Construction manual for a cretan windmill

By N.J. van de Ven

CWD 77-4 October 1977

WORKINGGROUP ONDEVELOPMENT TECHNIQUES CONSULTANCYSERVICES WINDENERGY DEVELOPINGCOUNTRIES

P.O.BOX217 7500AEENSCHEDE THENETHERLANDS

P.O.BOX85 3800ABAMERSFOORT THENETHERLANDS

Constructionmanualforacretanwindmill

By: N.J.vandeVen

October1977

WOTWORKINGGROUPONDEVElOPMENTTECHNIQUES P.O.Box2177500AEEnschedeTheNetherlandsTelephone(0)53893870 CWDCONSUlTANCYSERVICESWINDENERGYDEVElOPINGCOUNTRIES P.O.Box853800ABAmersfoortTheNetherlandsTelephone(0)33689111

PUBlICATIONCWD774 ThispublicationhasbeenpreparedbytheWorkingGrouponDevelopmentTechniquesWOTunderthe auspicesofCWD,ConsultancyServicesWindEnergyDevelopingCountries. TheWOTisanonprofitstudentvolunteersorganizationattheTwenteUniversityofTechnology,trying toassistpartiesinThirdWorldcountriesintheireffortstoimprovethesituationofthosegroups, deprivedoffullopportunitiesforlocal,selfprogrammedandselfsustaineddevelopment. ActivitiesoftheWOTencompasswindenergy,watersupplyandsolarenergy. CWDisajointactivityof: theEindhovenUniversityofTechnology theTwenteUniversityofTechnology DHVConsultingEngineers CWDisfinancedbytheNetherlandsProgrammeforDevelopmentCooperation. CWDpromotestheinterestforwindenergyindevelopingcountriesandprovidesprofessionaladvice andassistancetogovernments,institutesandprivateparties.

COPYRIGHT 1977 BYDEVElOPMENTCOOPERATIONINFORMATIONDEPARTMENT Allrightsreserved,includingtherightstoreproducethisbookorportionsthereofinanyform. Forinformation:CWDc/oDHVRaadgevendlngenieursbureauBV,P.O.Box85,3800AB Amersfoort,TheNetherlands.

5 CONTENTS INTRODUCTION 1. 1.1. 1.2. 1.3. 2. 2.1. 2.2. 2.3. 3. 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.b.1. 3.6.2. 3.7. 3.7.1. 3.7.2. 3.8. THEWOODWORKLATHE Assembly Transmission Operatingthelathe THEBOREHOLEANDTHEPUMP Makingtheborehole Thepistonpump Thefootvalveandthepiston THEWINDMILL Constructingthetower Thefoundation,theerectionofthetowerandthealignment Theheadconstruction Themovingparts Brakeconstructionandcontrol Therotor Thesailframe,therotorsupport Thesails Assemblyoftheheadconstructionandtherotor Mountingtheheadconstruction Mountingtherotor Finishingandtestingthemill PAGE 7 9 9 12 15 15 20 21 25 25 28 30 36 40 44 44 47 50 50 51 53 57

AnnexMaterial

7 INTRODUCTION Thedesignsdescribedhere,forawoodworklathe,apistonpumpandaslowrunning(sailwing) windmillhaveanintermediatetechnologicalcharacter. Thatistosayouraimhasbeentomakedesignswhichcanbeentirelyconstructedfrommaterialswhich areavailableeverywhere,e.g.logs,ruggedsawnwoodandpiping. Connectionshavebeenmadeusingwoodscrews(sometimestelephonepolebolts)andpiecesof threadedbar(commerciallyobtainableinlengthsoflm:M8,MIOetc.). Whenthesematerialsarenotavailable,usecanbemadeofmortisejoints,possiblyincombinationwith gluedandropetiedjoints. However,thelattertypemakeshigherdemandsonboththetoolsavailableandtheskillofthe constructors. Weonlyusedmanualtools(e.g.chisels,handsaws,handdrills,hammersetc.)toassemblethe prototypesoftheequipment. Wehavetriedtodescribeourexperienceasequipmentbuildersasclearlyandsystematicallyas possible.

l.THEWOODWORKLATHE Sincethepistonpumpneedscircularparts(valveandpistonbody)wedecidedtobuildalathefor woodwork.Thelatheismadefromroughwoodleftoverfrompreviousprojects,mainly.Connections aremadewithscrews,nails,lengthsofthreadedbarsandbicycleparts.Thelatheiseasytouseandis turnedbyfoottreadle. 1.1.Assembly Figure1.1.showstheassemblyofthelathe.Theframeconsistsoftwoparallelbeamswhichformthe supportforthetoolrestandthetailstock,bothofwhichcanbefixedtothehorizontalbeamswith woodenclamps. Theheadstockconsistsoftwouprightpiecesoftimber,oneofwhichactsasapost. Aballhead,sawnfromabicycleframe,isclampedintoagrooveintheendsoftheheadstock,usinga loopofwireorabracketofmetalstrip,thusformingarevolvingheadstockspindle. Asthelegsoftheforkhavebeensawnofftheballhead,alargecirculardisccanbescrewedontothe topofthefork(fig.1.2.). Thisdisciscenteredonthecentrepoint;thisisapieceofpipethatfitsintothecentretubeofthefork andcanbefastenedthere. Teetharefiledintheprojectingend. Thewoodendiscshouldpreferablyconsistofplywoodorasimilartypeoflayeredwood.Thiscanbe madebylayingseveralplanksacrosseachother,nailingorglueingthemtogetherandthensawingout thedisc. Aimofthediscistwofold:tofixtheobjecttobeturned,ifthisisnotturnedbetweenthecentres(disc shapedobjects),andtoactasaflywheel. Sincethelatheisdrivenbyapedalcrankmechanism,thediscisessentialandshouldbeaslargeas possible. Theassemblyofthetoolrestandthetailstockwiththeirlockingdevicesmaybeseenfromthe drawings. 1.2.Transmission Abicyclewheelfixedtoacrankisdrivenbymeansofabicyclefootpedalplacedonthelongaxisof thefrarne.Thedriveistransmittedbyaflatbelt(cutfromtheprofiledsurfaceofabicycletire)toa woodendiscthatiscoupledtothespindle.Atransmissionratioofl:4hasprovedtobethemost satisfactory. Itisadvisablethatthewoodenpulleyhasasphericalshapetopreventthebeltfromslippingoffit. Thereareseveralwaysofattachingacranktothebicyclewheel.Infig.1.1.thishasbeendoneby clampingtwopiecesoftimberinonelinebetweentherimandoneithersideofthehub.Thesetwo piecesofwoodbalanceeachother.

10

Fig.1.1Simplewoodworklathe

11

Fig.1.2

12

Fig.1.3 Thehandleshouldbeabout6cmlong,butexperimentscanbecarriedoutusingone'sownjudgment. 1.3.Operatingthelathe Wedistinguishbetweentwokindsofpiecestobeturned:longthinonesanddiscshapedones.The formerarefixedbetweentheflywheelandthetailstock.Itisadvisabletomakeacentrepoint,inthe formofasmallconicalholeofafewmillimetersdeep,attheendoftheworkpiecebeforefixingit. Thismaybedoneusinganailpunchorsimilarinstrument.Thepointedhandleofafileisanother alternative. Thenthefrontoftheworkpieceisplacedagainsttheserrateddrivencentrepointandhammeredintoit withseveralfirmhammerblowsagainsttherearend. Thetailstockisthenscrewedonandfixedwithslightpressureagainsttheworkpiece.Adiscshaped workpieceiscentredasaccuratelyaspossibleonthelargewoodenflywheelandthenfirmlyscrewed toit. Thetoolrestisplacedasnearaspossibletothesurfacetobeturnedsothatthecutterbearsasfaras possibleonthetoolrestandnotonthehands. Sincethelatheoperatorstandsononelegtooperatethelathe,hemustalsobeabletoleanonthetool restandstillbeabletohandlethecuttercorrectly(fig.l.4.)

Fig.1.4

13 Itisclearthattheoperatorneedsasteadyhand;itisalsoaquestionof"practicemakesperfect". Itispossiblethatnoneofthemoreprofessionalcuttingtoolswillbeavailable.Asimpleandadequate toolcanbemadefroman(old,blunt)file;preferablyonewithasquarecrosssection. Thefileissharpenedwiththeaidofagrindingstone,asshowninfig.l.5.

Fig.1.5 Ifthecutterstartsto"bite"orjumpduringturning,itmustbeheldataslant,thatiswiththehandle raised.Thecuttingprocessthenhasascrapingcharacter. Inthiswayverysmoothworkpiecescanbeobtainedwhichcanbefinishedorsmoothedtosizewith sandpaper,ifnecessary. Ingeneral,smoothersurfacesareobtainedonharderandshortgrainedtimber. However,thefinalresultislargelydependentontheskillandexperienceofthelatheoperator.

14

dehoutdraaibank thelathe

dehoofdspilenhetvliegwiel thespindleandflywheel

deleunspaanendelossekop support,bedandcenterhead

15 2.THETUBEWELLANDTHEPUMP Toobtainthemostefficientcouplingofthewindmillandthepistonpumpthewindmillisconstructed directlyabovethewell.Inthiswaythepumpcanbeconnecteddirecttothemill.Whenapistonpumpis usedtherevolvingmotionofthemillshafthastobetransposedinareciprocatingmovementofwhich thestrokecanbeadjusted.Thereciprocalmotionoftheverticalpistonrodisthentransmitteddirectto theplungerofthepump. Thewaterispumpedoutthroughthepumpoutletintoagutterwhichleadstoastoragetank. Sincethemillcanpumpanamountofapprox.100lperminutewiththepumpused,wehadtoreturn thepumpedwatertothetubewellbywayofabackflowpipefromthestoragetank. Thistypeofamillwillbebuiltaboveawellorundergroundriver,butasalreadyremarkedthesedid notexistonoursite. 2.1.Makingtheborehole Theboreholeshouldbeapprox.4,5mdeepwithadiameterofapprox.200mm.Drillingtothewater tableisdonewithasimplediskdrill, speciallymadeforthispurpose.Aconcentricholeismadeinacircular disk,whichisthensawnopenandbentasshowninfig.2.1.

Fig2.1 Thediskisweldedorrivetedtoapipe,whichcanbelengthenedwithconnectingpiecesifnecessary. Asharpeedgeisfiledontothecuttingsideofthedisk(fig.2.1.). Itisadvisabletoguidetheborerodbymeansofatripodsotheholeisdrilledasverticallyaspossible. Inordertorotatethedrillrodacrossrod(lever)canbefixedtothedrillrodbyaclamp.

16

Twopersons,oneoneachside,canoperatethedrill,whilefromtimetotimetheyhavetopullthedrill inordertoremovethesoil(fig.2.2.)Thiswillhavetobedoneaftera15or20cmprogressofthedrill.

Fig.2.2

Eveninhardersoilthistypeofdrillingissuitabledowntothegroundwatertable.Oncewaterlogged soilisreached,thewallsoftheholewillcollapse,causingwidening.Thedrillalsosticksandgets offcenter.Thereforethisdrillcannotbeusedbelowthegroundwatertable.Usuallyasupportpipeisput intothehole.Thelowerpartofthispipeisperforated. Theperforationcanbemadebydrillingholesinthepipe(lowerpart),orsawingcutsinthepipeorby usingexistingdrainpipes.Thelastisthebest. Asasbestosconcretepipewasavailableforthesupportofthepipe,therewasapreferencefordrilling holes,(5mm)overalengthofl,5mtoachievetheperforation. Inordertopreventfillingwithsand,thepipewasplacedintheholeandtheoutsidepackedwithfine gravel. Bydrillingcoreoutofthepipeuntilthegravelappeared,thepipecouldberammeddown,thusthe gravelwentdowntogetherwiththeperforatedsectionofthepipe.Drillingthecoreoutofthepipecan bedonebyapulsingram,whichconsistsofapipeinwhichabutterflyvalveismounted;thisistheso calledpulsingram(fig.2.3.).

17

deschijfboor thediskdrill

depulsboor theauger dezuiger thepiston

hetgebruikvandepuls augerinoperating

18

19

Fig2.3

Thevalveisanovalshapedpieceofleatherpartlyreinforcedbyhalfsteeldiscs(2mmsteel). Thesepiecesarerivettedontheleather.Thebutterflyvalveitselfismountedwithwoodenscrews(or nails)onapieceofhardwoodwithasharpedge. Thevalveismounted(clampfitting)inthepipeandsecuredwithscrews.Thepulsingramwillhaveto fitinthesupportpipewithafewcentimeterspace,andismovedupanddownonthebottomofthehole bymeansofadriverod. Thepulsingramistakenoutoftheholetobeemptiedfromtimetotime.Bymakingapivotbetween thepulsingramandthedriverod,theramcanbeeasilyemptied.whenthegravelalsoleavesthehole, thismeansthattheholeunderthesupportpipeislargeenoughtolowertheentiresupportpipe includingthegravelpacking. Thetripodcanbeusedasguidingtoramthesupportpipeeverytimeappr.10cm.Afterthistheaction withthepulsingramcanberepeated.Incasethesupportpipehastobelengtheneditisbetternotto useapipesocketbecausethismakesitdifficulttosupplynewgravelaroundthesupportpipe. Tobesuretheextendedpipeiswellcentereditisadvisabletoplaceamechanismwithselfguidance (fig.2.4.). Inthiswayitwillnotobstructthegravelfromgoingdownwiththepipesandthepipeswillremainwell centered. Whentheholeisdeepenoughthebottomisextradrilledandcoveredwithgravel.

20

Fig.2.4 2.2Thepistonpump Thecompletepistonpumpconsistsofa5mlongpipe(inourcasemadeofplastic)withaninner diameterof125mm. Thefootvalveislocatedat40cmabovethelowerend. Thepistonwhichisdirectlydrivenbythemillmovesjustabovethefootvalve.Thelowerendofthe pipehasacoarseperforationandrestsonthegravel(fig.2.5.).Thelowerendofthepipeisstopped withawoodendiscoraplasticcover,fastenedaroundthepipewithironwire.

Fig.2.5

21 Thepumpcylinderiscenteredwiththreewoodenkeys,whereitcomesoutofthesupportpipe (=drainagepipe). Thepumpcylinderrisesaboutonemeterabovethesurfaceandiscutoffatanangle.Thisisdoneto dischargethepumpedwaterinthedesireddirectionandtofacilitatemountingofthegutterandofthe piston. ThegutteritselfslopesslightlytowardsthestoragetankandisfoundedwithtwobeaInsdrivenintothe soilasshowninfig.2.6.

Fig.2.6 2.3.Thefootvalveandtheiston Asmentionedbeforethesepartsshouldbeexactlycircularshaped.Forthatpurposeaspecialfoot driven,woodworklathehasbeenconstructed. Becausethepistonactsnotonlyasaplungerbutalsoasavalve,thefootvalveandthepistonare manufacturedmoreorlessinthesameway.Theessentialdifferencebetweenthetwoisthatthespecific dimensionsarederivedfromdifferentdiameters(DandD').Agroovemustbeturnedaroundthepiston tosecuretheleathersealing. Thepistonandthefootvalvearemadeofwood;sinceinpracticethedimensionsappeartobelarge,it isnecessarytocomposethesepartsofmorethanonepieceofwood,asshowninfig.2.7. Thesplittinginhalvesofthepistonallowsconnectionofthepartswiththeaidofabolt/nutjointaround thelowerendofthewoodenpistonrod. Thelatterisplanedinaroundshape. Theboltheadandnutcanbesunkdownintothetwodiametricholesofthepiston.

22

23

Fig.2.7 Theleathersealinghastofitverypreciselyaroundthecircumferenceofthediscbeforeinstallation. Theendsoftheleathersealingshouldoverlapabout5mmandbebevelledwithafileorsandpaper. Theleatherisputintowatertomakeitmorepliantandsoft. Thesealingisfinallyrolledontothepistonandropedinthegroovewithironwire. Thehalvesofthefootvalvearebypreferencegluedtogethertofacilitatefutherpreparation. Aftertheleathervalveismountedonthediscwithaboltorapin,thewholeisputintothelowerendof thepumpcylinderwithaclampfitting. Althoughwoodwillswellinwateritisrecommendedtofastenthevalveinthepumpcylinderwith screws. Nowthepurnpcylinderisreadytobemountedasmentionedinsection2.2.

24

25 3.THEWINDMILL Thewindmillisbuiltabovethecenteroftheboreholeanddrivestheplungerdirectlybymeansofa verticalwoodenrod. Therotarymovementofthewindmillshaftisconvertedintotherequiredreciprocatingmotionby meansofanadjustablecrank. Thewindwheel(rotor)consistsofeightpolestowhichtriangularsailsareattached. Whenthemillisoutofuse,thesailsaresimplywrappedaroundtherotorpoles. Inordertobeabletodothisinasafemanner,abeltbrakeisusedwhichcankeepthemillshaft blockedinanyposition. Fromthelowerplatformonepersonisabletooperatethebeltbrakeandwraporunrollthesails. Thesecondplatformissituatedatthetopofthetower,fromwhichmostoftheessentialmovingparts canbelubricatedandinspected. Thewindvane,forkeepingthemillintothewind,isfixedontheextendingendofthemillhead. Thecentreofthemillshaftissituatedabout7mabovegroundlevel,therotorbladesbeingsixmetres indiameter. 3.1.Constructingthetower Thetowerisassembledcompletelyontheground,impregnatedwithtardestillateanderectedabovethe centreofthewell. Thelowerendsofthelegsareplacedinthepredugholeswithfoundation.Afterthepositionofthe towerwithregardtothewellholehasbeencheckedwithaplumbbobandawaterlevel,thelegsare providedwithimpregnatedbracesandcoveredwithmud. Fortheconstructionofthetowerfourpinepolesareused,approximately7metreslongandvaryingin diameterfromabout8tol5cm.Alsoneededare12semiroundlogs,eachapproximately3mlongand 4heavywoodenboardsfortheplatform,asteelpipe,havinganexternaldiameterof150mm,a wallthicknessof4mmandalengthofapproximately2m. Woodscrews(5u)andthreadedstuds(M10)areusedformostoftheconstructionparts. Afterthepoleshavebeencuttoequallength,firstlythetwotowerhalvesareassembledonaflatarea (fig.3.1.). Then,thetwohalvesareplacedontopofeachother,thelowerendisprovidedwithtemporary diagonalsandbothsidesarecompleted. Thefourtopendsofthepoles,thusfarbeingheldtogetherbyroping,aredisconnectedandthesteel pipeismountedasshowninfig.3.2. Theendsofthepoles,twobytwo,arepulledtowardseachotherbythreadedstuds(M10)andnuts. Itisimportanttoinsertacoupleoflargewashers,preferablyslightlybent,betweenthenutsandthe logs.Also,asmallbearingsurfaceshouldberaspedorplanedontheinnersideofthepolestoprevent crushingorsplittingofthewoodwhenfirmlyclampingthepipe.

26

Fig3.1

27

Fig.3.2

28 Acircularoroctagonalwoodensupportingdisc(assembledfromnailedandcrossedboards)ismounted ontopofthepolesbymeansof4screwboltswithcountersinkheads.Thisdiscwillcarrytheentire headofthewindmill.Whenstillinahorizontalpositiontwoplatformsarefixedtothetower. Itisrecommendedtomountallboardsofthelowerplatformcarefullyinoneplaneandalsoto countersinktheheadsofallmountingscrews(fig.3.3.).Thesemeasuresareabsolutelynecessaryto preventunpleasantstumblingontheplatform.

Fig.3.3 Tobeabletoreachthisplatformsafely,aladderislaterplacedontheinnersideofthetower. Thesecondplatform(attheupperendofthetower)onlyconsistsoftwoplanks.Thishasbeendonein ordertobeabletoclimbsafelyontothisplatformbymeansofthestepsattachedtothetowerlegs(fig. 3.4.).Theloweststepsmayserveasahandrailforthelowerplatform. 3.2.Thefoundation,theerectionofthetowerandthealignment Fourholes(60cmx60cmx90cmdeep)forthelegsofthetower,aredugaroundtheexistingornewly drilledwell. Then,eachholeisprovidedwithafloorofstonesonwhichthetowerlegswillrest,andifnecessary canbeshiftedalittle. Thetopofthefloorsarelevelled,inordertomakesuretheyareinonehorizontalplane.Thisis checkedwiththeaidofanaccessoryspeciallymadeforthispurposeandofawaterlevel(fig.3.5.). Toerectthetower,thefollowingprocedureissuggested. 3to4personspushupthetopofthetowerwiththehelpofaladder.Twomorepersonssupportthe towerwithwoodenbeams,eachtimetheladderisremovedfromthetopofthetower,topushitup againwithahigherstepoftheladder. Topreventthepushingstepoftheladdertoslideawayalongthepipeinthetower,thispushingstepis ropedtosomepartofthetower. Whenthetowerispushedupasfaraspossiblewiththeladder,alongdraglineisattachedaroundthe pipe.Threeormorepersonsnowpullthedragline,whileatleastthreepersonscontinuetopushwith theladder.

29

Fig.3.4

Fig.3.5

30 Topreventthetowerfromovershooting,twopersonskeepcontrolwithaseconddraglineonthe oppositesideofthefirst. Fig.3.6.illustratesthisaction. Awaterlevelisusedtocheckwhetherthepipeinthetowerisinanexactverticalposition. Correctionscanbemadebyplacingkeelblocksofwoodunderthelegs.Withaplumbbobthecorrect positionofthecentreofthepipeoverthecentreofthewellischecked. Afterthealignmentthelegsareprovidedwithbraces(fig.3.7.)andimpreqnatedwithtar.

Fig.3.7 Thentheholesarefilledwithamixtureofsandandwater.Thetemporarydiagonalsinthelowerpartof thetowermaynowberemoved. Now,thetowercanbecompleted.Firstofall,theladderisplacedontheinnersideofthetower,tobe abletoreachthefirstplatformsafely. Thelowerendoftheladderisdugintotheground. Whilethelegsoftheladderreachfirstuptothefirstplatformandarefirmlynailedtoit. Iftheladderisselfmadewepreferablystartfromknotfreelegs,approximately4mlong. Thesteps(roughlycutlaths)arepartlysunkdownintothelegsandnailedintoplace. Foreasyclimbingthetreadofthestepsshouldbeabout30to35cmandtheladdershouldbeatleast 35cmwide.(mindtheavailablespacebetweentheinneredgeoftheplatformandthepumpshaft). 3.3.Theheadconstruction Figure3.7ashowstheconstructiondrawingofthefralnewithdimensionsofthewholehead constructionincludingthetailvane. Figure3.8.showsablownupviewofallpartsofthehead. Thewoodenpartsare,likethoseofthetower,nearlyallconnectedtoedchotherbymeansofwood screws.

31

Fig.3.6

32

detoreninopbouw buildingthetower

dekopconstructie theheadconstruction

33

Fig.3.7a

34

Fig.3.8Headconstruction(movingparts)

35 Tighteningconstructions,likethoseofthecrankblocksandthebearingblocksareeffectuatedbymeans ofthreadedstuds(M12). Theframeconsistsofanwnberofverticaltmberbeamsconnectedbyhorizontalandslantingbeams. Inthiswayalatticeconstructionismade,whichisveryrigid. Thetwotriangularextensionpartskeepthevaneclampedandinthiswayalightandstrongtailis realised. Thetwoverticalbeamsatthereartogetherwiththehorizontalbeansareplacedaroundthetubewhich ispartofthetower. Becauseoftheswellingofthewood,spheringandhollowing,thetubeisgivenamarginofabout5mm whenthewoodisdry. Theeffectofthespheringandhollowingoftheverticalbeamscanbe compensatedasshowninfig.3.9.

Fig.3.9

Ontheendsofthetwoverticalbeamsatthefrontsidethebearingblocksarefixedbymeansofthreaded studsM12. Fig.3.10.showstheanchorageofthethreadendsinthebeams.

Fig.3.10

36 3.4.Themovingparts Thebearingblocksconsistoftwopartsandshouldbemadeofhardtimber. Inordertobesurethatthetwopartsfittogetherwell,theholesshouldbeboredwhiletheupperand lowerpartareclampedtogethertightly. Alittleholeintheupperpartofthebearingblockmakesitpossibletooilorgreasethebearings. Thecrankalsoconsistsoftwoparts. Bothpartsareclampedtogethertightlyandafterthattheholesareboredasshowninfig.3.11.

Fig.3.11 Afterdrillingoftheholes,athinlayerisplanedofffromtheinsideofthetwoparts. Thisisdonetomaketheclanpingofthemillshaftandcrankpinpossible. Theconstructionofthecrankinthiswaymakesitpossibletoadjustthelengthofthepistonstrokeina simpleway. Thelengthoftheconnectingrodischoseninsuchawaythatitjustdoesnottouchtherimofthe towertubewhenthecrankisinitshorizontalult_nateposition.Inordertoachievethis,itis recommended tomaketheconnectingrodasslenderaspossible. Thismeansthattheendsoftheconnectingrodshouldbethickened,whichcanbedoneasshowninfig. 3.12.

Fig.3.12

37 Theupperendoftherodshouldpreferablybemadeofhardwood. Thecrankpinhastobeabletoturninitwithaplayofaboutlmm. Forthesupplyofoilorgrease,alittleholeisboredagainandpreferablyinsuchawaythatthesupply comesoutunderthepin(fig.3.13.).

Fig.3.13 Thecrosspinisclampedinthelowerendoftheconnectingrod. Thelattermakesaswingingmotioninthecrosshead.

Fig.3.14

38

hetwiekenraam thewingframe

dedeelbarekruk twopartcrank

demolenasmetwiekenraam,kruk,drijfstangenleislof themillshaft,wingframe,cranck,connectingrodandcrosshead

39 Theholesforoilingorgreasinginbothsheldscomposingthecrossheadshouldbeboredinthesame wayasthoseintheupperendoftheconnectingrod. Theshieldsareplanedobliquetomakethecrossheadfitinthetowertube. Incasetheinsideofthetowertubeisrough(forinstancebecauseofcorrosionorthepresenceofa joint)itisrecommendedtocoverthecrossheadwithwearingplatesasshown.

Fig.3.15 Ingeneralthecombinationoftwowoodentreadsshouldbeavoided,inasfarasthesetreadsmove continuallywithregardtoeachother. Thereforewashersofsheetironortinnedplatearealwaysplacedbetweenthesetreads(seefig.3.8.and 3.15.:betweencrankconnectingrodandblock;betweenshieldconnectingrodandshield). Thenumberofpivotringsbetweenthebrakediscandthebearingblockatthefrontsideshouldatleast bethree. Inthiswaythewearandtearwilltakeplaceonthewashersandnotonthewoodenparts. Tomakesurethatthewashersnexttothewoodenpartsdonotmovewithregardtothem,theyare placedwiththeirhollowsidetowardthewood. Themetaltreadswhichmovewithregardtoeachothershouldpreferablyhaveadifferentmetal structuretopreventfretting.

Fig.3.16

40 Thewasherinthemiddlecouldbemadeofbronzeorbrass,whiletheothertwocouldbemadeof sheetiron. Ofcoursethebearingpropertyisimprovedbygreasingregularly. 3.5.Brakeconstructionandcontrol Asmentionedabove,thepresenceofabrakeisindispensableforthesafetyoftheoperatorandforthe protectionofthemillitself. Forthistypethesocalledbrakebelthasbeenchosen,workingonthefollowingprinciple:

Fig.3.17 Thebrakebeltenclosesthreequartersofthebrakedisc.Theoreticallythebrakemomentcanbevery high,depenhingonthetensionofthepullrope.Ofcourse,themaximumoccurringbrakemomentmust belimitedtopreventburstofe.g.thebrakebeltoritsfastening. Figure3.18.showshowthiscanbeachievedbyinsertingapullstringinthepullrope.Thepullropeis operatedfromthefirstplatformbymeansofahandleandanooseshapedcontrolrope. Theadvantageofthisconstructionisthatduringunrollingandrollingupofthesailsthemillcanbe stoppedinthewind.Inthiswayoperatingbyonemanispossibleandsafe. Atlooseningoffthebrakethebrakelevermustfallbackundertheinfluenceofapushorpullspring,so thatthesteelbrakebeltcomescompletelyfreefromthebrakedisk.Itmayhappenthat,byitsown weight,thebrakebeltstaystightenedtotheupperside.Thisiscausedbytherepeatedlytighteningand looseningofthebrakebeltandofcoursethiscanbeavoidedbysupportingthebrakebeltatseveral places(fig.3.19.). Eventuallysuchasupportmayconsistofalath,nailedtotheheadconstruction. Readjustingthebrakeafterwearandtearofthebrakediskcanbedonesimplybydrillingseveral(8 mm)holesattheendofthebrakebelt. Seefig.3.20.

41

Fig.3.18

Fig3.19

42

Fig.3.20 AInongotherthingsforthepurposeofreplacementthebrakediskisdesignedintwoparts.Bothhalves arefixedtothemillaxisbymeansoftwoM12threadedstuds,butonemustrealisethatitisdifficultto braketheaxisdirectly,thereforeitissensibletoapplyatightenedfasteningbetweenthebrakediskand thehuboftherotor.Figure3.21.showsaverysoundpossibility.

Fig.3.21

43 depasgemonteerdekopkonstruktie mountedheadconstruction

dedraagschijfmetplaatstalenring bearingdiskwithsheetironwasher

44 Bymeansoftwocountersunkscrewsthebrakediskistightenedintothehubbeamofthesailsupport, afterthatthetwohalvesaretightenedaroundtheaxisbymeansofthetwostuds. Therotorsupportitselfitfixedtothemillbymeansofapin(withaminimumdiameterof10mm) whichisdriventhroughrotorsupportandaxisatonce. 3.6.Therotor Itisclearthat"measuringandfitting"oftheheadconstructionwillbeeasiertodoontheground. Onlywhenthemovingpartsandthebrakesystemfunctionsatisfactorily,shouldtheframebeerected onthetowerwhichhasalreadybeenerected.Thenextstepistheconstructionoftherotorsupportand thesails. Afterfinishingthisjob,therotorwiththerotorshaftcanbemountedontheheadconstruction.See sections3.7.and3.8. 3.6.1.Thesailframetherotorsupport Beforetheeight3mlongrotorpolesarefastenedtothecentresupportingframe,holesmustbebored inthepoles.Thisforthreadingthesails.

Fig.3.22 Thebestwayistomakeonepolefirst,asillustratedinfigure3.22.,afterwhichthiscanbeusedasa model. Usingthemodelpoletheholescanbecopiedontheotherpolesandtransferredtothesails,aswillbe dealtwithlateron. Fig.3.23.showshowthepolesaremountedonthecentrerotorsupport.Itisadvisabletofastenthe endsofthepolestothehubbeamwithordinaryshortwoodscrews,whilefortheattachmentofthe supportingframethreadedstudsareused. Washersundertheboltheadsandnutsshouldbechosenlargerthannormal,inordertoavoidbruising. Theassemblywillbeeasierifthesupportingframetogetherwiththebrakediscandtherotorshaftare supportedhorizontallyonatable.Therotorshaftmustreachoutatleast2.50minfrontofthe supportingframeforguyingtherotorpoles.Thisfrontshaftisnecessaryforreasonofrigidityofthe rotoritself. Ifsuchalongshaftisnotavailablethenanother,lessthick,canbeusedbyinsertingthissmallerpipe intotherotorshaft.Thesmallerpipemustfitinsidethelargeraxlepipewithoutrattling.Thisextension pipemaybefastenedtotherotorshaftusingthepinthroughthehubbeamandtherotorshaft,aswas dealtwithinsection3.5.

45

Fig.3.23

Fig.3.24

46 Aftertherotorpolesaremountedontheircentralsupportingframe,theirguyropesaretied. Theseguysaretiedinsuchawaythatthesailpolesarebentupbyabout300mm(seefigure3.24.). Forconveniencyonerotorpoleisagainchosenasmodel. Anextraropeisusedtocheckthatallthepolesarebentupthesameamount. Thisextraropeisfastenedtothecentrepoint. Thereasonsforbendingtherotorpolesaretwofold: toleaveenoughspaceforthemovementofthesailsatthealtitudeoftheplatform toreducethebendingstressintherotorpolesnearthesupportingframeathighwindspeeds Ifropeisusedfortheguysthenadurabletypeshouldbeused. Whentherotorisassembledtotheheadconstruction,thereplacementoftheguyropeswillbevery complicated.Forthisreasonitisadvisabletouseatypeofropewithalonglifetime.Thisdemandof lifetimeisalsoofvaluefortheknots. Itisadvisabletomakedoubleknotsatthecentrepoint(figure3.25a). Figures3.25bandcshowhowtheknotsinthelastbutoneholeinthispolearetobemade.

Fig.3.25

47 Enoughguyropemustbeleftafterknotting,tomakeitpossibletotiethesailsontotherotorpoles. Asthesailswillberiggedbetweenonepoleandthenext,thepolesmustformarigidregulareight sidedfigure.Thisisrealisedbytyingthetipsofthepolestoeachotherwitharopeasisshownin figure3.26. About20mropewillbeneededforthis.Thisropemustbetiedjustsotightthataregulareightsided figurewillresult. Nowthesailsupportframeisreadyforriggingthesails.

Fig.3.26 3.6.2.Thesails Itmaybegenerallystatedforsailwindmillsthathalftheareasweptbythepolesmustbecoveredby sails. Plasticisedcanvas(thecanvascoversoflorries)isexcellentmaterialforthesails(strongand weatherproof).Ifthismaterialisnotavailablethenothersuitablematerialshouldbechosen. Thisalternativematerialshouldnotspliteasilynorstretchundertension(asplasticsheetingwill). Frayingofthecanvasmaybepreventedbysewingseamsalongtheedges. Thesailsarefastenedtothepolesbylacingwiththeendsoftheguyingropes. Todothis,roundholesarecutinthesailcanvasonthelongestsideofthetriangularsails. Topreventpossibletearingattheseholestheyarereinforcedwithsailrings. Infigure3.27.waysofmeasuring,cuttingoutandrigging(fastening)thesailstotherotorpolesare shown. Itisveryimportantthatthethreadrowismadeatthefrontsideoftheprofile.

48

hetvastrijgenvandezeiltjes lacingthesails

hetplaatsenenkontrolerenvanhetwiekenstel mountingandinspectionofthewings

49

Fig.3.27

50 Thesailisriggedinsuchawaythatitpassesbehindtherotorpoletowardsthenextpole.Theflapat thefrontsmoothsouttheairstream,soallowingasortofaerodynamicprofile.Withtheaidofthe sheetropefastenedatthepolepointofthesail,itispossibleto"set"thesailbyputtingtheloopatthe endofthesheetropeovertheendofthefollowingsailpole.Thetensioninthissheetropemustbe suchthatthedistanceindicatedinfigure3.27.isabout150to200mm. Thesailcanbebroughtinthewindbyattachingtheropeendofthesailtothenextpole,leavinga distanceofthesailendofapproximately1520cmtotheropebetweenthepoles.Seefigure3.27. Thelengthoftheropeendofthesailmaybeadjustedbyknottingitseveraltimesifnecessary. Later,experimentswiththelengthoftheropemaybesuccessful. Whenallthesailsarelacedtothepole,therotorisreadyforassemblyontheheadconstruction. 3.7.Assemblyoftheheadconstructionandtherotor Insection3.2.wealreadyexplainedhowthetoweriserected.wenowassumethatbecauseoftheladder andthehandrail,thetowerisaccessiblewithoutrisk.Ifthisisthecasetheheadconstructionand afterwardstherotorcanbemounted. 3.7.1.Mountingtheheadconstruction Theelevationoftheheadconstructionwithouttoolsandbymanualpoweronlyisveryrisky.You shouldconsiderthatinthetopofthetowerthereishardlyanyspaceorsupportformorethanone personwhilsttheheadconstructionmustbeliftedoverthetowertubeandputintotherightposition. Donottakeanyrisksandthinkofthedamageandhumansufferingthatcanbetheresultofanaccident. Taketheefforttoinstallasimplehoistontopofthetowertoreducetheriskofaccidentstoaminimum. Suchahoistcanbemadefromaladderwhichinaverticalpositionislashedbyaropetothetowerat thelevelofthefirstandsecondplatform.Thebottomrungoftheladderrestonthebeamsofthelower clanpingdeviceofthetowertube. Oneoftheupperrungscanbeusedasa"pulley"byleadingrope,whichisusedforraisingthehead, overit. Fastentheendoftheropeasneartothecentreofgravityoftheheadaspossible. Afewpersonsnowpushuptheheadandkeepitfreefromthetowerwhileotherspulltherope(seefig. 3.28.). Thewholeshouldberaisedtosuchalevelthatitslowerendiswellabovethetopofthetube.Two personsstandingontheupperplatformshouldholdtheheadintherightpositionwhileitisloweredon thepipe.rheladdergivesthepersonsinthetopofthetowerthesalneprotection. Donotforgettoinstallthepivotringbeforemountingthehead.

51

Fig3.28 3.7.2.Themountingoftherotor Actuallythismountingiscarriedoutasdescribedbefore.Therotorisplacedgentlyatonesideofthe tower.Werecommendtosupportseveralpolesslightlysothattheweightoftherotorwillnotbe supportedbyoneortwopolesonly. Remenbertoputthepivotringsbehindthebrakediscbeforehoisting. Topreventthenfromslippingofftheshaftwhilehoisting,theycanbefastenedasshowninfig.3.29.

Fig3.29

52

achteraanzichtvanhetwiekenraam; duidelijkishetvoorstelagertezien rearviewofthewingfram;thefrontbearingisclearlyvisible

hetuitzettenofoprollenvandezeiltjes foldinganddefoldingofthesails

aanzichtenvandekopkonstruktie viewsoftheheadconstruction

53 Whilehoistingweshouldtakecarethatnoguysgetstuckbehindaplatformoranyotherprotruding partofthetower. Assoonastherotorshaftisrestinginthelowerbearings,theupperbearingsshouldbemounted.Seeto itthatthenecessarytools,rings,washersandnutsareavailable. 3.8.Finishingandtestingthemill Thecrank,connectingrod,crossandpistonrodcannowbefitted.Donotforgetthebrakeandlubricate thebearingswithoilorgrease.Firsttrytoturntherotorbyhand.seetoitthatnopartsaretouching others,whileinmotion,e.g.thebrakedisktheheadconstruction,thecrankagainsttheframeorthe connectingrodagainstthetowertube. Ifeverythingisworkingproperly,youcanletthemillturnunderitsown(wind)powerbysettingout thesails. Trythebrakingsystemandadjustifnecessarybygivingthespringmoreorlesspretension. Werecommendtoletthemillturnforafewhourswithoutpausetoletthepumpcarryoffthesand whichwasbroughtdownbythegroundwater.Stopthemillasfewtimesaspossiblebutifnecessaryas brieflyaspossiblebecauseotherwisethesandwillsettleonthefootvalveandpiston.Sandcolumnsof 20to30cmonthepistonarenoexception. Duringthetestperiodthemillshouldbestoppedoccasionallytofindtheoptimumpositionofthe crankradiussuitedtothewindspeedsoccurringandanyadjusrnentofthetensionintheropeendsof thesails. Alternativescanbemadeaccordingtoyourowninsight. Tipsfortherationaluseofthemill: Makeafewpersonsfullyresponsiblefortheuseandmaintenanceofthemill. Ifbrakingthemillisnecessary,doitgentlyandnotsuddenly. Eachtimebeforeputtingthemillintooperationallpartsshouldbelubricated(oilandgrease) first.sticktotherule"lubricateoftenwithalittlegreaseratherthanseldomwithalot". Checkallboltedconnectionsperiodically.woodshrinksandthereforethetensioninthejoints diminishes. Trytopreventneglectoforattackonthewoodbyapplyingimpregnatingcompounds,tar productsorpaint. Duetothefactthatthemillisnotautomaticallysecuredagainststorm,somebodyshouldalways beathandtoreefthesailswhenastormorverystrongwindspringsup.

54 Practicaltipsformounting: Alwaysdrillholesforboltedconnections.Ifoneofthepartsissplitaconnectionoftimberis worthless. Alwaysusefairsizedwashersundertheheadsoftheboltsandnutswhenjoiningtimber,to preventdamagetothewood. Lightlyplaneroughsawnwoodandleveltheedges(bewareofsplinters). Alwaysdrilltheholesinthetwopartsoftimberjointsalwaysinoneaction. Theboltsalwaysfit. Provideafairsetof(hand)tools.Goodtoolsarehalfthejob(nothingismoreannoyingthan workingwithbluntanddefectivetools). Keeppeopleawayfrombeneaththemillwhenworkiscarriedoutinit(fallingpartsortools). Bytheway,aboxnailedtothetowerisveryusefulforputtingawaytools.

55

hetproefdraaien thetesting

56

57 Annex
Name
Woodworkinglathe: Frame Tailstock Toolrest Spindle Bicyclewheel Pedalcrankmechanism Disc Disc Pedal Bracket Sundries Drillingtool Tripool Drillrod Disc Crossrod Pulsingrod Leathervalve Steelplate Rivets Rodpush Sundries Theborehole Drainagepipe Filterbedmaterial Lattice Sundries Pump: Pumpcylinder

Material
Naterial
wood wood wood wood wood

Number
2 2 1 1 1 1 1 1 1 1 3 l l l l l l ~10

Size(inmm)andremarks
80x80x1500bed 50x160x1200verticalbeam lathes25x50 50x160x160andlathes 50x160x120andlathes frombikeframe builtupwithplanks300mm l50mm 25x50x1500 ~250mm woodscrews,nails,threadedbarsandnuts

wood wood wood steel

log wood pipe steel steel steelor Pvc leather steel wood

80x3m,ropedorconnectedwiththreadedbar 35x6m 200,thick3mm,weldorrivettopipe 120x0.5m 120x200 120x200forstrengthenedvalve 3mmforstrengthenedvalve 25x50,aslongasnecessary woodscrews,nails,threadedbarsandnuts 150,aslongasnecessary 25x50,insteadoftheutilisationofsockets screwsfortheassemblyofthelatticetothepipe lengthsasfollowing: diameter head 150mm 3 120mm 4.5 100mm 6.5 80mm 10 70mm 12.5 60mm 18 50mm 25 dependsonhead

Pvc wood Pvcor steel

m m m m m m m

Piston Valve Sealing Valves Pistonrod Quitter Sundries

wood wood leather leather wood wood

l l l 2 1

dependsonpumpdiameterofcylinderdependsonpumpdiameteror cylinder 25x50,aslongasnecessary planks screws,nails,etc.

58
Nane Tower: Poles lstPlatform 2ndPlatform Ladder Handrailandsteps Towertube Sundries Headconstruction: Frame: Legs Beams Taillattice Tail Sundries Themovingarts: Bearingblocks Rotorshaft Crank Connectingrod Crosshead Wearingplare Crankpin Crosspin Washers Washers Sundries Brake: Belt Disc Pullspring Lever Sundries Rotor: Hubbeam Bars Sailbar Rope Sail Pin Sundries log halfround logs wood wood wood wood steel 4 12 4 2 l l 100150;length~7m 100;length~3m 30x200;length~2m 30x200;length~0.8m 2steps:80x80length~3m lattice:25x50(steps)length~4m lattice:25x50(stepsandhandrail)length~6m 140length~2.5m screws,nails,threadedbarandnuts Material Number Size(inmm)andremarks

wood wood wood canvas

4 4 2 l 4 l 2 l 2 2 l l 3 4 l 2 l 1 l 4 8 l

30x80length~6m 50x160length~0.7m 25x50length~1.25m 1.5x1.5m;ifnecessarythesailsrnustbebordered screws,nails,threadedbarandnuts 70x70x200 50length~3.5m 55x110x400 30x30x600 l10x30x400 350x130;thickll.5mm fixedwithscrews 25x200 25x130 80x50~2mm thick60x25~2mm thickscrews,threadedbarandnuts lx60;length~lm 60x160 bars:30x30length~700 screws,threadedbarandnuts 60x160x600 30x60x600 40x50length3.20m;theendofthebarsmustberounded mmlength~90 ~12m2;ifnecessarythesailmustbebordered 10mm;length~160mm screws,threadedbarandnuts,washers

steelpipe wood wood wood steel plate tube tube steel steel

steel wood steel wood

wood wood wood canvas steel

59

60

61

62

ThisisareportfromaseriesofpublicationsbyCWD Titlesofotherreportsandhowtoobtainthemare describedonthelastpagesofthisreport