instructables
How to Make a Very Simple Savonius Wind Turbine
by adriancubas
The in uence that more and more Wind Turbines have
on World Energy Production is indisputable. It is very
common to explore these types of devices during class
time when learning about Science, Technology,
Engineering and Mathematics (STEM). While using these
learning tools, you o er to your students wider
possibilities of acquiring knowledge and skills in these
subjects while exploring, designing and manipulating
small models of them. These projects are also bene cial
for teachers since they provide interesting and
entertained opportunities to integrate theory with
practice while motivating the students and supporting
the teaching learning process.
In my experience, it is common to see students
experiment with small electric motors to which small
propellers are attached. The propellers along with the
motors are able to generate an electric current while
interacting with the wind. Along with it, they manage to
turn LEDs on and make small electrical devices work.
There is a lot of knowledge behind these experiments
and it is fascinating to see the expected results.
It is important to note that the Horizontal Axis Wind
Turbines (HAWT), like the one in the previous example,
are not the only ones who may generate this current.
That is why in certain cases other types are usually used,
such as the Vertical Axis Wind Turbines (VAWT), where
the Savonius type stands out. In my case, I think it is also
important to deal with this type of Wind Turbines in
classes in order to stretch the students’ understanding.
--- Printed templates
In this Instructable I o er the steps that I followed for the
construction of a VAWT (Savonius). I did my best to make
---Cardboard
it easy to replicate as I believe it is worth experimenting
with it in a classroom environment. Bearing this in mind,
---Four pencils
the materials and tools that were considered for the
How to Make a Very Simple Savonius Wind Turbine: Page 1
construction of the model are cheap and likely to be
accessible.
With these steps and the guidance of a teacher, students
will be able to build and explore the mechanical
principles and engineering of a common type of VAWT.
They should also be able to apply and understand
certain physics principles and mathematical knowledge,
such as: Drag, Friction, Torque, Electromagnetic
Induction, Center of Mass and balance, Gravity Force,
Direct Current, the Determination of Planes by three or
more points, certain Geometric Figures, among others.
Another important aspect is the fact that they will be
able to relate the model’s construction with Renewable
Energy Sources and address the importance that this
entails for the Sustainability of life in our Planet.
Although I am presenting how I made the Cardboard
and Pencils Version, I o er all the CAD les including STL
and DXF for those who prefer and nd it convenient
other construction methods such as: 3D printing, CNC
cutting, laser etc. ... Also for those who prefer to
transform, adapt, scale, etc. ... my design, I included a
STEP le of the entire assembly. If you want another type
of le or need my help, do not hesitate to contact me.
I did this project together with my 10 year old son. We
both really enjoyed its construction!
Supplies:
---School Eraser

--- Three toilet paper rolls

--- Small electric motor (3-6V DC)

--- LEDs

--- Scissors

--- Sandpaper

--- Pair of compasses

--- Soldering iron and solder (Optional)

---Permanent marker

--- Paper Glue

--- Hot Silicone Gun

--- Hair dryer, fan or similar for experiments

https://youtu.be/kqhWURb0ilY

Step 1: DESIGN CONSIDERATIONS

How to Make a Very Simple Savonius Wind Turbine: Page 2

This is not the rst VAWT I have built, in this link Gravity. I placed the motor on the edge with a tendency
(https://www.instructables.com/Portable-Savonius- to fall backwards. Though the eraser that is xed to the
Wind-Turbine-With-De ectors/) I attached a previous shaft of this motor collides with the lower surface of the
one that I also published earlier. Since this version has Savonius rotor, the assembly does not fall backwards.
been designed speci cally for the school environment, However, it is able to adapt to its position variations
to be ensemble with the students as part of a class while rotating.
project, I considered the use of highly accessible
materials. Among the materials that I initially considered One aspect that I have found that can cause certain
were pencils, cardboard, and erasers. problems in the generation of this type of simple Wind
Turbines is the direct coupling of the motor shaft to the
The graphite in pencils is used as a lubricant in locks, I Savonius Rotor shaft. The RPM obtained with this
have use it before and it works. I asked myself if I could method are low, which in certain cases cannot obtain a
use it as a substitute for ball bearings so as to simplify minimum voltage and power value in order to turn on
the model construction and I think it has been a total the LEDs. The use of multiplier mechanisms such as
success. For this Savonius Wind Turbine, I decided not to pulleys or gears is usually convenient in these cases, but
use ball bearings in order to facilitate its construction. In it also complicates the construction. The solution I
contrast, a pencil is used. propose solves this problem while simplifying this entire
process.
Most of the frame is made of 4mm thick cardboard. At
rst, I had my doubts if it would be e ective. Since this The erasers that are included in the pile pencils were
material is much more exible than plastics, for example, used at the base of the whole assembly to avoid slipping
it was necessary to create the cardboard structure to and they worked very well.
accommodate 3 piles of pencils to avoid any instability.
During this part of the modelling, students should be The dimensions of this Wind Turbine are rather small and
exposed to the material selection. It is impressive to see are conditioned by the dimensions of the materials that
how they may be able to reach to interesting and deep were used. Speci cally, the length of the pencils, the
conclusions by themselves while nding the best length of the cardboard cylinders and the dimensions of
solutions no matter how old they may be. the sheets where the templates are printed, avoiding
complications and making their construction as easy as
In the prototype that I am presenting below, no special possible. With these conditions and due to its
attention was paid to ensuring that the base discs were dimensions, the torque obtained is relatively low, which
perfectly vertical with respect to the central axis (pencil), is why relatively high wind speeds are required. If you
trying to recreate an expected result after the use a hair dryer or similar it will work without problems
construction process by the students. In this version of even on the lowest speed selection. In an outdoor
pencil and cardboard, some kind of suspension had to environment the wind will have to be strong for it to
be created so that the motor could adapt to the vertical turn on the LEDs. If you want more torque, I suggest
changes of position of these discs while they rotated. tying two pencils on each pile and using taller half-
These position changes are detrimental to electrical cylinders, perhaps like the ones on the Pringles Can.
generation, since if the wheel coupled to the motor shaft
(generator) is not in continuous contact with the I recommend that the teacher should rst build a rst
Savonius rotor, the LEDs will not be able to turn on. At model version and anticipate the possible complications
rst, I considered using springs, rubber bands, and even that the students may encounter. Depending on the
sponges placed under the electrical motor. After available time, students’ background information and
thinking a bit and maybe while taking advantage of this age, 2 or 3 sessions may be used for the construction
experiment moment to elicit from your students’ and analysis of this Project.
previous knowledge, I decided to use the Force of

https://youtu.be/rEZPHNuPPcw

How to Make a Very Simple Savonius Wind Turbine: Page 3

 View in 3D Download

https://www.instructables.com/ORIG/FER/2572/KNKBM4RV/FER2572KNKBM4RV.step

Download

https://www.instructables.com/ORIG/FJL/SMB2/KNN6IUJY/FJLSMB2KNN6IUJY.rar

Download

https://www.instructables.com/ORIG/FUF/YM6L/KNKBM4NU/FUFYM6LKNKBM4NU.rar

Step 2: THE TEMPLATES

To obtain the Templates it is rst necessary to print them It can be di cult to cut the cardboard if the scissors are
on paper. I included a PDF document with the very small. Using larger scissors like this can be
templates. After printing them you will have to cut the convenient.
gures with a scissors along the contour line. Using the
paper glue, glue them to a base cardboard and again cut
out the excess parts.

How to Make a Very Simple Savonius Wind Turbine: Page 4

 Download

https://www.instructables.com/ORIG/FEI/UNA3/KNN6IULG/FEIUNA3KNN6IULG.pdf

Step 3: OBTAIN THE SAVONIUS ROTOR BLADES AND GLUE THEM TO THE BASE DISK

Overlap the cardboard cylinders over the base circle
marks and with a permanent marker make a mark of the
middle of each cylinder. With a pair of scissors, cut
vertically upward from each mark to the other end. You
should get 5 semi-cylinders that will make up the blades
of the Savonius Rotor. Using some glue, glue them on
each mark. The glue should be strong. In my case I used
Super Glue but the hot silicone should work without any
problems. In any case, the teacher must be very
attentive in this step when the students carry out this
operation. Wearing protective glasses is recommended.

How to Make a Very Simple Savonius Wind Turbine: Page 5

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Step 4: POSITIONING THE CENTER AXIS (PENCIL)

First, you will need to sharpen the pencil at each end. students their history here or indicate their study.
Verify that the pencil is of HB or similar denomination.
This will ensure that tip is hard and lasts for a long time With the tip of the scissors, pierce the center mark of the
before readjusting and / or re-sharpening the pencil. base disk and insert the pointed pencil. Try to make it t
more tightly. Don't paste it yet.
The story behind making something as simple as a
pencil is amazing. I recommend you consult with your

How to Make a Very Simple Savonius Wind Turbine: Page 7

Step 5: POSITIONING THE UPPER DISC AND FIXING THE CENTRAL AXLE

Before you can place the upper disc in its position, you will have to pierce its central mark also with the help of the tip of
the scissors. Then, insert the disc and verify that the blades are aligned and touching their marks. Using glue, x them in
position. Insert the center axle (pencil) a little further, leaving a reasonable slack to t the wheel and generator at the
bottom. With more glue, x the pencil to the two base discs.

How to Make a Very Simple Savonius Wind Turbine: Page 8

Step 6: PREPARING THE STAND BASES
Since these bases are also made of cardboard and to
prevent the tips of the shaft pencil from snapping on
them, two small squares of thin aluminum sheet were
placed. In my case, I took advantage of the used instant
glue containers. With scissors I cut out these pieces and
later glued them on top of the central marks. With the
help of a pen I made some indentations where the tips
of the pencils would be contained. The coe cient of
How to Make a Very Simple Savonius Wind Turbine: Page 9
friction between the tip of the pencil and these plates is
low, something very favorable. Since these plates are
also smooth and the rotor mass is low, the wear on the
tips is also minimal. Later I inserted the piles (pencils) in
the base, letting their erasers protrude at the bottom. Try
that all the erasers of these pencils are level. With glue,
x these pencils to the bottom base.
How to Make a Very Simple Savonius Wind Turbine: Page 10
Step 7: COUPLING THE SAVONIUS ROTOR TO THE BASES

Place the upper base, it should be tight and you should not glue it. Insert the Rotor making sure that the tips of the
pencils are lodged in the grooves of the center plates. Fit the entire assembly by sliding the top base down or up. Check
that when you blow it the Rotor turns freely

How to Make a Very Simple Savonius Wind Turbine: Page 11

Step 8: PREPARING THE FINAL ASSEMBLY

How to Make a Very Simple Savonius Wind Turbine: Page 12

To create the wheel that will be placed on the motor
(generator) an eraser was used. First, its center is
determined. Using a compass or a coin a circular mark is
made. With a scissors it is cut until it takes a circular
shape. The shape is perfected with sandpaper.
Another way to carry out this operation would be by
making the cut itself with the help of the compass as
seen in the image.
The circular eraser is inserted into the generator shaft
and glued to it. Try not to allow glue to get inside the
motor, which would cause a jam. The eraser should only
be in contact with the shaft and not with any other
surface of the motor.
If the motor is brand new, it should have its terminals
with holes. If you insert the tips of the LED legs and join
them mechanically by bending them, you may avoid
having to use the soldering iron and solder. Note the
polarity of the LED and the polarity that appears on the
How to Make a Very Simple Savonius Wind Turbine: Page 13
generator terminals when it rotates should match.
Pieces of cardboard are glued to the base of the
generator until the necessary height is reached so that
the wheel of the generator makes contact with the lower
part of the base disc of the Savonius Rotor. A little glue is
placed on the central part of these cards and it is
attached to the edge of the base where it will be held.
The motor must pivot and adapt to the possible position
variations of the Savonius Rotor base disc when it
rotates.
Nothing else, you are ready! I am looking forward to
hearing from your experiences while using this model in
your classrooms. I am sure the students will learn the
di erent theories while enjoying!
I hope you nd it useful.
Good luck!
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