WinDIY - HAWT Wind turbine

Meanwhile I have almost finished the development of the wind sensor called Anemosens for WinDIY_2. (https://hackaday.io/project/179999-windiy2-horizontal-axis-wind-turbine)

I have summarized a few details in the following video. You can also find more information here: https://hackaday.io/project/180202-anemosens-sla-printed-anemometer

In the last few days I have been working on the first drafts for the anemometer for WinDIY_2 (project log: https://hackaday.io/project/179999-windiy2-horizontal-axis-wind-turbine). You can find the first information about this in the following project log: https://hackaday.io/project/180202-anemosens-sla-printed-anemometer

Since I've always wanted to build an anemometer anyway to be able to collect wind data for my weather station, I built the sensor modular so that it can also be used in other situations (e.g. a weather station).

I tried to make the wind sensor as compact as possible. The sensor electronics will be built into the 27mm thick shaft. Later I want to build an adapter board so that the wind data can then also be read via RS485 or USB. :)

Hey guys,
i started the development and build of a new version of WinDIY.
I will post more information in a new project log and on my Instagram.

You can find more infos here:

• https://www.instagram.com/nerdiy.de/
• https://hackaday.io/project/179334-windiy2-horizontal-axis-wind-turbine
• https://nerdiy.de/en/news-mai-2021-aktuelle-projekte-und-entwicklungen/

I hope to see you there :)

As a little reference i added also the brake actuator instructions. This is not really a part of WinDIY but i thought it is nice to have it here to see how the brake actuator is made and constructed. :)

See the instructions here: https://hackaday.io/project/172328/instructions

Literally on last minute. Here comes the application video for the Hackaday Prize. :)

After having programmed the controller for almost a week, it was finally time to test WinDIY again.

To do this, I set up the wind turbine on a small hill nearby.

First the bad news:

Since the test on my generator test stand, I was a bit skeptical whether the generator was suitable for WinDIY. At approx. 20 revolutions per second (!) The generator generated approx. 25W. First of all, the performance is really low and, secondly, the required speed is much too high.

I think the nerdiskerator was a cool project to learn about the difficulties of a 3D printed generator. With this experience I will now start to develop a better generator!

The good news:

The brake and the pitch actuator work. You can see very well how the wind turbine stops or slows down when the blades are in the sail position and starts up again when the sail position is ended.

The brake also works better than expected. In between I was a little worried whether the 3D printed structures could withstand the brake pressure. But after numerous tests on the test stand and now with WinDIY, I am surprised how well it works.

Overall, I am happy with the results. Nevertheless, I already have a couple of ideas to make the whole thing better: Both the setting speed of the pitch actuator and that of the brake actuator could be faster. I'll take care of that for the next design upgrade.  😊

This video shows that the brake actuator blocked the rotation (at full power pitch setting):

Another video of the brake actuator blocking the turbine:

Random videos of it running:

And some pictures of the buidl. :)

Here is a small video from the first successful test of the brake actuator on my test stand. The generator is driven by a 250W motor. It is regulated down to approx. 20% via the PWM of the speed controller. The brake pressure could also be increased.

Now that I've posted some instructions for the individual components, here are the instructions that show how the individual components can be assembled. As always, I look forward to any constructive criticism. 😊

Here are the instructions:

Hackaday.io: https://hackaday.io/project/172328/instructions 

Nerdiy.de: https://nerdiy.de/en/howto-windiy-zusammenbau-der-vorbereiteten-komponenten/

The instructions for setting up the wind vane are online. I hope I haven't forgotten anything and everything is easy to understand. I look forward to constructive criticism. 😊

Here are the instructions 

 Hackaday.io: https://hackaday.io/project/172328/instructions 

 Nerdiy.de: https://nerdiy.de/en/howto-windiy-windfahne-zusammenbauen/

The instructions for assembling the hub and its mechanics are online. I hope I haven't forgotten anything and everything is easy to understand. I look forward to constructive criticism. 😊

Here are the instructions 

 Hackaday.io: https://hackaday.io/project/172328/instructions 

 Nerdiy.de: https://nerdiy.de/en/howto-windiy-nabe-inkl-mechanik-aufbauen/