This page will discuss the workshop in Colorado where Kevin, Jesica and I built our own axial flux wind turbine

The wind turbine pictured above, is Rich’s from Otherpower.com
We helped erect this tower while we were in Colorado in December 2007.
This is a 7 footer on a 45 foot 4 inch square tube tower.
A single magnet rotor is on the opposite side of the green stator with the coils.
This alternator is wired for 12 volts.

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The images we took while at the workshop have a few gaps in the projects.
I will try to put the images in the order we did each phase of the project.
I’d like to say we built our wind turbine from scratch , but the truth is the guys at Otherpower had many of the steel pieces cut out for us.
My understanding is the metal shop where they get these parts made uses a waterjet cutting for precision.
See this article on water jet cutting http://www.flowcorp.com/waterjet-applications.cfm?id=108

To purchase the kit, see Otherpower’s products

Above you can see the intricate design and precision cut parts made with waterjet cutting.

Let me get started with what we did build.

Brian winding copper wire in the proper shape for the coils. We will build the simple coil winder for our shop.

The trick is to count turns while keeping the wire taught. Easier said than done.

For me it is like rubbing my belly while taping my head.

Above we have a matched set of coils laid out for three phase output. Three sets of three coils.

The only wires to come out will be three ends, no common. This is called a Delta transform

These drawings are from wikipedia

Choosing the proper wire gauge and amount of turns determines the output voltage.

Above the coils are placed in polystyrene mold in preparation for pouring polyester resin to make the stator.

Wind Power workshop part 2

After the stator coils are set in the mold it is time to build the magnet rotors.

Our axial flux alternator has two coil rotors on either side of the stator.

The aluminum plate on the right is the magnet template.

Below we place the magnet template over the rotor. The cutouts are the same shape as the magnets.

Above each magnet is placed in the opposite polarity as the magnet next to it.

Have a good grip on these magnets before you try this.

Above the magnets are placed on the rotor with the template removed.

Each magnet is super glued in place in preparation for the nest step.

Above the rotor has been banded with stainless steel strap.

Next section we’ll get the rotors and stator ready for casting