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PicoTurbine Deluxe

Windmill Plans

Instructions, Teacher’s Guide, and

Technical Notes

An easy to build project for adults and children

grade 10 and above. Explains wind power

generation concepts, including three phase

alternators, rectification of three phase current,

battery charging, and load regulation concepts.

BETA

CHOKING HAZARD - Small

parts, wire. Not for children under

4 years.

Page 1.

WARNING:

THESE PLANS ARE PRESENTED IN “AS IS” CONDITION. BY USING THESE

PLANS YOU HOLD PICOTURBINE.COM, XIBOKK RESEARCH, AND ALL

MEMBERS, INVESTORS, EMPLOYEES, AND OWNERS OF THOSE

ORGANIZATIONS HARMLESS FROM ANY DAMAGES ARISING FROM THE

USE OF THESE PLANS OR THE RESULTING MACHINES. IN NO CASE

SHALL PICOTURBINE.COM OR XIBOKK RESEARCH BE LIABLE FOR ANY

INCIDENTAL DAMAGES. THESE PLANS ARE NOT WARRENTEED FOR

FITNESS FOR ANY PARTICULAR PURPOSE.

Revision 1.0A, October, 1999

www.picoturbine.com

Support PicoTurbine.com!

If you have purchased this document as a part of a PicoTurbine.com kit, we

appreciate your support!

If you have downloaded this document as a free plan, we hope you enjoy it,

and ask that you patronize PicoTurbine.com in the future so we can keep

financing new projects. We have a complete line of Renewable Energy

books, projects, and kits that are expanding every day. Use the “Voluntary

Contribution” item on the order form if you believe you have received value

from these plans. Or, stop by the web site and buy something! Tell your

friends about us! Suggest our projects for youth groups, Scouting Groups,

YMCA or similar organizations, classrooms and home schools. The

proceeds will be used to support more fun renewable energy projects and

kits at PicoTurbine.com. Thanks and have fun!

PicoTurbine.com is a wholly owned subsidiary of Xibokk Research.

Page 2.

CONTENTS

PART 1: INSTRUCTIONS FOR BUILDING PICOTURBINE DELUXE........................................... 4

RELATED PLANS AND KITS............................................................................................................ 4

PICOTURBINE DELUXE MOTIVATION .......................................................................................... 4

PICOTURBINE DELUXE BUILDING TIME...................................................................................... 4

BEFORE YOU BUILD PICOTURBINE DELUXE .............................................................................. 5

Step 1: Check Your Materials............................................................................................................ 5

Step 2: IMPORTANT: Review Safety Rules........................................................................................ 6

Step 3: Building the Rotor ................................................................................................................. 7

Step 4: Building the Stator ................................................................................................................ 8

Step 5: Building the Frame ............................................................................................................... 9

Step 6: Building the Blade Assembly ............................................................................................... 10

Step 7: Putting the Turbine Together............................................................................................... 10

Step 8: Wiring for DC Output.......................................................................................................... 11

Step 9: Wiring for Battery Charging................................................................................................ 12

PART 2: TEACHER’S GUIDE ........................................................................................................... 13

K EY C ONCEPTS ................................................................................................................................... 13

G ROUP P ROJECTS ................................................................................................................................ 13

M OUNTING ......................................................................................................................................... 13

E XPERIMENTS ..................................................................................................................................... 13

Data Logging ................................................................................................................................. 13

Electric Brakes ............................................................................................................................... 14

Hybrid Systems ............................................................................................................................... 14

PART 3: TECHNICAL NOTES .......................................................................................................... 15

T HREE P HASE A LTERNATOR W INDINGS ............................................................................................... 15

S TAR AND D ELTA W IRING ................................................................................................................... 15

B ATTERY VS . R ESISTIVE L OADS AND E FFICIENCY ................................................................................. 16

Battery Load Formula..................................................................................................................... 16

Resistive Load Formula .................................................................................................................. 16

Comparison of Battery vs. Resistive Loads ...................................................................................... 16

D UMP L OADS ...................................................................................................................................... 17

A LTERNATIVE D ESIGNS AND M ATERIALS ............................................................................................. 17

Double-disk Alternator ................................................................................................................... 18

Woodless Construction ................................................................................................................... 18

Alternative Blade Designs ............................................................................................................... 18

B ETTER B EARINGS .............................................................................................................................. 19

TEMPLATES....................................................................................................................................... 21

COIL WINDING FORM TEMPLATE ............................................................................................... 21

ROTOR TEMPLATE ......................................................................................................................... 23

STATOR TEMPLATE ........................................................................................................................ 25

Page 3.

PART 1: Instructions for Building PicoTurbine Deluxe

RELATED PLANS AND KITS

This plan and the associated kit build on concepts explained in the following related kits from

PicoTurbine.com. All plans are free for download and can be built with locally available parts. If you

cannot obtain parts locally or just want the convenience of ordering a ready made kit, they are available for

a nominal charge.

• PicoTurbine Educational Windmill Kit

This inexpensive kit is easy enough for children as young as fifth grade to build with some

adult supervision. Using only cardboard, wooden dowels, magnets, and wire, a complete

working windmill can be constructed in about 1 hour. The kit includes a bicolor LED that

lights up from the electricity produced by the eight inch tall wind turbine. PicoTurbine.com

has shipped this kit all over the world, and it is distributed by Paxton/Paterson throughout the

United States to High Schools as part of their Alternative Energy course module.

• PicoTurbine DC Experiments Kit

This easy to use kit teaches AC to DC rectification concepts. It includes a solderless

breadboard and electronic components such as diodes and capacitors to allow projects to be

built without soldering, making it safe for a classroom environment. Building on the

PicoTurbine windmill, it teaches four different circuits for use in rectifying AC current to

direct current, explaining the concepts with interesting experiments.

For more information or to download free plans or order kits, visit http://www.picoturbine.com and visit

the “Project List” page.

PICOTURBINE DELUXE MOTIVATION

The original PicoTurbine Educational Windmill kit is a great way to learn about renewable energy

technology. It produces just enough power to light up a small lamp or LED (about 2 volts at 25 milliamps).

While it makes for a very cost effective educational experiment, many people have asked for a larger

version that is weatherproof and actually produces enough power to be useful.

PicoTurbine Deluxe is the answer to this request! While it only costs about three times as much as the little

PicoTurbine kit, it is weatherproof and produces about 30 to 50 times as much power as the small version.

In fact, the power produced is sufficient to charge NiCad batteries, or with alternative wiring could even

provide a 12 volt battery bank a small trickle charge in a good stiff wind (see Alternative Designs section).

This project builds on the smaller PicoTurbine Windmill kit, which explained basic wind power theory.

This kit goes several steps farther, and explains 3 phase wiring concepts as well as battery charging vs.

resistive load concepts. Once this project is mastered, the student or adult hobbyist will understand a great

deal of wind power and alternator construction theory, and if desired will be ready to try a full sized wind

turbine such as the PicoTurbine-250.

PICOTURBINE DELUXE BUILDING TIME

The total build time will vary with your skill level, but generally speaking you should allow 6 to 8 hours of

building time to complete this project, especially if you have not done similar types of projects in the past.

This assumes you have all materials on hand and organized. Because of the need to paint certain parts and

allow glue to dry, the actual build time must typically be spread over a 2 day period. Allow 3 to 4 hours for

each day with an overnight period to wait for parts to dry and set. These times are approximate, of course,

and it may take you more or less time than estimated here.

Page 4.

BEFORE YOU BUILD PICOTURBINE DELUXE

THESE PLANS ARE CONSIDERED BETA TEST LEVEL . This means they are not fully

tested and are only for people who don’t mind building an experimental project. In

particular, there has not been enough testing to ensure the NiCad batteries used can

withstand repeated charge/discharge cycles with the electronic components used, or

whether the overcharge shunt circuit will protect it sufficiently in sustained high winds.

We believe the main risk of this lack of testing is that the lifespan of the NiCad batteries

could be shorter than normal, although there could be other problems that are unknown at

this time.

Step 1: Check Your Materials

The following materials are supplied with your PicoTurbine Deluxe kit. If you did not purchase a kit but

are using free downloaded plans, you must obtain these items from local supply houses:

¤ One steel disk, 14 gauge, 8” in diameter with a 3/8” hole in the center. You may need to

contract with a local metal shop to have these made if you do not have tools to cut steel. You

may be able to find steel “punch-outs” of the correct size at a scrap metal supplier and bore

the center hole using a cobalt drill bit. A small variation in diameter is ok. Thicker metal is

also ok.

¤ 16 ceramic grade 5 magnets, 1.875” by 0.75” by 0.375” thick, magnetized on the large faces.

¤ About 1.5 pounds of 20 AWG enamel coated magnet wire.

¤ 2 pieces of corrugated plastic, 24” long and 8” wide. Best is 2 millimeter, which is what ships

with our kits. Most suppliers only carry 4 mm which is harder to work with but can be made

to work by scoring one side half way through (see instructions below).

¤ A 3/8” inner diameter roller thrust washer. This is a small set of roller bearings about the size

of a large washer.

¤ A small solderless breadboard.

¤ Six diodes rated 1 amp and 100 volts (1N5400 or similar).

¤ Two “AA” sized NiCad batteries plus holder.

¤ One small lamp, rated 3 volts and 100 milliamps.

¤ A zener diode, with a zener voltage of 2.4 volts and rated at 500 milliwatts.

¤ A power resistor rated at 2 watts and 10 ohms.

¤ A red LED.

¤ A plastic enclosure large enough to hold the battery pack and circuit board.

¤ A small SPST switch.

¤ A ¾” wire nut.

The following items are not supplied with your kit in order to reduce shipping costs. They should be easy to

obtain from a hardware store. All together these items cost in the neighborhood of $20 to $25. You may

have some parts lying around in your basement such as scraps of wood or washers.

¤ One 3/8” threaded rod, 3 feet long.

¤ Twelve flat washers and eight nuts to fit the 3/8” rod. The washers should be 1” wide, of the

“fender washer” variety. At least 2 of the nuts should be locking nuts, such as serrated

locknuts or nylon insert lock nuts.

¤ One sheet of Plexiglas (or similar plastic sheet) 8” x 10” x 0.09” in thickness. The thickness is

not critical. Some other materials that will work are polycarbonate (Lexan or similar), acrylic

sheet, or any hard plastic material that can be drilled. Most large hardware stores have

Plexiglas in this size because it is used for framing pictures. Try a glass store or picture frame

store if your hardware store does not stock such a material.

¤ Three pieces of plywood 1 foot square, ½” thick (or thicker).

¤ A small scrap of ¼” plywood, about 2” square or more.

Page 5.

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