIN / 3-per-blade

Tools Needed

  • Wrench Sizes

    • Phillips Head Screwdriver for #10 Screws
    • 3/8" for #10 Machine Screws
    • 1/2" for Hub, Alt Top Mount
    • 9/16" for Alt Bottom Mount
    • 15/16" for Alt Center Bolt
  • Drill Bits

    • Drill bit for Top Alternator Bolt hole size 5/16" bolt

Knowledge obtained

  • Alternator excitement
    • Pole #1 closest to Batt. is Excitement Source
    • Pole #2 Turns ON/OFF Pole #1 Excitement at ~15Vdc and under
    • Pole #2 Isn't linear ( i.e. doesn't apply more excitement as voltage goes down )
    • Pole #1 @ 2.8Vdc, 0.35A = 0.98W but isn't strong enough to build voltage
    • Pole #1 @ 4.5Vdc, 1.24A = 5.58W is IDEAL for 9x gear-up
    • Pole #1 @ 10.7Vdc, 2.60A = 27.82W
    • Pole #1 @ 14.2Vdc, 3.50A = 49.7W
  • Wiring
    • Use diodes to route alternator Batt. back into Pole #1 ( excitement )
    • Use diodes to ensure Batt. feeds battery only when charge levels
    • Startup feed of 4.5Vdc diode into Pole #1
    • Using above, when wind increases excitement increases till battery can charge
    • Need a Wind kick in start ( DC-DC Buck on battery w/Arduino turn on? )