Prototype 10Kw Wind turbine (Plans for 11 KW Wind Turbine).pdf

Prototype 11Kw Wind turbine

Simon Brookes

Date: 12/12/2005

The site

The site is on the cliffs on the south West coast of England. The average wind speed is

8.5 meters per second. Height above sea level is 210meters above see level. The turbine is in

clean clear air.

The base

The base was dug into the shale rock and a concrete block 2-meters by 2-meters and 2-

meters deep tapering to 1-meter square at the top was laid. Set into this was 1.5 meter by

20mm bars threaded at the top. A hinge was constructed out of 20mm plate so the tower could

be lowered with a winch or tractor.

Tower

This is constructed of standard steel water or steam line pipe and flanges. 15mm webs

were welded on the flange to stiffen the joints. 22mm 8.8 hardened steel bolts were used to

join the three sections together.

Section 1

3-meter length of 16-inch pipe

Section 2

3-meter length of 14-inch pipe

Section 3

3-meter length of 12-inch pipe

Total height 9 meters 4 guy ropes of

16mm steel rope connected at the top of

section 2 connected at the other end to a 1

cubic meter block of concrete set into the

ground. 6 meters square from the base.

Yaw Bearing

A 12-inch standard steam flange plate was used as the base to weld the yaw post to.

Stiffening webs of 100 by 15mm was welded to the post and the flange. The base had a 30mm

hole bored in the centre to take the hydraulics and power down the tower. A length of thick

wall pipe was machined to take taper bearings and the top threaded internally and externally.

The external threads had two lock nuts to adjust the taper bearings and the internal to accept

the slip ring unit. The bearings used were single row taper thrust bearing part number 30216,

which is 80mm by 140mm by 30mm . The lock nuts where tightened to get free movement with no

vertical movement. The bearings were packed with grease.

Motor frame

This is made from 75mm x 150mm by 6mm channel two lengths were welded to the

separating webs and then welded to a 15mm plate to fix to the yaw bearing post. 15mm plate

webs were welded to the frame and the yaw post to strengthen it. 100mm x 100mm box

section fitted to the front to take the main shaft pillar bearings.

The motor, gearbox and main bearings were fitted to the frame with 10.2 strength bolts and

nyloc nuts. Packing shims were fitted below the gearbox and main bearing blocks to get them

in line. 30Kw flexible couplings were fitted between the gearbox and motor plus the main

drive shaft.