Low speed axial generator. My first generator

It is difficult not to notice how the stability of electricity supplies to suburban facilities differs from the provision of urban buildings and enterprises with electricity. Admit that you, as the owner of a private house or cottage, have repeatedly encountered interruptions, inconveniences and damage to equipment associated with them.

The listed negative situations, together with the consequences, will no longer complicate the life of lovers of natural spaces. And with minimal labor and financial costs. To do this, you just need to make a wind power generator, which we describe in detail in the article.

We have described in detail the options for manufacturing a system that is useful in the economy, eliminating energy dependence. According to our advice, an inexperienced home craftsman will be able to build a wind generator with his own hands. A practical device will help to significantly reduce daily expenses.

Alternative energy sources are the dream of any summer resident or homeowner whose site is located far from the central networks. However, when we receive bills for electricity consumed in a city apartment, and looking at the increased tariffs, we realize that a wind generator created for domestic needs would not hurt us.

After reading this article, perhaps you will make your dream come true.

A wind generator is an excellent solution for providing a suburban facility with electricity. Moreover, in some cases, its installation is the only possible way out.

In order not to waste money, effort and time, let's decide: are there any external circumstances that will create obstacles for us in the process of operating a wind turbine?

To provide electricity to a summer house or a small cottage, it is enough, the power of which will not exceed 1 kW. Such devices in Russia are equated to household products. Their installation does not require certificates, permits or any additional approvals.

Neodymium magnet is a rare earth metal that is resistant to demagnetization and has the ability to magnetize some materials. Used in the manufacture of electronic devices (computer hard drives, metal detectors, etc.), medicine and energy.

Neodymium magnets are used in the manufacture of generators operating in various types of installations that produce electric current.

Currently, generators made using neodymium magnets are widely used in the manufacture of wind turbines.

Main characteristics

In order to determine the feasibility of manufacturing a generator on neodymium magnets, you need to consider the main characteristics of this material, which are:

  • Magnetic induction AT- the power characteristic of the magnetic field, measured in Tesla.
  • Residual magnetic induction Br— the magnetization possessed by a magnetic material at an external magnetic field strength equal to zero is measured in Tesla.
  • Coercive magnetic force hc- determines the resistance of the magnet to demagnetization, measured in Amp / meter.
  • magnetic energy (BH)max-characterizes how strong the magnet is.
  • Temperature coefficient of residual magnetic induction Tc of Br- determines the dependence of magnetic induction on the ambient temperature, measured as a percentage per degree Celsius.
  • Maximum operating temperature Tmax- defines the temperature limit at which the magnet temporarily loses its magnetic properties, measured in degrees Celsius.
  • Curie temperature Tcur- defines the temperature limit at which the neodymium magnet is completely demagnetized, measured in degrees Celsius.

The composition of neodymium magnets, in addition to neodymium, includes iron and boron, and depending on and their percentage, the resulting product, the finished magnet, differs in classes that differ in their characteristics given above. In total, 42 classes of neodymium magnets are produced.

The advantages of neodymium magnets, which determine their demand, are:

  • Neodymium magnets have the highest magnetic parameters Br, Hsv, Hcm, VN.
  • Such magnets have a lower cost in comparison with similar metals that have cobalt in their composition.
  • They have the ability to work without loss of magnetic characteristics in the temperature range from -60 to + 240 degrees Celsius, with a Curie point of +310 degrees.
  • From this material it is possible to make magnets of any shape and size (cylinders, disks, rings, balls, rods, cubes, etc.).

Wind generator on neodymium magnets with a power of 5.0 kW

Currently, domestic and foreign companies are increasingly using neodymium magnets in the manufacture of low-speed electric current generators. So LLC Salmabash, Gatchina, Leningrad Region, produces similar permanent magnet generators with a power of 3.0-5.0 kW. The appearance of this device is shown below:

The body and covers of the generator are made of steel, further coated with paints and varnishes. On the body there are special fasteners that allow you to fix the electric apparatus on the carrier mast. The inner surface is treated with a protective coating that prevents metal corrosion.

The generator stator is made of electrical steel plates.

The stator winding is made with enamel wire, which allows the device to work for a long time with maximum load.

The generator rotor has 18 poles and is mounted in bearings. Neodymium magnets are placed on the rim of the rotor.

The generator does not require forced cooling, which is carried out naturally.

Technical characteristics of the generator with a power of 5.0 kW:

  • Rated power - 5.0 kW;
  • Rated frequency - 140.0 rpm;
  • Operating range of rotation - 50.0 - 200.0 rpm;
  • Maximum frequency - 300.0 rpm;
  • Efficiency - not less than 94.0%;
  • Cooling - air;
  • Weight - 240.0 kg.

The generator is equipped with a terminal box, through which it is connected to the electrical network. The protection class corresponds to GOST 14254 and has a degree of IP 65 (dust-proof design with protection against water jets).

The design of this generator is shown in the figure below:

where: 1-body, 2- bottom cover, 3- top cover, 4- rotor, 5- neodymium magnets, 6- stator, 7- winding, 8- coupling half, 9- seals, 10,11,12- bearings, 13 - terminal box.

Pros and cons

The advantages of wind turbines made using neodymium magnets include the following characteristics:

  • High efficiency of devices, achieved by minimizing friction losses;
  • Long terms of operation;
  • No noise and vibration during operation;
  • Reducing the cost of installation and installation of equipment;
  • Autonomy of work, allowing operation without constant maintenance of the installation;
  • Possibility of self-production.

The disadvantages of such devices include:

  • Relatively high cost;
  • Fragility. With a strong external impact (impact), a neodymium magnet can lose its properties;
  • Low corrosion resistance, requiring a special coating of neodymium magnets;
  • Dependence on the temperature regime of operation - when exposed to high temperatures, neodymium magnets lose their properties.

How to DIY

A wind generator based on neodymium magnets differs from other generator designs in that it can be easily made independently at home.

As a rule, an automobile hub or pulleys from a belt drive are taken as a basis, which are pre-cleaned if these are used spare parts and prepared for work.

If it is possible to manufacture (machine) special discs, it is better to stop at this option, because. in this case, it is not necessary to adjust the geometric dimensions of the coils being wound to the dimensions of the workpieces used.

Neodymium magnets should be purchased, for which you can use the Internet or the services of specialized organizations.

One of the options for manufacturing a generator on neodymium magnets, using disks specially made for this purpose, is proposed by Yalovenko V.G. (Ukraine). This generator is manufactured in the following sequence:

  1. Two disks with a diameter of 170.0 mm are machined from sheet steel with a central hole and a keyway.
  2. The disk is divided into 12 segments, for which the corresponding markup is performed on its surface.
  3. Magnets are glued into the marked segments so that their polarity alternates. To avoid errors (by polarity), it is necessary to mark them before sticking.
  4. The second disc is made in the same way. The result is the following construction:

  1. The surface of the suits is filled with epoxy resin.
  2. From a wire (enamel wire) of the PETV brand or an equivalent, with a cross section of 0.95 mm 2, 12 coils of 55 turns each are wound.
  3. On a sheet of plywood or paper, a template is made corresponding to the diameter of the disks used, on which a breakdown is also made into 12 sectors.

The coils are placed in marked segments, where they are fixed (duct tape, adhesive tape, etc.) and switched off in series with each other (the end of the first coil is connected to the beginning of the second, etc.). the result is the following construction

  1. From wood (board, etc.) or plywood, a matrix is ​​made in which coils laid in a pattern can be filled with epoxy resin. The depth of the matrix must correspond to the height of the coils.
  2. Coils are placed in a matrix and filled with epoxy resin. The result is the following workpiece:

  1. From a steel pipe with a diameter of 63.0 mm, a hub is made with a shaft attachment unit, which is manufactured by the generator. The shaft is mounted on bearings mounted inside the hub.
  2. A rotary mechanism is made from the same pipe, which ensures the orientation of the generator in accordance with the wind flows.
  3. Manufactured spare parts are put on the shaft. The result is the following design, plus a rotary mechanism:



This article is devoted to the creation of an axial wind turbine on neodymium magnets with metal-free stators. Windmills of this design have become especially popular due to the growing availability of neodymium magnets.

Materials and tools used to build a windmill of this model:

1) a hub from a car with brake discs.
2) drill with a metal brush.
3) 20 neodymium magnets measuring 25 by 8 mm.
4) epoxy resin
5) mastic
6) PVC pipe 160mm diameter
7) manual winch
8) metal pipe 6 meters long

Consider the main stages of building a windmill.

The hub of the car with a brake disc was taken as the basis of the generator. Since the main part of the factory production, this will serve as a guarantee of quality and reliability. The hub was completely disassembled, the bearings in it were checked for integrity and lubricated. Since the hub was removed from an old car, the rust had to be cleaned with a brush, which the author planted on a drill.
Below is a photo of the hub.

Then the author proceeded to install the magnets on the rotor disks. 20 magnets were used. Moreover, it is important to note that for a single-phase generator, the number of magnets involved is equal to the number of poles, for a two-phase generator, the ratio will be three to two or four poles to three coils. Magnets should be mounted on disks with alternating poles. To maintain accuracy, you must make a placement template on paper, or draw sector lines directly on the disk itself.


You should also mark the magnets along the poles with a marker. You can determine the poles by bringing the magnets alternately to one side of the checking magnet, if it attracts - plus, repels - minus, the main thing is that the poles alternate when installed on the disk. This is necessary because the magnets on the discs must be attracted to each other, and this will only happen if the magnets facing each other are of different polarity.


The magnets were glued onto the discs using epoxy resin. To prevent the resin from spreading beyond the borders of the disk, the author made borders around the edges with mastic, the same can be done with adhesive tape, simply wrapping the wheel in a circle.


Consider the main differences in the design of single-phase and three-phase generators.
A single-phase generator will vibrate under load, which will affect the power of the generator itself. The three-phase design is devoid of such a drawback due to which the power is constant at any time. This is because the phases compensate for the loss of current in each other. According to the modest calculations of the author, the three-phase design exceeds the single-phase one by as much as 50 percent. In addition, due to the absence of vibrations, the mast will not swing additionally, therefore there will be no additional noise during the operation of the rotor.

When calculating the charging of the 12th battery, which will start at 100-150 rpm, the author made 1000-1200 turns in the coils. When winding the coils, the author used the maximum allowable wire thickness to avoid resistance.
To wind the wire on coils, the author built a home-made machine, the photos of which are presented below.


It is better to use coils with an ellipsoidal shape, which will allow a greater density of magnetic fields to cross them. The inner hole of the coil should be made according to the diameter of the magnet or larger. If you make them smaller, then the frontal parts practically do not participate in the generation of electricity, but serve as conductors.

The thickness of the stator itself should be equal to the thickness of the magnets that are involved in the installation.


The form for the stator can be made from plywood, although the author decided this issue differently. A template was drawn on paper, and then the sides were made with mastic. Fiberglass was also used for strength. In order for the epoxy resin not to stick to the form, it must be lubricated with wax or petroleum jelly, or you can use adhesive tape, a film that can later be torn off from the finished form.

Before pouring, the coils must be precisely fixed, and their ends must be brought out of the mold, in order to then connect the wires with a star or triangle.

After the main part of the generator was assembled, the author measured and tested its operation. When manually rotated, the generator generates a voltage of 40 volts and a current of 10 amperes.


Then the author made a mast for the generator with a height of 6 meters. In the future, it is planned to increase the height of the mast by using a thicker pipe at least twice. To keep the mast stationary, the base was poured with concrete. A metal mount was made for lowering and raising the mast. This is necessary in order to have access to the screw on the ground, since it is not particularly convenient to engage in repair work at a height.

This section contains homemade wind turbines made on the basis of disk, axial generators. The main feature and advantage of such generators is the complete absence of magnetic sticking. The stator does not contain iron, the coils are simply filled with epoxy or polyester resin. But unlike classical generators with iron stators, such a generator requires at least twice as many magnets to get the same power. But wind turbines with such generators start at low wind speeds.

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Expensive and not always fully effective undertaking. Samples of windmills available for sale have a limited service life, low maintainability and a high price. Buying such a kit is beyond the reach of many potential users. The way out becomes, which is much cheaper and allows you to get a device with high efficiency and performance.

It has a high maintainability and, as a result, a long service life. Often, the design during operation is modernized, improved and adjusted to the maximum possible parameters, which cannot be done with factory kits.

Low speed wind turbines

The most attractive designs of windmills for most regions of Russia are samples that give high performance in light and medium winds -. They are characterized by the ability to start rotation at low flow rates, giving out sufficient voltage to power consumption devices.

Power generation on such devices is produced by generators adapted to work with windmills. The specificity of the design of such generators is high sensitivity, since the device is initially designed to operate at low rotation speeds.

In order to ensure the specified mode of operation, it is necessary to exclude the excitation winding from the design, replacing it with permanent magnets. As a result, there will be no need to supply voltage for the formation of electromagnets, the induction will become more stable, independent of the power source on the rotor winding. In addition, there is no need for a brush assembly that supplies power to the excitation winding.

Making a permanent magnet rotor

Construction of a permanent magnet generator in some sense easier than with electromagnetic excitation. The creation of such a device can be carried out both on the basis of a ready-made generator, and with the help of improvised materials.

Car alternator modification

The creation of a permanent magnet rotor requires a fairly serious intervention in the design. It is necessary to reduce the diameter by the thickness of the magnets plus the thickness of the steel sleeve, which is put on the rotor to form a continuous magnetic flux and at the same time serves as a landing pad for the magnets. Some experts do without a sleeve, installing magnets directly on the rotor with a reduced diameter and fixing it with epoxy.

The manufacturing process requires the participation of production equipment. The rotor is clamped into the lathe and the layer is carefully removed so that the installed magnets rotate with a minimum clearance, but quite freely. The magnets are installed on the rotor plates with alternating poles.

The greatest effect can be achieved by installing relatively small magnets arranged in rows in the longitudinal direction. A smooth and powerful magnetic flux is achieved, affecting the power windings of the stator with a uniform density at all points.

Making a rotor from a hub and a brake disc

The considered method refers to ready-made generators that need minor design changes. These devices include automotive generators, often used by amateur designers as a basic device. Often, generators are assembled completely on their own, without a ready-made device.

In such cases, they act somewhat differently. The basis is an automobile hub with a brake disc. It is qualitatively balanced, durable and adapted to loads of a certain kind. In addition, the size of the hub allows a large number of magnets to be placed around the circumference, allowing a three-phase voltage to be obtained.

Magnets with alternating poles are placed at an equidistant distance from the center. Obviously, the largest number can be established by gluing them as close as possible to the outer edge. The most accurate indicator will be the size of the magnets, which will determine the possibility of placement at a certain distance. The number of magnets must be even so that the rhythm of the alternation of the poles does not go astray during rotation.

The sticker of the magnets on the hub is made using any glue, the best option is epoxy resin, which is completely filled with magnets. This protects them from moisture or mechanical stress. Before pouring along the edge of the hub, it is recommended to make a side of plasticine, which does not allow the epoxy to flow down from the hub.

The design of the generator on the automobile hub most convenient in the manufacture of a vertical windmill. It is noteworthy that a similar scheme can be used without a hub, on a disk cut from ordinary plywood. This design is much lighter, allows you to choose a convenient size, which makes it possible to create a sensitive and productive device.

Windmill with axial generator on neodymium magnets

The strongest magnets with optimal parameters for use in the design of the generator are Neodymium magnets. They are somewhat more expensive than usual, but they are many times superior and make it possible to create a powerful device with a relatively compact size.

There is no fundamental difference in design. Neodymium magnets are made in various form factors, allowing you to choose the most convenient option for you - thin oblong bars, tablet shape, cylinders, etc. if a metal rotor is used, then it is not necessary to glue the magnets, they themselves are attached to the base with force. It remains only to fill them with epoxy to protect against corrosion.

The easiest way to buy such magnets is through the Internet, at the same time you can immediately choose the most convenient form.

Stator manufacturing

The stator is the fixed part of the generator that carries the power winding that induces an electric current. Depending on the type of construction, the stator can be used from a ready-made device (for example, from a car generator), or made from scratch on its own. The manufacturing technique is different in each case, but the principle remains the same - around the circle surrounding the rotating rotor, there are coils that generate alternating current.

At car alternator modifications sometimes the power windings are not touched, preferring to change the design of the rotor and stop there. Most often, the reason for this is poor technical or theoretical training, when the master has a very vague idea of ​​\u200b\u200bhow exactly such things are done. Let's take a closer look at the question:

Selecting the number of phases

Many craftsmen try to make their task easier by making a single-phase generator. In this case, the simplicity is very doubtful, since the savings in effort are obtained only at the stage of winding the coils. But during operation, an unpleasant effect is obtained - the voltage amplitude has a classical form, which is why the rectified current has a pulsating structure.

Jumps are contraindicated for batteries, they create a negative effect on all nodes of the complex and contribute to a quick failure. Vibration appears, which can cause complaints from neighbors, a source of discomfort for people or animals.

The three-phase design, on the contrary, has a softer envelope; in the rectified state, the current practically does not have any deviations. The power of the device has a stable value, the mechanical and electrical parts of the unit are kept in working condition.

The choice between a three- and a single-phase device should definitely be made in the direction of a three-phase design. The number of coils wound increases, but the number of turns is not so great as to give up a better result due to an illusory time saving.

Modification of the oscillator stator

It has ready-made power coils tightly packed in the stator channels. To obtain a qualitative result, it is necessary to change the sensitivity of the stator, since the nominal speed of an automobile engine is in the range of 2000-3000 rpm, and at the peak it can rise to 5000-6000 rpm. The windmill is not able to give out such parameters, and the use of an overdrive will significantly reduce the power of the impeller.

The solution to the problem is to increase the number of turns, for which the old windings are dismantled, and new ones are wound in their place, with a large number of turns from a thinner wire. At the same time, it is impossible to use too thin a wire, since with an increase in the number of turns, the resistance also increases, making the generator less productive. It is necessary to observe the "golden mean", increasing the amount carefully, without excessive zeal.

Important! Such an operation requires calculation, but in practice they most often do it easier - they wind as many turns as the stator design can accommodate. The result is usually positive, since too many turns cannot be accommodated.

Production of an axial type stator

This design is suitable for an axial-type generator, the rotor of which is made of a hub and a brake disc from an automobile wheel. The stator has the shape of a flat disk, along the circumference of which power windings are located. They must be wound with a sufficiently thick wire so that the number of turns is sufficient, but the resistance does not reduce the effectiveness of the structure. The number of coils is a multiple of three so that each phase has the same number.

They are connected to each other by a star, for each phase 1, 4, 7, 10, etc. are connected. When winding a single-phase stator, each coil is wound in the opposite direction - the first is clockwise, the second is counterclockwise, then again clockwise, etc. they are connected in series.

The finished stator is installed coaxially with the rotor. The gap between the coils and neodymium magnets should be minimal, but the rotor stroke is free, without contact with the coils.

To protect against moisture, dust or other influences, the coils are usually filled with epoxy. To do this, a rim of plasticine is first made along the outer edge of the stator disk with a height slightly exceeding the fill layer.

Impeller assembly

The impeller should provide maximum sensitivity. Before you start creating a windmill, you should study in detail the meteorological situation in the region, the direction and speed of the prevailing winds, the frequency and strength of squally gusts, and the possibility of hurricanes. This information will help you choose the most suitable wind turbine design (vertical or horizontal, size, number of blades, etc.).

Creation of the impeller made from improvised material based on the parameters of the generator. The size of the blades should allow the start of rotation at low flow rates, but not create an excessively large obstruction. This will reduce the risk of the mast falling in a strong gust or squall.

Regions with unstable and frequently changing winds (which are the majority in Russia) are more suitable for the operation of vertical structures. Horizontal windmills are considered more efficient, but need to be mounted on high masts, which creates maintenance problems.

The impeller of the wind turbine must be well balanced and firmly connected. Installing the kit on the roof of the house is prohibited, especially if several families live in it. It is recommended to choose an open place on a hill near the house so that the length of the cable does not create much resistance. There should be no obstacles, tall trees, or buildings nearby to block the direct flow of wind.