Nerdiskerator – Generator from the 3d printer

A few days ago I posted the building instructions for a project of mine: WinDIY a 3D printed wind turbine.

Even if I still have some work ahead of me, most of the functions of WinDIY are already working. What unfortunately has not yet worked is the main purpose of a wind turbine: generating energy.

Because the generator I installed in WinDIY does not match the expected speed of the wind turbine. While the generator delivers approx. 30W from approx. 20 revolutions per second (!) The wind turbine would probably be destroyed at this number of revolutions.

Here I have to invest a few more hours at the workbench. 🙂

Since the generator works in principle and it may. there are also scenarios to which it could fit, I still want to introduce it here. At least tips for developing your own generator should be extracted from it. 🙂

And why actually “nerdiskerator”? This nickname of the disk generator comes from “NERdiys DISK genERATOR” = Nerdiskerator. 🙂


Overview

  • Disk generator than can be mainly 3D printed
  • One stator disk containing 12 manually or automatic wound coils
  • Coils are cast with epoxy
  • Two rotor discs, each containing 20 neodymium magnets 
  • Each rotor disc is supported with a ball bearing 

Pictures

Below are a few pictures of different components from different stages of development.


Videos


Development

I have documented most of the development and the individual difficulties on Hackaday.io. You can find the link here. 🙂

https://hackaday.io/project/172445-nerdiskerator-a-3d-printed-disk-generator


Electronics

In addition to WinDIY, the nerdiskerator also has a few security features.

Since the generator is made from filament the temperatures in it should not be too high, as the filament used can then become soft. This is because three NTCs are encapsulated in this to monitor the coil temperature in the stator.

Of course, some electronics are required so that these sensors can be read out and, if necessary, responded to. To do this, I started developing a circuit board on which all the necessary components are housed.

You will find information about this here on Nerdiy.de soon.

The following components are currently installed on the board:

  • Three-way bridge rectifier
  • Step-down regulator
  • Three independent charging circuits for one LiPo cell each
  • Three I2C motor drivers to control the motors of the brake actuator and the pitch actuator
  • various current and voltage sensors to measure the energy generated and consumed
  • Connections for two Hall sensors for measuring the generator speed
  • Connections for three sliding resistors to measure the positions of the pitch actuator and the brake cylinder
  • Connections for two force sensors to measure the contact pressure of the brake cylinder
  • Connections for four NTCs to measure the temperatures of the generator windings and the load resistance.
  • Connection to discharge the rectified voltage to a consumer
  • Connection and electronics to be able to connect a load resistor PWM-controlled.
  • Vibration sensor to detect abnormal vibrations
  • two temperature sensors to monitor the temperatures on the PCB
  • an electronic compass
  • a micro-SD card slot
  • a climate sensor for measuring the ambient temperature, humidity and air pressure

Software

The software is developed using the Arduino IDE. You can find the current status in the Nerdiy-Git under the following link:

https://github.com/Nerdiyde/genCtrlr

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