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HOW TO MAKE a PORTABLE WIND TURBINE

By adriancubas (/member/adriancubas/)
in Teachers (/teachers/) > Grades 9-12 (/teachers/projects/?
groups=9-12)

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Performance tests on my Horizontal Axis Portable Wind Turbine design!!…

design!!…

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E
Generally when I want to get away from the city and camp, I take some kind of power
source with me. Within my preferences are the Power Banks. With a small and light one,
of approximately 40 Watt hours (Wh), I can charge my cell phone about 2 or three times
and that is fine if I am only going to spend a day and do not need to power other
equipment such as my camera, for example. If I want to spend more time then I usually
take a 222Wh “Solar Generator” with a 60W portable panel. For the energy needs that I
have in this type of excursion, it is generally enough for me.

About a month ago I made an excursion of several days and to my surprise at the end of
the second day my energy sources had been completely exhausted, also no Sun. I have
discarded fuel generators because they are very noisy, polluting and can cause fires.
There was a small stream near where I camped and there was also wind that I could have
taken advantage of, but I really wasn't prepared for it. I promised to find a solution and
include it in my new adventures. I am sure that there are several people around the world
with this type of need, that is why I carry out this project so that they can also benefit.

In this project I show you how to make a small portable wind turbine, mostly 3D printed, with
dimensions similar to a 2L soda bottle when folded. Although its generation capacity is
limited, having it can be beneficial during emergencies or when access to more convenient
energy sources is zero or very limited.

Although the initial motivation to carry out this project was not linked to teaching at
school, I consider that it constitutes an excellent opportunity to link this type of
technology with the teaching-learning process. To be able to present a product of this
type at School Science Fairs, which harnesses the energy of the wind wherever the
conditions exist, small, very portable and easily installed, should be striking and
interesting. Students could answer questions and present the results of electrical
measurements of their performance at different wind speeds. I think it would be an
enriching experience for everyone.

Among the science topics related to this project are:

Renewable Sources of Energy

Conservation instructables
of energy:(/teachers/)
https://en.wikipedia.org/wiki/Conservation_of_energy
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(https://en.wikipedia.org/wiki/Conservation_of_energy)
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(/teachers/)

Faraday's law of induction: https://en.wikipedia.org/wiki/Faraday%27s_law_of_induction

(https://en.wikipedia.org/wiki/Faraday%27s_law_of_induction)

Drag and Lift Forces: https://en.wikipedia.org/wiki/Lift_(force)

Rotational speed: https://en.wikipedia.org/wiki/Rotational_speed

(https://en.wikipedia.org/wiki/Rotational_speed)

Inertia: https://en.wikipedia.org/wiki/Inertia (https://en.wikipedia.org/wiki/Inertia)

Rotation around a fixed axis:

https://en.wikipedia.org/wiki/Rotation_around_a_fixed_axis
(https://en.wikipedia.org/wiki/Rotation_around_a_fixed_axis)

Alternating current: https://en.wikipedia.org/wiki/Alternating_current

(https://en.wikipedia.org/wiki/Alternating_current)

Voltage: https://en.wikipedia.org/wiki/Voltage (https://en.wikipedia.org/wiki/Voltage)

Current: https://en.wikipedia.org/wiki/Current (https://en.wikipedia.org/wiki/Current)

Impedance: https://en.wikipedia.org/wiki/Impedance
(https://en.wikipedia.org/wiki/Impedance )

Battery: https://en.wikipedia.org/wiki/Rechargeable_battery
(https://en.wikipedia.org/wiki/Rechargeable_battery)

DESIGN CONSIDERATIONS

For some time the idea of designing a portable wind turbine had crossed my mind. From
my experience and for it to be useful I knew it had to be small, maybe the size of a soda
bottle, able to fit inside a backpack. Its mass should also be as low as possible.

Since the plane of rotation of the propellers in typical wind turbines is perpendicular to
the position of the electric generator, they are initially inconvenient to transport and
store once assembled, even when small. I also didn't want to have to use tools to mount
and dismount the blades every time I was using it. Folding blades, that was the idea, but
how to implement it? It took me a while to come up with the answer. Have you seen the
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way bats sleep? teachers
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The wings are folded towards the body, that could be the answer. Nature
is an excellent source of inspiration, millions of years of evolution support it. Taking the
previous idea as inspiration, I designed this wind turbine.

Since on my travels I usually carry some kind of lightweight tripod to take pictures when
the light conditions are low or to make time-lapses, perhaps also using it to support the
wind turbine would save the need to carry other equipment. There are thousands of
possibilities to support a camera and make it compatible with those pre-existing
technologies, I think it would be convenient.

Regarding the generator to use, it was another difficult part to decide. Ideally it would
have been to design and build a customed one, but  unfortunately, I did  not have the
possibility of building a quality one as I did not have the required manufacturing
technology at hand. That is why, a NEMA 17 stepper motor has been selected as
generator due to its availability. Another reason to consider when selecting a stepper
motor is that  you don't need to use multiplication gears to get a useful voltage and it
doesn't have brushes.

As creators we may have an amazing digital design, but it should be able to be built with
the available resources. 3D printing! Thanks to it, we can now replicate this project as
many times as we want. If a part gets damaged, we print it again and voila!

The typical dimensions of a 3D FDM printer are usually between 22 cm wide by 22 cm

deep by 25 cm high. All pieces were included within these margins to maximize
replicability.

 Tip V Question | Comment

Supplies

Cable Glands https://amzn.to/3KxIsqa (https://amzn.to/3KxIsqa)

6002-2RS Double Rubber Seal Bearings https://amzn.to/3LRV8sk

(https://amzn.to/3LRV8sk)
Collet Propeller Adapter Update https://amzn.to/3wH3HkC (https://amzn.to/3wH3HkC)
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(5mm diameter hole for the stepper motor nema 17 and 6mm diameter threaded shaft)
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You need to replace the bullet tip with a 11mm outer diameter hex nut

Stepper Motor Nema 17 Bipolar https://amzn.to/35ZAOpm (https://amzn.to/35ZAOpm)

24 Gauge Electrical Wire 2 Conductor https://amzn.to/3DYYCGC

(https://amzn.to/3DYYCGC)

Capacitors 35V 1000uf Low Impedance https://amzn.to/3v7zkBV

(https://amzn.to/3v7zkBV)

Bridge Rectifier https://amzn.to/3utpRWz (https://amzn.to/3utpRWz)

M3 Stainless Steel Bolts Screws and Nuts Assortment Kit https://amzn.to/3Kz4LeU

(https://amzn.to/3Kz4LeU)

Gorilla 2 Part Epoxy https://amzn.to/3utDXXV (https://amzn.to/3utDXXV)

Socket Head Cap Screw, 1/4-20 x 1" https://amzn.to/3746JWr (https://amzn.to/3746JWr)

1/4" Stainless Flat Washer https://amzn.to/3KpAzmx (https://amzn.to/3KpAzmx)

Tripod Nut Barrel https://amzn.to/3joq8DQ (https://amzn.to/3joq8DQ)

Camera Hot Shoe Mount to 1/4"-20 https://amzn.to/3O2b9xy (https://amzn.to/3O2b9xy)

3D Printer

 Tip V Question | Comment

Step 1: DOWNLOAD AND PRINT ALL THE STL PARTS OF THE

ASSEMBLY
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You can download the STL files from here. As I make changes to any of them, I will
replace the corresponding file so that the most up-to-date ones are the ones that are
published.

I've included a STEP file in case you want to take a closer look at the assembly or change
something depending on your interests. If you need any special type of file format let me
know and I'll see if I can help.

I have printed my prototypes in PLA. I will probably end up printing it in ABS or PETG,
although PLA has worked very well for me so far.

In this system, the parts are subjected to relatively high mechanical stress. That is why I
have printed all the pieces at 100% infill with the exception of the propellers and tail, that
I finally decided to print at 40%. The layer thickness was 0.28mm in all cases. I used a
Longer LK4-PRO printer with a 0.4mm nozzle.

The propellers were printed one at a time. They took about 6 hours each. I used supports
and the position was as shown in the picture. The fill pattern was CUBIC and I used CURA
(Slicer Software).

Update: The versions E1 and F1 are for steppers motors with cable connector

B.STL(https://content.instructables.com/ORIG/FC5/717U/L2UG81IH/FC5717UL2UG81IH.stl)
Download (https://content.instructables.com/ORIG/FC5/717U/L2UG81IH/FC5717UL2UG81IH.stl)

C.STL (https://content.instructables.com/ORIG/F1W/ZFLC/L2UG81II/F1WZFLCL2UG81II.stl)
Download (https://content.instructables.com/ORIG/F1W/ZFLC/L2UG81II/F1WZFLCL2UG81II.stl)

D.STL
Download (https://content.instructables.com/ORIG/FRP/K6BY/L2UG81JA/FRPK6BYL2UG81JA.stl)
(https://content.instructables.com/ORIG/FRP/K6BY/L2UG81JA/FRPK6BYL2UG81JA.stl)
 E.STL instructables (/teachers/)
(/teachers/)
teachers
(/teachers/)
Download (https://content.instructables.com/ORIG/FMX/H5WH/L2UG81JH/FMXH5WHL2UG81JH.stl)
(https://content.instructables.com/ORIG/FMX/H5WH/L2UG81JH/FMXH5WHL2UG81JH.stl)

F.STL (https://content.instructables.com/ORIG/FUX/385T/L2UG81JI/FUX385TL2UG81JI.stl)
Download

G.STL(https://content.instructables.com/ORIG/F6P/JRJK/L2UG81JP/F6PJRJKL2UG81JP.stl)
Download (https://content.instructables.com/ORIG/F6P/JRJK/L2UG81JP/F6PJRJKL2UG81JP.stl)

H.STL
Download (https://content.instructables.com/ORIG/FNY/AGPS/L2UG81K2/FNYAGPSL2UG81K2.stl)
(https://content.instructables.com/ORIG/FNY/AGPS/L2UG81K2/FNYAGPSL2UG81K2.stl)

I.STL
Download (https://content.instructables.com/ORIG/FHH/FRGH/L2UG81KG/FHHFRGHL2UG81KG.stl)
(https://content.instructables.com/ORIG/FHH/FRGH/L2UG81KG/FHHFRGHL2UG81KG.stl)

J.STL
Download (https://content.instructables.com/ORIG/FVK/D3U0/L2UG81L5/FVKD3U0L2UG81L5.stl)
(https://content.instructables.com/ORIG/FVK/D3U0/L2UG81L5/FVKD3U0L2UG81L5.stl)

K.STL
Download (https://content.instructables.com/ORIG/FUF/9WQ7/L2UG81NC/FUF9WQ7L2UG81NC.stl)
(https://content.instructables.com/ORIG/FUF/9WQ7/L2UG81NC/FUF9WQ7L2UG81NC.stl)

L.DXF
Download (https://content.instructables.com/ORIG/FQI/VC25/L2UG81ND/FQIVC25L2UG81ND.dxf)
(https://content.instructables.com/ORIG/FQI/VC25/L2UG81ND/FQIVC25L2UG81ND.dxf)

L.STL
Download (https://content.instructables.com/ORIG/FR2/R1CD/L2UG81NE/FR2R1CDL2UG81NE.stl)
(https://content.instructables.com/ORIG/FR2/R1CD/L2UG81NE/FR2R1CDL2UG81NE.stl)

M.STL
Download (https://content.instructables.com/ORIG/FFC/RG5W/L2UG81NH/FFCRG5WL2UG81NH.stl)
(https://content.instructables.com/ORIG/FFC/RG5W/L2UG81NH/FFCRG5WL2UG81NH.stl)

N.STL
Download (https://content.instructables.com/ORIG/FBN/WDBC/L2UG81NI/FBNWDBCL2UG81NI.stl)
(https://content.instructables.com/ORIG/FBN/WDBC/L2UG81NI/FBNWDBCL2UG81NI.stl)

A1.STL
Download (https://content.instructables.com/ORIG/FVZ/GL9H/L3K65AQP/FVZGL9HL3K65AQP.stl)
(https://content.instructables.com/ORIG/FVZ/GL9H/L3K65AQP/FVZGL9HL3K65AQP.stl)
 E1.STL
(/teachers/)
Download
instructables (/teachers/)
(https://content.instructables.com/ORIG/FUI/0U0Q/L3K65AQQ/FUI0U0QL3K65AQQ.stl)
teachers
(/teachers/)
(https://content.instructables.com/ORIG/FUI/0U0Q/L3K65AQQ/FUI0U0QL3K65AQQ.stl)

F1.STL
Download (https://content.instructables.com/ORIG/FF8/3R6X/L3K65AQT/FF83R6XL3K65AQT.stl)
(https://content.instructables.com/ORIG/FF8/3R6X/L3K65AQT/FF83R6XL3K65AQT.stl)

ADAPTADOR TRÍPODE.STL
Download (https://content.instructables.com/ORIG/FYF/0C05/L4CQXSUZ/FYF0C05L4CQXSUZ.stl)
(https://content.instructables.com/ORIG/FYF/0C05/L4CQXSUZ/FYF0C05L4CQXSUZ.stl)

 Tip V Question | Comment

Step 2: INSTALL THE COLLET PROPELLER ADAPTER IN POSITION

To do this you must insert it inside the hole that the Central Hub (Part-A) has. On the
other side, place and adjust the nut until the assembly is tight. Since the Blades (Part-C)
and Hub will rotate in the opposite direction to the tightening direction of the Collet
Propeller adapter, there is less risk of the assembly coming loose.

 Tip V Question | Comment

Step 3: BOLT THE BLADE ENDS TO THE CENTRAL HUB

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All the holes in the designed parts are for M3 screws. Place the pieces as shown in the
images, but do not overtighten them. The Blade Ends (Part-B) shall be able to articulate
freely 90 degrees.

 Tip V Question | Comment

Step 4: ADJUSTMENT OF THE ANGLE OF ATTACK OF THE BLADES

Blade Ends have a scale with a bigger center mark. The Blades also have a mark. Put some
epoxy glue inside the holes of the Blade Ends and Insert each Blade into its position.
Match the center mark on the scale to the mark on the Blade. Rotating slightly the Blade
counterclockwise advance between 2 and 3 marks on the scale. Each mark corresponds
to 5 degrees of advance, so you would be giving it an angle of attack of approximately
10-15 degrees.

Note: It's possible to experiment a bit on this, I'd love to hear your results!
  (/teachers/)
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Tip V Question | Comment
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Step 5: PLACEMENT OF THE STEPPER MOTOR AND CONNECTIONS

BETWEEN THE ELECTRICAL COMPONENTS

The generator (Stepper Motor) should be bolted to the box (Part-E) as shown in the
image. For this, 4 M3 screws declared in the list of components are necessary. The
generator cables should protrude to the rear.

With the help of a multimeter in the electrical resistance measurement position, the two
pairs of cables that have continuity must be identified. Each pair of wires connect to the
AC inputs of each Full Wave Rectifier, their order does not matter.

The + and - outputs of each rectifier are connected to each other in parallel and in turn
also in parallel with a capacitor of 35V maximum voltage. The value of the capacitor is
not critical, although one equal to or greater than 1000uF is suggested. With this, the
sum of the currents of each phase coming from the generator is achieved, while the
voltage is equalized. The corresponding image shows how the connections were made
in Prototype 1. A two-way cable is fixed to the piece (Cover-F) and soldered to the + and
– terminals of the capacitor.

To test that everything is as expected, rotate the generator shaft a couple of times and
set a multimeter to the position for measuring DC voltage across the capacitor terminals.
You should have a constant voltage value. If you short the ends of the wires, it should
discharge the capacitor.
In the measurements made and at the RPM range obtained during the field tests, it was
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possible to conclude that the maximum open circuit voltage obtained does not exceed
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25V. The maximum short-circuit current was in the order of 0.7A. The output is not
regulated. These voltage and current values make it possible to charge 18650 lithium
batteries with a protection circuit. Finally, the cover is placed with the help of 4 M3
screws and their corresponding nuts.

 Tip V Question | Comment

Step 6: ASSEMBLING THE PASSIVE YAW SYSTEM

To the generator box (Part-E) you must glue the Tripod Nut Barrel from the components
list with epoxy glue and wait for it to dry. You will also need to glue the nut you removed
from the Camera Hot Shoe Mount ¼ to the M-piece. This nut was chosen because it has a
larger contact area and lessens the chance of the M-piece breaking during operation. Do
not allow the glue to cover the thread of the nut, in case glue gets on the thread, clean it
before it dries.

Fix the bearing to the generator box using the screw, washer and part N as shown in the
images and in the exploded view. Subsequently, the M piece must be inserted into the
previously screwed-in bearing. It should fit tight. In case it is not, use a little glue to fix it.
The assembly should rotate freely.

 Tip V Question | Comment

Step 7: FIXING THE VANE
instructables SYSTEM
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In order for this Wind Turbine to be able to orient itself correctly in the direction of the
prevailing wind, it must have an orientation system. Tube (Part-G) must be glued to the
generator box lid (Part F) using epoxy glue and allowed to dry. At the other end of the
tube, piece H is also fixed. The assembly should be as shown in the image.

This assembly was designed in this way so that the Vane could be better accommodated
when the Wind Turbine was fully folded and took up less volume for storage or transport.
It can be rotated in 90 degree increments in the plane parallel and perpendicular to the
ground.

 Tip V Question | Comment

Step 8: MEASUREMENTS TO THE GENERATOR, RESULTS AND

CONCLUSIONS
The following shows how the students could characterize the generation capacities of this
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Wind Turbine in teachers
(/teachers/)
laboratory practices. The teacher could be guided by this example to carry
out research activities of this type.

During my field tests, the maximum voltage value obtained in the internal capacitor was
approximately 22V. The wind speed recorded that day was 22km/h, with gusts of 26-
28km/h.

In the lab, if we spin the generator rotor until we get that 22V, we could measure the
maximum RPM reached during the field tests. Other values of electrical magnitudes
could be determined to try to characterize the nema 17 stepper motor in its role as
generator in this Wind Turbine.

To carry out the experiments, a three-phase induction motor was used, which could vary
the frequency of the supply current with a Variable Frecuency Drive (VFD) and with it, the
RPM of its operation. This motor was attached to the chuck of a drill with which the
generator shaft would be fixed. Attached to this mandrel was a small magnet that would
pass close to a 2000-turn coil of fine gauge wire, when the entire assembly rotate. This
coil would be connected to the signal input of an oscilloscope where pulses would be
detected. Measuring the time elapsed between pulses with the same phase and
determining its reciprocal, the frequency expressed in Hertz (Hz) would be determined.
In turn, a multimeter would be placed at the generator output and the voltage and
current would be measured based on the RPM. At the end graphs of dependency of
these magnitudes based on the RPM would be generated. One area of interest was
determining the best series-parallel configuration of 18650 lithium cells to be charged by
the generator. Two 1500mAh 18650 cells balanced at a voltage of 3.7V were used in the
experiments. Conclusions:

      • The nema 17 stepper motor (generator) apparently is not capable of supplying a

short-circuit current greater than 0.65 A. From 500 RPM, a pre-limit value of 0.6A is
obtained.There is no need for current limiting circuits to charge 18650 lithium cells
directly, just a voltage protection circuit (included in protected cells)

   • The 22V obtained during the field tests correspond to about 870 RPM of the generator.
Typical values would be between 500-700 RPM.

      • The open circuit voltage has a linear behavior as a function of RPM. At 600RPM
approximately 14.5V is obtained.
      • At typical 700 RPM  you get 0.5A charging current on a 1S2P 18650 system, versus
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approx 0.26A onteachers
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a 2S1P 18650 system.

   • It makes no sense to use configurations of three or more 18650 cells in series. High
RPMs are required that this wind turbine could hardly reach.

   This is all for now, hope you liked !

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1 Person Made This Project!

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13 Comments

(/member/riesmmm/) riesmmm (/member/riesmmm/) 2 months ago

I've been working through this project and I'm just about finished, but I decided to just 3d print
a little collett that fits snugly around the motor shaft and then fits snugly into the hex space in
part A

Collet.stl (https://content.instructables.com/ORIG/FWB/GMTI/L4E6GRJ9/FWBGMTIL4E6GRJ9.stl)

Reply / Upvote

(/member/Robasaurus/) Robasaurus (/member/Robasaurus/) 3 months ago

I'm building this. You've done a great job but I've found a few small problems.

1) It would be very helpful to have a better picture of the propeller collet adapter that's needed
and link to the specific one that we need. The current link takes you to a page with a lot of
different adapters and I purchased the wrong one.

The picture of your propeller hub shows a hexagonal opening for the prop adapter nut. My
part printed with just a large round opening.

2) I already have bunch of NEMA 17 stepper motors and none of them will fit in the housing
because they have a wire connector that sticks out too far. I suspect that others might have
the same problem. I have the software and skill to create a housing with another 5 mm of
room on one side, but most people don't. So you might want to warn everyone or redesign the
housing.
 (/teachers/) instructables (/teachers/)
Otherwise, this isteachers
(/teachers/)
a great project with excellent instructions. I've printed two-thirds of the parts
so far and I'm very impressed with how well they fit together.

4
replies
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Reply / Upvote

/1 (/member/rethus/) rethus (/member/rethus/) 3 months ago

on Step 8

Nice Project. The benefit over an solar panel might be, that you also could build an adapter to
be able to use it as water- Turbine too... if wind is not blowing.

3
replies
F

Reply / Upvote

(/member/scotfor/) scotfor (/member/scotfor/) Question

3 months ago
on Step 8

Nice project!

Could you provide a circuit diagram and a summary of rectification and voltage regulation?

Thanks.

2
answers
F

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