How to Build a Small Scale Wind Turbine with Used Materials

Building a small scale wind turbine from used or recycled materials can be a fun and educational project. With some basic mechanical skills and creativity, you can generate clean energy for small loads like charging batteries or powering LED lights. Here is a step-by-step guide on how to build your own small wind turbine on the cheap.

Materials Needed

To build a small scale wind turbine you will need the following materials:

• Rotor blades - The most common materials used are wood, PVC pipes, sheet metal, plastic barrels etc. Three blades work best for conversion of wind energy.

• Generator - You can salvage a small DC motor or alternator from old appliances like computers, printers etc. Make sure it spins freely.

• Frame - The frame holds the rotor blades and generator. You can use wood, steel tubes or aluminum for the frame. PVC pipes also work well.

• Bearings - Allow smooth rotation of the rotor shaft. Scavenge ball bearings or use bushings made from smooth pipe, PVC couplings etc.

• Fasteners - Bolts, nuts, screws, washers to hold the frame together.

• Charge controller - Regulates power from the generator to the battery. Get from electronic reuse stores.

• Batteries - Store the generated electricity. Secondhand lead-acid or lithium batteries work.

• Wires and cable - For connections. Can salvage from electronic waste.

• Tools - Basic tools like drill, saw, wrenches, multimeter etc will be needed.

Design Considerations

Here are some key factors to consider when designing a small wind turbine from scrap materials:

• The rotor blades convert wind energy into rotational energy. Make lightweight blades about 1-2 feet long for a small turbine.

• More surface area of blades increases energy production. Consider using many small blades vs few large blades.

• The generator should match the rotor power output. Too small and it won't produce much, too large will have high friction.

• Aim for a tip speed ratio of 6-8 for optimum efficiency. Calculate as (Blade Tip Speed)/(Wind Speed).

• Use a tail vane to keep rotor perpendicular to the wind.

• Place tower at least 10 ft high to access faster wind speeds. 20+ ft is better.

Step-by-Step Assembly

Follow these steps to build a small wind turbine from reused parts:

1. Make the Rotor Blades

• Cut 3 blades from any available sheet material - wood, plastic, metal etc.

• Shape into curved aerofoil design for better lift. Copy dimensions from online DIY guides.

• Balance and carve blades equally for smooth spinning. Remove material from heavy blades.

2. Build the Frame and Tail

• Join frame pipes into a strong triangular shape.

• Attach generator or alternator to frame using recycled brackets.

• Add tail vane from sheet metal or wood to keep rotor perpendicular to wind.

3. Attach Blades to Shaft

• Insert rotor shaft through bearings on the frame.

• Secure blades 120 degrees apart using bolts, screws or glue.

• Test spin rotor to ensure smooth rotation without wobble.

4. Wire the Circuit

• Connect generator terminals to charge controller input.

• Wire charge controller output to battery for charging.

• Connect an inverter to battery to convert DC to AC for appliances.

5. Mount on Tower

• Assemble tower sections from electrical conduit, metal pipes or wood.

• Hoist assembled turbine to tower top and fasten securely.

• Tilt turbine into the wind for optimum orientation.

Safety Precautions

Building and installing a DIY wind turbine requires working safely:

• Wear protective gear like gloves, goggles when building.

• Learn and follow electrical safety or get help wiring the system.

• Check local building codes for small wind turbine regulations.

• Mount tower securely so it does not fall. Stay clear when raising tower.

• Prevent overcharging of batteries by using charge controller.

• Keep children and pets away from the turbine when operating.

Conclusion

Constructing a small scale wind generator from scrap materials is a great way to reuse unwanted parts and build a functional renewable energy system. With some mechanical aptitude and by following wind turbine designs online, you can build a unit to provide power for LEDs, batteries or other small loads. Use proper safety precautions when working on this project. The end result will be the satisfaction of creating your own power from reused materials and the wind!