Magnet Generator for Wind Power.pdf

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This guide is meant as a general reference for those interested in seeing alternate designs and methods from the Hugh Piggott approach to axial-flux wind turbine construction. It has omplete plans for building a 1 KW magnet generator.
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  1 |Page    Spring 2010 Senior Design Project, Spring 2010 | UAF Wind Team UAF   W IND T EAM   A XIAL -F LUX W IND T URBINE FOR R URAL A LASKA    2 |Page  CONTENTS 1. Foreward .................................................................................................................................................................................. 4   1.1 Abstract .............................................................................................................................................................. 4   1.2 Acknowledgement of Support ............................................................................................................................ 4   1.3 Problem Statement ............................................................................................................................................ 5   1.3.1 A Finite Energy Source ............................................................................................................................................... 5   1.3.2 Current Axial- flux “D.I.Y.” Generators ........................................................................................................................ 7   1.4 Project Advisors .................................................................................................................................................. 7   2. Design of Wind Turbine ........................................................................................................................................................... 8   2.1 Permanent Magnet Generator (PMG) ................................................................................................................ 8   2.1.1 End Caps ..................................................................................................................................................................... 8   2.1.2 Rotors ......................................................................................................................................................................... 9   2.1.2.A Magnet Jig and Mold Hardware ........................................................................................................................ 10   2.1.2.B Mold Assembly .................................................................................................................................................. 11   2.1.2.C Casting ............................................................................................................................................................... 12   2.1.3 Stator ........................................................................................................................................................................ 16   2.1.3.A Molds ................................................................................................................................................................. 17   2.1.3.B Coils.................................................................................................................................................................... 17   2.1.3.C Resin Casting ...................................................................................................................................................... 19   2.1.3.D Stator Wiring ..................................................................................................................................................... 25   2.1.3.E Air Gap Optimization.......................................................................................................................................... 25   2.1.4 Rotor Mount (Flange) ............................................................................................................................................... 26   2.1.5 Driveshaft ................................................................................................................................................................. 26   2.1.5A Bearing Selection ................................................................................................................................................ 27   2.1.6 Casing ....................................................................................................................................................................... 27   2.1.6.A Purpose .............................................................................................................................................................. 27    3 |Page 2.1.6.A Implementation ................................................................................................................................................. 28   2.1.7 Tension Spacers........................................................................................................................................................ 28   2.1.8 Generator Assembly ................................................................................................................................................. 29   2.2 Furling Tail/Mounting Bracket .......................................................................................................................... 31   3. Testing Results ....................................................................................................................................................................... 35   3.1 Bench Testing ................................................................................................................................................... 35   3.1.1 Safety First................................................................................................................................................................ 36   3.1.2 Power Curves ........................................................................................................................................................... 36   3.2 Truck Testing .................................................................................................................................................... 37   3.2.1 Safety First................................................................................................................................................................ 37   3.2.2 Truck Testing Results ................................................................................................................................................ 37   4. Appendix ................................................................................................................................................................................ 38   4.1 Component Drawings and Models ................................................................................................................... 38    4 |Page  1. FOREWARD Disclaimer: This guide is meant as a general reference for those interested in seeing alternate designs andmethods from the Hugh Piggott approach to axial-flux wind turbine construction. Any individual or group thatdecides to utilize this guide in any way does so at his/her/their own risk. Powerful magnets, electricity, resinfumes, machine tools and dynamic machinery can be dangerous and caution should always be exercised. Theauthors of this document, the University of Alaska  – Fairbanks and the Center for Global Change are notresponsible for any consequences of using this document. 1.1 ABSTRACT The UAF Wind Team is developing a wind turbine that utilizes an axial-flux permanent magnet generatorin order to examine viability for rural Alaska. The design is based on the work of Hugh Piggott of Scoraig WindElectric but modified to accommodate Alaska’s wide range of seasonal weather conditions. The team iscomposed of two sub-teams: design and testing. The design team is composed of Ben Kellie and PatrickO ’Callaghan and the testing team is composed of Jet Tasker and Tristan Kitchin.  The purpose of building this turbine is to study viability of axial-flux technology in rural Alaska. Axial-fluxtopology is mechanically simpler than that of the radial flux, which may have an effect on its maintenance. Aprototype generator will be developed and tested to determine maintenance needs, performance andeconomics.The wind turbine will be bench tested as well as field tested in Fairbanks, Alaska. Ultimately, our hope is that some “arctic recommendations” can b e established for citizens who want to utilize the axial-fluxtechnology in northern climates. 1.2 ACKNOWLEDGEMENT OF SUPPORT This project was made possible through the support of the Center for Global Change, a UA foundation.Without their funding and support, we would not have been able to learn so much. The support is sincerelyappreciated.
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