Wind Turbine Mk II Instruction Manual

Wind_Turbine_MkII_Instruction_Manual

User Manual:

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Page Count: 16

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!

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5!Watt!

3dprintable!Wind!Turbine.!

Product!Liability!Waiver!

This! agreement! releases! ‘3dp’! from! all! liability! relating! to! injuries!

that! may! occur! during! the! use! of! this! Prototype! Wind! Turbine.! By!

downloading!the! plans! for! this! Prototype! you! agree! to! hold! ‘3dp’!

entirely! free! from! any! liability,! including! financial! responsibility! for!

injuries!incurred.!

The! user!acknowledges!the!risk!involved!in!operating!a!product!of!

this! type.! These! include! but! are! not!limited!to!the!release!of!high-

energy! debris! or! electric! shock.! The! buyer! participates! voluntarily,!

and!accepts!all!risks.!!

By! downing! these! plans! you! understood! and! agree! to! the! above!

terms.!

!

MKII

!

!

Introduction!

This! document! contains! the! Manufacturing,!

Assembly! and! Operational! instructions! for! 3dp’s!

Wind!Turbine.!

This! fully! functional! wind! turbine! has! been!

specifically! design! to! be! manufactured,! assembled!

and! operated! at! home! with! its! unique! 3d! printable!

design.! The! wind! turbine! is! optimized! to! produce! a!

power! output! of! 5! Watt! (12volt! ~4amps)! at! 5m/s!

wind! speeds,! perfect! for! battery! charging!

applications.!

The! wind! turbine! has! been! designed! with! a!

unique!Passive!Variable!Pitch!(PVP)!design.!The!PVP!

maintains!an!optimum!power!output!through!control!

of! the! turbines! rotational! speed.! Whilst! optimizing!

power!output!the!PVP!also!protects!the!Turbine!from!

dangerous! over! speed! conditions,! limiting! its!

maximum! revolutions! per! minute! in!wind!speeds!

greater!than!5m/s.!

The! main! components! of! the! turbine! have! been!

designed! for! Additive! Layer! Manufacturing! (ALM)!

methods! using! PLA! plastic.! 95%! of! the! ALM!

components!require!no!post!processing!as!these!parts!

do! not! require! ‘print! supports’! reducing! material!

usage!whilst!improving!the!overall!finish!of!the!part.!!

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!

MKII Design Improvements

The MkII has three design improvements, the first is an

all important tail fin to allow the turbine to turn into the

wind and extract the maximum wind energy in

changeable conditions, the second is a stiffer tower

structure with bigger bearings and increased diameter

locating pin to support the increased loads from the tail

whilst allowing for the third improvement which is the

inclusion of Split Ring Electronics. The Split Ring

Electronics allows the turbine to spin around the tower

axis without any limitations it brings the power

electronics into the tower where there is more space and

its easier to access.

The MkII requires the following new parts:

• Structure

• Rear Structure

• Tower Header

• Nacelle

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

10.00

11.00

12.00

13.00

14.00

15.00

16.00

17.00

18.00

19.00

0

100

200

300

400

500

600

700

800

010 20 30 40 50 60 70 80 90 100 110 120

Voltage Output (14 Volts = design intent))

Revolutions per Minute (RPM)

Blade Pitch Angle (90 deg = design intent for max lift)

Wind Turbine Test Data

4.1 m/s <RPM>

4.5 m/s <RPM>

4.9 m/s <RPM>

4.1 m/s Voltage Max (V)

4.5 m/s Voltage Max (V)

4.9 m/s Voltage Max (V)

Keep Out Zone

Pole Length is dependant on

Installation type

3

2

1

5

6

7

8

9

8

AA

SECTION A-A

SCALE 1 : 2

4

ITEM NO.

PART NUMBER

PRINTED

QTY.

1

Tower Assy

SEE ASSEMBLY DRAWING

1

2

Structure Assy

SEE ASSEMBLY DRAWING

1

3

Rotor Assy

SEE ASSEMBLY DRAWING

1

4

Shaft Nut

Y

1

5

Nacelle

Y

1

6

M3 12mm

2

7

M6 300mm

Threaded Rod

1

8

M6 Nut

4

9

Tail Fin

Y

1

A

8

7

F

2

3

4

5

6

1

B

E

D

C C

E

B

D

F

A

4

6

8

1

3

5

7

2

Wind Turbine Assy Drawing

3dp_MKII

8

9

1

6

10

16

15

16

14

7

AA

13 12

SECTION A-A

SCALE 1 : 2

1711

18

19

20

4

3

2

5

13

14

14

ITEM2+13

Interference Fit

ITEM NO.

PART NUMBER

PRINTED

QTY.

1

Disc

Y

1

2

Crank

Y

3

3

Pitch Arm

Y

3

4

Piston

Y

1

5

Piston Cover

Y

1

6

Nose Cone

Y

1

7

Blade

Y WITH ENBEDDED NUT

3

8

Shaft

Y

1

9

Shaft Shroud

Y

1

10

Nose Cone Tip

Y

1

11

M3 Nut

6

12

Pitch Bearing

6

13

M5 40mm

3

14

M3 12mm

Self taping

9

15

M4 50mm

3

16

M4 Nut

6

17

M3 25mm

3

18

M5 50mm

1

19

M5 Nut

1

20

Pitch Spring

1

A

8

7

F

2

3

4

5

6

1

B

E

D

C C

E

B

D

F

A

4

6

8

1

3

5

7

2

Rotor Assembly

3dp_MKII

1

2

3

4

5

6

7

9

8

10

Both Cogs require

a grub screw

(part not shown)

A

A

B

B

SECTION A-A

SCALE 1 : 1

1

5

3

4

2

SECTION B-B

SCALE 1 : 1

NEMA Stepper motor wiring

routed here.

Structure assembly

ITEM NO.

PART NUMBER

PRINTED

QTY.

1

Structure

Y

1

2

Stepper Motor Bracket

Y

1

3

Generator Cog Driven

Y

1

4

Generator Cog Driving

Y

1

5

Structure Rear

Y

1

6

Stepper Motor NEMA11

1

7

M3 12mm

4

8

M3 25mm

2

9

M4 25mm

2

10

Main Location Bearing

2

A

8

7

F

2

3

4

5

6

1

B

E

D

C C

E

B

D

F

A

4

6

8

1

3

5

7

2

3dp_MKII

A

A

Tower Pole

Standard home drain pipe

64.50

SECTION A-A

SCALE 1 : 1

2

1

3

4

5

6

7

Slip Ring is an interference fit

no screws should be required

however holes have been included

incase they are required

ITEM NO.

PART NUMBER

PRINTED

QTY.

1

Tower Footer

Y

1

2

Tower Header

Y

1

3

Tower Pole

1

4

Tower Shaft

Y

1

5

Main Tower Bearing

2

6

Slip Ring

1

7

Tower O-Ring Setting

& Seal

1

A

8

7

F

2

3

4

5

6

1

B

E

D

C C

E

B

D

F

A

4

6

8

1

3

5

7

2

Tower Assy Drawing

3dp_MKII

A

DETAIL A

SCALE 1 : 1

Piston

Pitch Alignment Feature on Disc

Blade

Blade setting Face

Alignment Plane

Step

Task Description

1

Depress the Piston to the stop

2

Hold the piston in the depressed position throughout the operation

3

Thread each blade onto the M5 bolt and tighten down

4

Align Blade Setting Facing face with Pitch Alignment Feature on the Disc

5

Use a spring washer, washer or rubber o-ring to ensure the blade is

aligned and tight. This is likely to take a number of attemps.

6

Repeat the operation for all Three blades

A

8

7

F

2

3

4

5

6

1

B

E

D

C C

E

B

D

F

A

4

6

8

1

3

5

7

2

Blade Setting Instructions

3dp_MKII

A

A

B

SECTION A-A

SCALE 1 : 1

9.10

DETAIL B

SCALE 2 : 1

USING SLICER SOFTWARE PLUG-IN.

Pause the print at a height of 9.1mm

insert M5 nut. Before resuming the print

ensure the nut is below the print surface.

A

8

7

F

2

3

4

5

6

1

B

E

D

C C

E

B

D

F

A

4

6

8

1

3

5

7

2

Blade Drawing

3dp

MKII

BILL OF MATERIAL

Shell thickness 1.2mm

Bottom/Top Thickness 1.2mm

* Component requires an embedded nut, see blade drawing.

Description Item No. Part Name Printed QTY

Layer Height

(mm)

Fill Density

(%)

Print Speed

(mm/s)

Support type

1 Tower Assy NA 1

2 Structure Assy NA 1

3 Rotor Assy NA 1

4 Shaft Nut Y 1 0.1 100 20 None

5 Nacelle Y 1 0.1 30 50 None

6 M3 12mm N 2

7 M6 300mm Threaded Rod N 1

8 M6 Nut N 4

9 Tail Fin Y 1 0.1 15 50 None

1 Tower Footer Y 1 0.3 30 50 None

2 Tower Header Y 1 0.3 30 50 None

4 Tower Shaft Y 1 0.1 80 50 None

3 Tower Pole N 1

5 Tower Location Bearing N 2

6 Slip Ring N 1

7 O-Ring N 1

1 Structure Y 1 0.1 50 50 None

2 Stepper Motor Bracket Y 1 0.1 100 50 None

3 Generator Cog Driven Y 1 0.1 100 20 None

4 Generator Cog Driving Y 1 0.1 100 20 None

5 Structure Rear Y 1 0.1 50 50 None

6 Stepper Motor NEMA11 N 1

7 M3 12mm N 4

8 M3 25mm N 2

9 M4 25mm N 2

10 Main Location Bearing N 2

1 Disc Y 1 0.1 70 50 None

2 Crank Y 3 0.1 100 20 None

3 Pitch Arm Y 3 0.1 100 20 None

Wind Turbine Assembly

Tower Assy

Structure Assy

Rotor Assy

Print Settings

4Piston Y 1 0.1 100 50 None

5 Piston Cover Y 1 0.1 50 50 None

6 Nose Cone Y 1 0.1 100 50 Touching Build Plate

7 Blade Y* 3 0.1 30 50 None

8 Shaft Y 1 0.1 50 50 None

9 Shaft Shroud Y 1 0.1 15 50 None

10 Nose Cone Tip Y 1 0.1 100 20 Touching Build Plate

11 M3 Nut N 6

12 Pitch Bearing N 6

13 M5 40mm N 3

14 M3 12mm N 9

15 M4 50mm N 3

16 M4 Nut N 6

17 M3 25mm N 3

18 M5 50mm N 1

19 M5 Nut N 1

20 Pitch Spring N 1

Rotor Assy

MAIN%LOCATION%BEARING%

Brand:'EU'Budget'

Inside'Diameter:'25mm'

Outside'Diameter:'37mm'

Width:'7mm'

Seals'/'Shields:'Rubber'Sealed'

http://simplybearings.co.uk/shop/advanced_search_

result.php?search_in_description=1&keywords=F680

52RS'

PITCH%BEARING%

Brand:'EU'Budget'

Inside'Diameter:'9mm'

Outside'Diameter:'17mm'

Width:'4mm'

Seals'/'Shields:'Non'

http://simplybearings.co.uk/shop/advanced_search_

result.php?search_in_description=1&keywords=F689'

'

PITCH%SPRING%

RS'Pro'Steel'Alloy'Compression'Spring,'80.5mm'x'

8.63mm,'0.17N/mm'

http://uk.rs-online.com'

'

'

SLIP%RING%

file://localhost/link'http/::www.dx.com:p:4-wires-1-

5a-240v-d12-5mm-micro-capsule-slip-ring-for-cctv-

monitoring-robot-black-388255'-'.WDXzrHcTmRu'

!

!

Electrical!

The! Turbine! Power! Circuit! shown! is! used! to!

convert! Alternating! Current! from! each!of!the!two-

stepper! motor! coils! to! Direct! Current,! smooth! the!

signal!and!regulate!the!output.!!

!

Turbine Power Circuit

- + - +

- +

M

Stepper Motor

NEMA11

RFull Wave Rectifier Vishay VS-2KBP005, Bridge Rectifier, 2A 50V, 4-Pin D 44 Stock no.: 468-1603

CCapacitor

Panasonic 4700?F 25 V dc Aluminium Electrolytic Capacitor, FC Radial Series 5000h

Stock no.: 315-0669

Vr Voltage Regulator Magnatec L78S12CV, Single Linear Voltage Regulator, 2A 12 V, 3-Pin TO-220 Stock no.: 633-032

RS Components Stock Numbers

R

R

C

C

Vr

M