1.5Kw Motor Conversion

Hi guy’s,

Back in 2009 I decided to make a start making my own motor conversions for a wind generator.

This post will detail the build where the magnet arrangement is in the Offset pattern. The Offset pattern is where the 8 magnets, 4 south facing and 4 north facing are spaced at less than 45 degree angle to eliminate the cogging. Now if the magnets were placed at 45 degrees  they would all be aligned and it would need a huge set of stilsons just to move the shaft.

So after talking with online colleagues I settled on a 43.75 degree spacing which after drawing the setup in autocad it turned out to just about right.

Now rather than machine the existing rotor I decided to machine a new one out of a steel shaft to the dimensions I designed in autocad.

I machined the smaller diameter on the left which holds the dual ball bearing longer than needed to allow for a fan to put at the rear of the motor. The output shaft was machined to 25mm for the conlock fitting for the blade mount.

This conlock fitting is designed to clamp shaft and bore where both are parallel. Thus not needing a keyway and the lock is easily broken using the cap screws.

For extra safety a 10mm tapped hole and cap screw is used just for piece of mind.

Now in order to machine the flats on the rotor I setup my Bridgeport milling machine with my rotary table and used a 5/8″ slot drill to machine the flats. For the 43.75 degree spacing used 43.75, 87.5, 131.25, 175, 218.75, 262.5, 306, 349.75 which was easily dialed in as the rotary table does have have a vernier scale.

The magnets I used were 2x1x1/2″ N42 epoxy coated with a 3mm countersunk hole which I bought from America. Each magnet lightly screwed in then I poured some Stupid glue (superglue for the many) under each magnet then tightened it down. The next job a casting the rotor in epoxy to totally seal the magnets and also allow me to fully machine the casting to ensure the rotor shaft was balanced.

I machined the OD for a total of 2mm clearance on the ID of the motor housing, put the bearings on then using a chain block on my 2 tonne engine hoist (with several large steel billets positioned to counter act any pull from the magnets) and lowered the rotor home.

Now for the blades I decided to make a 3 metre set for my first real attempt at wind turbine blade. At the local scrapyard I came across some old Oergon posts then after making some templates for the angles got stuck into carving out the excess.

Here is a pic of the first blade under way.

Here is a picture of the project finally finished and up and flying.

This my first motor conversion is still up and working today and recently it was brought down for a bearing replacement. It has seen many 100+ K winds and loves them and when it’s doing 500+rpm in high wind a small noise can be heard from the blades over the noise of the wind, where at lower speeds they are silent.

Wind Generators

Ok here is my idea to provide the world with my concept of making a wind generator to stand the test of time and be (when the wind blows) a reliable source of power.

My idea comes off years of research where an online user called Zubbly showed how a 3 phase motor can be turned into a wind generator. By replacing the rotor with a new rotor containing magnets in one of two configurations one can have a reliable wind generator that won’t burn up as when the wind blows to an extent of high speed the generator will plateau and actually go down due to motor reactance.

So my concept will provide a reliable wind generator at an acceptable cost .

Now down to the nitty gritty………

As 3 phase motors are used as the base for this design I do think for now sourcing them from China  will be the best cost base as there are no real motor builders left in Australia. (Come in Mr.Song)

Now for the magnets, I will design in Autocad the profile needed for the rotors and get (Mr.Song) to quote a price.

As far as the machining of the new rotor I have an off grid machineshop to make them and as summer is coming along on my off grid system it is machineshop fun time.

Where the motors need to wound with new wire the one wire test with the new magnet rotor must be done to determine the amount of turns to be wound so for the voltage needed the turns on the windings can be worked out.

Ok with using used 3 phase motors Zubbly said go off the plate rating of current and that will get you an average of what the wind generator can do. So lets say and I have done this that 2hp I did as my first conversion has lasts 7 years and I brought it down for a bearing replacement, the 3 metre blades I made out of Oregon boards I got cheaply are standing the test of time.

Now we need to think about what the power of these Wind Generators can do and think about controls to dump power if the batteries are charged.

This is where I want to bring young kids and teach them and provide a safe working place where elderly folk are welcomed to provide support ( and an income).

What is needed is an investor to provide the needed funds to get this concept off the ground so I can teach the young kids of today how the wind can be your friend. Where this free trade agreement with china is expected to wipe out manufacturing in this country it should be abolished and the natural interest be counted as the main priority.

Regards Bryan

P.S. To continue