WinDIY – The wind turbine from the 3D printer

On a camping trip away from modern infrastructure, you quickly notice how much you have gotten used to the fact that electricity is somehow available anytime and anywhere. The stupid: Most of the time you will realize this when the electricity is not there.

For this case there are now power banks. But what if the power bank is empty? Charging on the go is difficult without electricity.

I faced the same problem on a camping trip a few years ago. At that time I even had a mobile solar cell with me. This provided some energy, but not enough due to the lack of sun. The sun just wasn’t shining strong enough. But what I had at the moment was wind.

And so the idea of building a wind turbine that can be produced with the 3D printer was born.

Forgotten at first, this idea got a fresh impetus when I stumbled upon a couple of neodymium magnets at the flea market. For little money I got magnets with which a suitable generator can certainly be built.

Over time, this has resulted in the project presented here. Below you will also find detailed building instructions for the individual components.

Note: The wind turbine is currently (10/11/2020) not yet running perfectly. The blades still have to be adjusted and the generator does not match the characteristics of the wind turbine either. So there is still some work to do here. But maybe. the components shown are a suggestion for everyone who is working on their own design of a 3D printed wind turbine. ?


Overview

  • Wind turbine made from 3D printed parts
  • HAWT design
  • Rotor diameters from 0.5 to 1.2 m possible
  • 3D printed wings
  • Uses a 3D printed disc generator to generate power
  • Safety functions through active pitch adjustment of the wings, mechanical brake and electronic brake function via the disc generator
  • Can be printed with any “normal” FDM printer (20 x 20 cm bed size)

Videos


Pictures

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


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/172328-windiy-hawt-wind-turbine


Instructions to build yourself

The structure of WinDIY consists of several individual segments. Since all parts can be printed on a 3D printer with a printing area of 20x20cm, the individual parts must of course still be put together after printing.

Mostly M3 screws and nuts are used in order not to use too many different parts. You can find detailed material lists in the corresponding article.


Electronics

As mentioned above, WinDIY has a few security features. So that these can be controlled in a controlled manner, some electronics are of course necessary. To do this, I started developing a circuit board on which all the necessary components are housed.

The following components have been installed on it so far:

  • 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/genCon

4 comments

  1. Ich hab gelesen es gibt Probleme mit der Drehzahl? Ich bin mir nicht 100% sicher wie es mit dem Drehmoment welches erzeugt wird aussieht aber ein gut Laufendes Planetengetriebe in der Rotorname sollte die Drehzahl deutlich steigern und würde nicht viel Platz weg nehmen?
    Geiles Projekt by the way

    1. Hey Daniel,
      danke für den Vorschlag. 🙂 Ich arbeite aktuell daran die gesamte Konstruktion etwas zu vereinfachen. Das Planetengetriebe hatte ich dabei noch gar nicht auf dem “Zettel”. Danke für den Hinweis. 🙂
      Beste Grüße
      Fab

  2. Hallo,
    Die Magnete sind in Halbach Anordnung? Das erhöht den Magnetischen Fluß.
    Der 3-Wege Brückengleichrichter ist ein Standard-Modell mit Doiden? Evtl mal MosFET versuchen.
    Dioden fressen immer etwas Spannung – bei Brückengleichrichtern ist das das doppelte der Durchlassspannung. Also bei Silizium Dioden verlierst Du gleich mal 1.4 Volt.
    Mit MosFET verlierst Du fast nichts – microvolts.
    Bei Google mal “mosfet als diode” suchen lassen.
    Gerne diese Methode auch im Spannungswandler anwenden.
    Wenn ausreichend Drehmoment da ist, aber zu wenig Drehzahl, vielleicht ein Planetengetriebe benutzen. So machen es auch die “großen”.
    Und die Spulen mit mehr Windungen wickeln. Das erhöht deren Spannung und man bekommt schon bei niedrigerer Drehzahl was raus.

    1. Hey Michael,
      eine Halbach Anordnung ist es nicht. Der gebaute Generator ist auch noch recht simpel und aufgrund der nicht wirklich passenden Magnete nicht optimal. Einen kleinen Eindruck kannst du hier bekommen: https://nerdiy.de/nerdiskerator-a-generator-from-the-3d-printer/
      Die MOSFET Gleichrichter-Lösung finde ich auch sehr interessant. Allerdings hatte/habe ich etwas Respekt vor der korrekten Ansteuerung der MOSFETs und habe es deswegen erst mal etwas weiter unten auf “der liste” eingetragen. Andererseits sind die ersparten Verluste schon recht spannend.
      Vielen Dank für deine Hinweise. 🙂
      Beste Grüße
      Fabian

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