Brakedrum Windmill Hugh Piggot 2000

41 Pages·2000·0.43 MB·English

Brakedrum Windmill Plans
First devised in 1993, revised Oclober 1999

CONTENTS,
PREFACE TO THE YEAR 20H RDITION, sesectenanneaneinee sie
ANOTE ON MEASUREMENTS AN CONVERSIONS. 2
ACKNOSLEDUEMENIS.
FOREWORD, BY PAULGIRE
MATERIALS YOU WILL SERB.
‘TOOLS YOU WILL NEED...
wry ports.
ow [DID IT
GHIMEIEAL NOTES
BLADES,
SPEEDING
GETING PARTS.
DISMANTLING THE BACK AXLE «
DISMANTLING THE ELECIRIC MOTOR.
FITTING THE MAGNETS 10 THE BRAKE DRUY
WINDING THE CoN,
(CONRECTING UP THE COUS
WIRING TO THE BATTERY.
MODIFICATIONS FOR FORD M4 10 TRUCK.
MATHEMATICAL MODEL OF GRAKEDRUM ALTERKATOR
INPUT WAR AML
ASSUMPTIONS, 8
OUTPUT VARIABE ES AND FORMULAS 8
MaxinGTHIr PROPELLER.
PLTTINGIT ALE TOGETHER,
PERFORMANCE CHAKT

SUPPLIERS ..
UK. Suuers.
USA SuinuEas 2
Caen Ween 2
Macs mow Clava 3

Hugh Piggolt. Sconaig Wind Clestric, Dundonaell, Ross shive, IV2% 2RE, Scotland. UK,
Telephone: [phone] Pan: (OUBS4) 633 233
up: tmepages emerprive nev ughtpiygeat’
Disaibuted in the USA by PieoTurkine.om, hale: piooturbine.com

Copyright © 1993-1909 Llugh Piggott AU rights reserved in the UK and other ous,
PREFACE TO THE YEAR 2000 EDITIO?
‘This new edition of Rrakeurm Wein! Plans is wanpletely reraaste ane eonisins many’ mince coneetions os Well
as same sigan nes wtormation,

Fare fist me since 4 initia. release in 1993, this tion hac bsen completely «e-ypesel rom serach, The previous
sitions were loking muther worn: they were maintaine using “eu and pes ofthe ol fashioned sire tha Titeraly
used Scissors ard wluc' AL o¢ ts diayrams have been redone, some improved sigaificorly from the largely and
<drasen figures in the previous editions

“The formating al Kewures 2 eonsisient method ul giving measurements in both metric and North American units,
-Mitic unis alovays appear frst, then equivakn: Newh American units av given in squane brackets flloweng In some
‘esses Bri temninology chat is unfamiliar ta/ North American readers sas “\anslatod” using square braces as
well

Numerous minor sorestions and clarifications have heen made, based cn questions usked hy renders and found during
pra. valing, No-doubs. these willbe af eet benef ta people building these phar

‘New informacion has boon ded regarding modifications fer using the Zord 34 1un pickup tuck, a comma ruck in
North America, This iafcuation sas fumished tome by Me. Bub Budd, who has been reaching workshops on ROW €9
build wind etre based on ds design for sewer yore,

Inabition, a neve section gives mathernalica? model thal can be easily programmed inte any spreaésheet application
‘This model allows che ambitious vind! build 1 modify desien paramaters of Ihe sllemator to suit indivi
needs. For example. one can deteemine the ike effet of changing the nerahcr of maguets and col tums of wine
ee cil inthe altemstor in mderto oblain a desied cetput ata given speed.

ANOTE ON MEASUREMENTS AND CONVERSIONS.

In some cases, North American cuaversions are rounded to the nearest coaumanty avcilable size that will wrk prper-
ly. hor example. M0 ehreaded rod is Hmm in diameter. hut the near-eyuiwnlent 3H inch chreaded rod is used as the
equivalent even though technically 2:8!" inches is only 2mm. In cher casce where impeecise wneasurements are being,
described the disctepancy may be even greater, Pur example. wher. describing shaving ofl woud fora blade, I may say

‘slave off about Imm [U/16"] Even though 1/16" ineh is quite a hit more then Lana it esl used because isa
comnencnly used measurement meaning “a Title bi’

Tre one cave whete North American units are used dircelly inthe text is when specifing pipe. This is becanse waler

pipe is commonly specified via its "nominal bore” size which i given in imperial units. Far exople, a pipe might be

specified as “1.5 inch numsina bore”. The outer dimension fr such a pize would be 48imm [oearly 2°], We will speci
both the nominal ove ce as ell as gvamg ner and outer dimensions in hoth metric and North Ametwcan unit

ACKNOWLEDGEMENTS
Thanks to Elhot Bayly of World Power Fechnalogies. and Ganlen Proven of Proven Wind Turhine, for inspiration
Stove Wade of Wiod and Sum LA. (UK) and Michael Eavis of Glatcnburylestival fir motivation t produce the Gist
‘machine, Robert Budd of wwvessindiill.onoa far building a North Armetionn version, Steve Pendergast of
FiveTobine.com for treless diligence retyping the wae thing, and belie ur clarity i
FOREWORD, BY PAUL GIPE

Hugh Piggott’ plans for luring a used Wiekedeum into a eindmll is a weleame addiviou fo the lerane on small
swim chines. rckedrne Wind Poms is especialy walle hecause plas Tor building

have not kopt pace with she recinolegs. Mos plans date from the 1970s—or even eae.

ar own wind Lrhine

rte yer. the plas in dhs kde ace Ba a wind tubine eat rally wosks fiom semen wh Hives with and depends
Con wind energy. The brekedram sind sv proven design that ugh has operated a ayemote. windswept hell
in aorthoest Scotland since T9¥3. lis site 9a the Seotsig Peninsula fs se sindy im fact hal several commercial witd
turhines failed within a ise yeas Caome, unfovtuntely, much Sooner. Hugh's prototype of the braked ‘sind in
these plins has operates eliaby tha he substantlly imensysd its ouput within & fee yeare aie installation Ad it
‘sontioues oem tots.

‘The beauty ofthese plans car. e Found. Lygh’s use of eonvenieutly bundy sexap yard parts, Fhe design is based oa
rar brake drut usod ty Ford tnicks widely avilable in bods Bean whe transit van and Neeth Aemerca ie F250
and £254),

Another plus | ugh’ ellmanatin of slip rings and yane hearings. Slip eings olen bedevil he design of commercial
wend tcbixes as well as heme built machines, Lhiey’re nor necessary and seklom found on uany ind turbines builtin
TTurope. LIagh vise avoided them, instead subscaaing a simple pendant cable. his greatly simplifies dis desten ax
does Hugh's use pipe-on pipe for» simple aa harly yaw syster That alls the turbine to respond lo changes in
vind dinetion

Hugh's braked ‘sind also ineorpocies the durable “inside out” allemtir desig dn the papelar—and
‘essfil—small wind wthinesbulleby Bergey Windpower and Werld Power Fechnolagies, With this ltemator eontigu-
ration there's ao aoed c bull» eumplicatod ub tha attaches the blades awkwardly toa small aeler shall. ain
some ether designs, Iislad a simple plywood sandwich hols the blades igh tothe rotor and tis esse is
mounted tiroety io the generator housing: he bras drm In send cuuncs it docsn't got more stajahcevwan than
this.

‘Aad Bike all rate evexmercal wind turbines texday these plans use “sel furlmg” to protect the product af your labo:
in high sinds, Hugh’s an expert on “his tectanique ta limi the speed ofthe wind mubins’s rotor and the simale design
feud in these plans would! be helpful lai few comercial wind wsbine companies sh hiven" quite mastered the
a

inctedeum Windhill Plo iacindes detsiled structions Fox building the cutie wind eorbin, from sarvine your own
blades fra 2.1 ete [? foot] digmeler eutor wv building your own rennancat-nasnet. direct-drive stematse capable of
generating reul power, By following these plans ym wll comshrael a gerne wind turhine—not just tay-—that can
‘allah chug cur 300 9 4N0 sets

Braakedbuns Winch! Plans isa great companion to Hueh’s Windpower Workshop, Both are x valuable ait.on o any
inion lary

Pru Gip
“Tehachapi, 1999
MATERIALS YOU WILL NEED
He oss Say Mom DMseMHMONIMEL SES R eee et 253 Nokes ese ge]
er The rear Fub froma Ford Feansitcouble | Similar huhs may work, see section
H sehool war or Perd 34 cn trek DISMANTLING THE BACK AXLE.
BO [Bleck manets, 64 x32 x 20mm ‘See section SI-FPLIERS,
[Ls x LAS NOS}
v amined ooge from 2S Fersepower electric | This the par made Teum a slack cf ia
utes, 203mm [80] ir diameter sheets of veel
Bie | Enamel sone copper magnet wire, 075mm | See svetion SUPPLIERS,
[1.75 pours] 2G AWG thickness,
Abwut 503g | Epoxy or similar sin See ssetion SUIFPLIERS.
[1 pound]
Several shoes _| Glass fibre surfing issue. or din fabric
2 Single phase bridge retfirs raced atleast | See sostion SUPPLIERS.
39 amps end PHY nf at leat 1M! vals
v Picee of aluminum serup, anpresimately 290. | forthe rectifiers. Any shape willde. An
200mm [8" 8°]. be used as aheat sink | ald sanecpan may wark nivel:
q ‘Mild ste), at 96 x 90% Comm ‘Used For mowing
eeeer al
5 Mild steel. fst 125 5 25 x mm For siatoe mounsing ups and horianntas
[rascals]
T ‘Stee abe 6000 48mm overall x dram hick | Poe for moat
[20° 2" black pipe or sina)
q ‘Steal tohe 250164 mm overall 4mm thick | Used as a bearing
Lo" x25")
T ‘Stee abe 150% 43 mm overallx mam hick [Tal bearing,
[63 132")
q ‘Steel tabe 1,007 24 everall x 4mm wick | Por tl
Baas)
v Uhreaded rad pls nats, S00 mm x mma
diameter (2¢" long. x 38" diameter]
cy Wood sevens, SOmmn [2° ong
r Wood [000 x 1x 50 ram ‘Mist fe kaart, fv las, See seria
flo by fone 49° long) MAKING CHE PROPELLER.
7 Wood 750 x HUD x 99 mm Masthe aoc ree, forb ales, See section
[oso by four, 39" long MAKING THIF PROPELLER.
3 Vlywand, 3¢Omra Uismeter di Br Tamm | Marine or presture eae plywood
thick [1° diameter disc 2y 122" thick] requite
“Abo 1 Ther Primer and gis paint For wood pat
Tin
‘Abont 72 Ther [vhamrnerte [Rest-olewun] ov salar pase Re
Ltpint)__| see pars, .
TOOLS YOU WILL NEED

Ee eee
socket panes (wretches, hammer ese srw
suse gers

‘We rsh aps pool pen]

Te elena pts

Hacksaw with good quafity new, Hades Sandvik blades weegmmmended,

‘Angle grinder, clewic dill and sharp bis Cobalt bits rosommended.

Preses oF Tm (1/16"] aluminum sheet For shims between magncts during assembly.
Thickness is anproxinae

‘Scraps of plywood Tr enil-former and cheek pieves, See sootion
OIL

Former for clamping coils, made from 75x 50mm | See see

fF'x 2] umber

G clamps [C clamps]
Tinie, schlering icon, multicore solder, tape

Electr welder and steel welding tods, size 25 or 3 mim
‘Wood working iach: caw, pln, spokeshave "Ta carve Wades

WHY DO IT?

Thave heen hing windmills ftom scrap naterals for twenty years. It cus the cost and Lk vecycling, Tie biggest
hesdache has always heen to find a sultcble generator. A generator fora windmill has to work a ow speed. be efficient
(oot waste! of power), and lau be celiable and aftndable.& rough spec.

Vehicle dymamos [DC generators] and stemators were tae obvious first choive, but they need rater high speed (RIM)
and ate incficient. | eared to rewind Lucas alternators, so ney woul work at low RPM, but the efficiency wea Srom
bad to worse, so-most ofthe energy caught (tom the wird was wasied heating up the altrmatr.

The best bet tumed out to be dynamos from buses or jeeps. A low speed 24 vole dynamo can be simply converted 0 a
very low spa 12 ott dyamo. ord thes ley od machines ae rugged ecient, and cheap. Ihave described low
{Dmake tha into windmills in my booker “Srapyard Windpower Reale", st puiahed in 1482. update in 192,
tus nos oof ein.

“There are many successful windmills in operstion based on these dynamas, but Ihave become painflly aware ofthe
horfoamings. The wart thing isthe pefonnance in ight winds. Here is ie reason why:

All yeneralorsvegure maagotisn. they work by dragging cols of wice Uuayh ate Geld, Viele
dyamos and akernsors use electromagnet, and these need about 40 watts of power SI ALL LIMES, So the
rst 40 was of power you generate is used up enerpisng the feld cols, and only when the wind is sanget do
‘yo see an actual “pein erms of charging. the bailry

(OM dynamos a also harder and harder to obtain in good condition, and there are maintenance problems wilh tke
bribes.
‘The esl type of generac Fo a small wind torins s + purzose-huill permanent mayncteliemator PMA}. This
requires Feld Soil 0 energie, and has no bashes to cause prublems. There are scrap permanent maguet machines
svhiclscan ke useful. suck as computer tope drive maters, washing miachine motors, serves, ete, Put T have found no
reliable souvee, (See Sapplirs at thy cid ot the booklet for some sources.)

Buyang permanent magnet mac! nery naw i expansive, and [arelbr tare ted making alternates bul on
solee} bossy, My rs atten. ¢sdevaled in "Serapyard Windpower”. I eas a rather Irboriows. welded fabrication of
steel diss. Megns ghaed cn the fives af the steel dices (sxe figure I) coated past evils sal i a stationary ise snd-
‘wich! between, as in he deste ed hy Marlee ir theic Rurdand sein urine. (worked very reliably hut Fl thac
it had heen too rch hassle to justify baud ametber

SECTIONAL View OF STATO
CISK TYPE ALTERNATOR 77, R
f

/ Pocimens or 10 cong prsgersicas

fi

[o~ srarorone
A Macher BLOCKS,
fa sree os

Figure 1

But over the years, quite few pecple have built these, using the plans in “Scrapyard* and I hope to produce a new set
of plans foran axial design some day

Sill American wind emis such as Ibe Whisper and Tergey machines use a ditfeveat geometry forthe PMA. The
magnets ate clued fo the inner surface of aeylinder tec be) shish rates, The coils which produce the eutput acc
‘wound on a saGonary cone af lainatal ron mater, with slot in ts cute sutface forthe coils to fit ino see fewre
2h Che setomary part with be cols sealed the state. Te scorned to me tha a mach s’mpler wheel-bub PMA vould be
iui using s rake dum rather than steel discs anu ollie dis ancricaa ste, Long whol base Fond Teansit vans
sind 34 ton trucks have big brake durason the back axle, shd ence ent bearings.

HOW I DID IT
Finding suitable magnets was nota problem Herent Fletronies in Pirminy'am eave the Rest quote, though Lewd
hove gol smaller qeanitesfrrm Mugnet Applications at rege the unt price Newadays I would recommend CER
MAG inthe LX. (ou see Suppliers a: the end for ether iternatéal sburees), The ime diarmeter of ve rake dum
ie 254 mm (10° The length 4 ran: [25°]. chose magnet blocks 04 unm x32 arm wah dhckness 2 na
he big pesblera ws fining laminate material forth core of the Salo, to cam the coils, The core has to be rade fom
‘hin laminates of soft son staked into a sold block. Yiu can see them in ransformer cores ar dame armatures, Lf yeu
use sold in. de changing magnetic fields woul set up wasteful ehly current in the ron, bur te lacquer heaween the
laminates prevents (hs. I aed a core “hat fied close up the magnets, wi only a sal gr gap. and slots 0 cary
The elas in ve Arterican design A small ar gap allows the musiiomn magnetic fied smeneth, ac the diameter uf
(he lamented materiel I needed was much bigger Gan standard sizes in serap dymaros, and to have it purpose made
‘would have added over a lundied pounds [abou US $160] to the cost ofeach alcrator.

. mae i
o\ SECTIONALI
VIEW) | se

Nae
SSS

2 ty
wt
\ Ve v
YK \
A

AMERICAN STYLE PMA BASED ON A ROTATING CYLINDER
Figure 2

Feta while almost sbundoned the whole idee, I could see no way to make the ator at law cost, Then Gendon Proven
of Proven Wind Turbines enesuraged me gy ry aliTeert lnc.

ry

Figure 3
“The way 1 uid iin the end was using aminates fom «very ordinary hig 3 phase, S hotse power eerie motor. The
laminates are the wero way out, wth slots on the inner bore. and an mos smooth outer surface, diameter 203mm
[8°]. Rather dan pacing the evils inthe sks, 1 eloed chem ot the cuter lace cf he luratet core, inthe 4 San
B16" sap between core and magnet faces This vep is erether lege one for the magnetic fel and the field is weake
sed Muck of alo “Teake™ stv frm ane roan lo ils neighbor, lr svcd jumping the gap, But the lial
‘were cheap (liom a aerap motor) and the eauling altemater dass wosk,

1 Fe the aerator was quit a success, Fr its sigh. its not as ficient as an aerator wal the righ sort of lami-
rations and a smaller air gmp, bul does have seme adlanczges. Hor one ting, this set of laminstcn is much easier
Find, bo, the aleenaloestans up aor enily in lig sande chan it sent ifthe sie gap sere narrow, Machines with
sald ic gops have much higher maguetic drag, wll ofls dhe ssdill Rack Pou sani up i Fight winds,

1 gluod the gus. he autside othe laminacins eth epoxy resin. [need a ery thin liver of evils, s0 Ls. G
lamp ela] to press tem cm mn she sminatems, The wd former sac is esity made by carving hole
toys in che vied with an intemal radi of bOdeam [41°]

Gelomp E™ holding
coils white
epoxy sets

‘wooden former

From pest cxperiense, the eaemonest problem with permanent magnet alternators is thatthe magnets slat fa mb the
‘fale. 50 Lalleseed pleary of clearance. around 2mun [116"L. So only just wer half the airgap is filled with coils,
‘You could yet more power hy making the coils thicker, but atthe cost of lower reins. ive never had problem,
‘wih the magnets hitting this stator, oven when te bearings Were guile luck.

Ihe esuting windril bas 20en one ofthe est Teer bil, and immediately set ty wrk nel prepared plans so others
could the same. | actualy bul it fer t¥e low wind speeds of Ibe Glastonbury Festival site i 1943, where it prewest
te as good a3 the Marte fn 1800 sind eating in Jove sous

Aer the Festal, . put up on hllup sts nae my home, powering a netghbor's heuse, Here it had the chance to
prove itself as high wind speed survivor. The filing lai system protets it aginst ove speed. At fr we st the ta
1p ta fit che oup t 304 seas, bur afer couple af trouble fiee years L added raone eight to it 30 my neighbor
ets 500 oes ell actully eather es, a neury bls lo in the cable to the house}
ere is same data for che altomator(emnnected “stn” ['V"] for 24 vals:

Iemal sistance. 4 ohes
Cutin RPM: 200 REM

S2NRPM Ocipu: amps 30 volts = 90 wans
SOD RPM Geypac — Samps gl 42 volls 278 watks

‘See scoton PERFORMANCR ct the end athe booklet fir mune details

‘se tohien Wy minted eeader wi. have suspscel that thre wil he quile some het yenerate wt the windings wien
‘he alteratoe is paring aut 9 amps, Tact the loss wil be aban 360 sean, so che altemato is nly ubout SF efi-
cet ths in.

This in nol winder etfckoney: bat dhe important thing ist be effisient i Bight winds, wher power is scare (an this
slteewmor seria isha), Ta igher wid, there is en power i une ame als plenty af cooling to event
ssindings ftom buening out?

emule as best tp rom the stator, you shuld ideally lus it with only a small current and use higher voage
in bieber winds. Tae Markee 1800 wind tubine has a special controler which Uocs this (rant of te reason why this
sxindmill sso expensive}. One solute would be to use sta PY°| connect in low wins, change to dela ini
winds, Resistive Tends Cheaters, Tghis) will week wilh bolls eFiienes Rom the altemator than barter lous boxe
The wa

‘But this isnot the orca isu, aml im Tc you will uve u very pool windmill even i you ignore the abc ve ermsidscae

GENERAL NOTES
1 shoul be very surprise ifunyie fishy Deve han exacs aMtuyh this couree of ation wend cortinly ghee
ce resus Jn pect, is most Tkely tt:

+The parts whish are obtained will vary slighty in size and shape fiom dvs supeested
“ Tndisidvals will have their own ides for simple ler was suite ome skis and eesourees

Fer amply, | have made muck we oF sles welding, bul fbr some i will he cesce to bolt pieces of steel lngether
and wsaveid welding,

BLADES

1 prler fo make blades trom weed. but thes ean alse be made flow glass Vibe and cesin, 9 even fra metal, Metal
‘blades will tend to sufer fom fatigue. und this dacuer wuld be resgnise. Gordon Proven has a very interesting.
technique foe masing blades ftom palypropslene shects. bot lau not qualified to describe his properly

wwe used a3 bladed propeller for this windmill, beeavse ey nim move smocthly dian 7 bladers un laser than 4 ot
mre bles woul. You cull uve large, 2-blaled propeller iestea. The pitch w/the blades would aosd 7 be finer
(Hauer) inthis ease, You cool ineexse the digmter em 2.hex [7°] 19 2.7m [5] using « higher tip speed rai (we my
bok “Windpower Worksuep"

SPEEDING

The altzmator ca be rin thnough a bol drive to clan higher speed, ssa more pow, fram the same racine i
this in consider wortnhule, Halt dive or ter gearing 1s aot only mars werk to make. bul will intishuee fietion,
Which may make starting dificult in Bale ind.
‘The windmill described here ets in aa very low wind speel ec batery changin applications, whene reliable, slow
charge i ost desinble, Ts its mast ffckom when it ents in, lis il iellisent by the time it delivers 300
swans, dire driven by a pepelle. and wie as deseribed here. For hw spec euti,

Higher yaputs could he abtained with grod etticiency by rannirg ita higher spool, and citer reviring the wus in
arallel arcups. or operating at higher vahage. Thor is 3 wade-off betveen speed uml power hie

tore space allows the allemakor to handle more poe, bul also brings more problems wn noise, wear. Fatigue and
slbvation, 4 banter approach to gotrng more pawr would he tp use 8 kuger brakeram or fbricete somthing, wil
larger diameter. all up 19 you, but Tam avallable 0 eve advize cn the phone oe in answct te ltr email. ot FAX
nuites.

GETTING PARTS
Thave isa list of suppliers inclndod (see section SLIPPLIERS), te help you fir! the pacts you teed. yo line eter
souross iT am sure hey exist} perhaps you sual fet me know, and T shall pose te information om 4 ethers, Lf lens is
anything you really eaunoc get hold of laminadons may be a aecblem) then 1 may he able fo lip out, The Peed ¥4 an
ruck brakedrum can he used eth different dimensions fbr magnets snl laminations, Soe seetion MOODIFICAIIONS,
POR FORD 3/4 TON TRUCK,

DISMANTLING THE BACK AXLE

‘What you need isa big brake dren lium Ford irnsil long whee] hase war similar, Taxes Ton with ths
stm Sze rake drum, rl there wll probably be eer rakes, Hout whee huh usually have dsc brakes there day
and so ae not suitable for ths design of altsmato. You need “fully tating” bearings on te ln Le che hub mest be
supparte by 180 hearing races, even aller se hall’ shall fs removed. Ja the case ofthe tal there are to tapered
seller bests

Rear Axle Pirrentiat aisha

J
>

“The Rraked-um rast be feet tn
sovommodate the windings

Figare 5

The Firs step is treme the ul bell which caries tke deve ftom the gearbox. cul lo the hub, This is done by
removing the six small nuts near the cerme ofthe hub. and sirapy paling the rcular lange which is aetualy the end
the shal

Next you need to remove the outer bearing race, which i ened by he lege thin muss. The outer nul hich has
boon zevcaled by removing the half shafy is locked by tak hent award lrora a wasker behind the nwt, Kroc his
bvkwanls witha serewcriver oc punch, deivem by a hammer, x0 that the nut can sae. The nut is undone futicloc
wise) ley placing a chisel agaist a come, and driving it around with ahammer, Lif cue he washer. and remove the
secend mu in the same vay. Now the hearing ence is [ree to come ou, but U may’ nod Wish 1s. The easiest way [we
to persucde is o ref the haf shalt back-osiron sticking out, not im) and tighten p40 or chree nus, Pulling and wags

the shall saw elease the bearing. When it cme oot korp it lean, Feil eed ln ke washed in patol and
repicked with grease (in moderation) efine nefirung