2015-05-14 (Th) Wind Generator Test Base

Pieces were arranged to make five stations. Pulleys and bearing adapters had been printing for several days during work shifts and sleep. 5/16" (8mm) hardware was purchased if it was not stocked. Each station was constructed identically to ensure consistency in tests. Originally threaded rod was going to be purchased in bulk and cut to size but five pieces of 24" (0.61m) threaded rod was purchased to simplify.

Parts awaiting assembly

Parts were distributed identically to each station. Each station already had the PVC structure with motor and mount. The spinning apparatus starting at the bottom was:

  • 3/4" (20mm) Carriage bolt
  • Printed pulley
  • 5/16" (8mm) washer
  • 5/16" (8mm) nylon insert nut
  • 5/16" (8mm) coupling nut
  • 608 Bearing with included speed ring
  • Printed 3/4" PVC bearing adapter
  • PVC T connector
  • Printed 3/4" PVC bearing adapter
  • 608 Bearing with included speed ring
  • 5/16" (8mm) threaded rod 24" (0.61m) long
  • 5/16" (8mm) nut
  • 5/16" (8mm) washer
  • 5/16" (8mm) washer
  • 5/16" (8mm) nut

 Collection of parts for spinning assembly

The first step to assembling was to put on a pair of washers surrounded by a pair of nuts. These were tightened against each other to give a firm hold at one end of the rod so a nylon insert nut could be put onto the other end of the threaded rod. A short carriage bolt was pushed through the printed pulley and locked into place due to the square axle hole. A washer and nylon insert locknut were put on opposite and tightened with a wrench. The strength of the pulley was sufficient to tighten the nut which was a pleasant surprise. The coupling nut was also put onto the short carriage bolt. Another lock nut was put onto the threaded rod until it was on far enough to go all the way through the bearings, printed bearing adapters, PVC T, and coupling nut.

One end of threaded rod with nuts and washers

Pulley assembly

Approximate distance to put locknut on

The locknut was put on far enough to stick out the bearing and go into the coupling nut

Finally the long O-ring was put on the pulleys and all stations spun well. In each station the motor could be heard spinning quickly. Motors have not been tested to ensure each of them outputs the same voltage nor have they been energized. All five units were assembled identically but one has a warped threaded rod which should be replaced since concentricity is important to reliability.

Single station

Five stations

Files for Wind Generator Test Base:
The OpenSCAD file below is not necessary unless you want to change something
 To do:
  • Design electrical
  • Design and write program
  • Build
  • Test for usability
  • Go to next phase and test turbine designs

The rest of the posts for this project have been arranged by date.

First time here?

Completed projects from year 1.
Completed projects from year 2

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2015-05-11 (M)