Electricity is a necessity nowadays. But sometimes one is held up at a place where this necessity is absent. Although generators can be used in most areas, in many cases these are insufficient and go off-road due to various reasons. Moreover, these are expensive and require a lot of fuel. Some other sources of energy can also be used e.g. solar inverters and wind turbines, but these are expensive. Here is an account of building an inexpensive and simple wind turbine to solve our ever increasing need for electricity.
Materials.
(a) A geared, 24V, PMDC (permanent magnet direct current) motor with rating of 300rpm at 24V.
(b) A three feet piece of 6” or 8” PVC pipe.
(c) A round piece of thick plastic for hub. (If one has access to metal turning machines, a metal hub would be better).
(d) A 12 Volts 7.5AH secondary battery.
(e) One 24 volts Diode from electronics shop.
(f) Some flexible wire for wiring.
(g) Some binding wire.
(h) A few tools from the signal platoon.
(j) A long GI pipe for mounting. (The higher the pipe, more wind the turbine will catch).
(k) Six nut-bolts of adequate length.
(l) One portable DC to AC converter.
Preparation
(a) The first step is to save the motor from the elements. For this, an empty can of Desi Ghee was used. The motor was secured using some binding wire. See the picture of the finished product below.
(b) The next step was to create a set of three blades for the turbine. The piece of PVC pipe was cut longitudinally into three long pieces. These pieces were then cut diagonally to get two sets of three blades each.
(c) A round piece of thick plastic was used for the hub (a bottom of plastic bucket of good quality did the trick). Two holes were then drilled every 120 degrees. See picture given below.
Construction
(a) The blades were given one hole each and bolted to the hub. One blade was then bolted using both holes and fixed. The other two blades were then so adjusted that the tips were equidistant (This is required to reduce vibrations in the turbine).
(b) The position of the other hole was then marked and another hole drilled at the marked point. Then the other two blades were also fixed and tightened.
(c) A rudder has purposefully not been installed as the wind direction at my place of work is uni-directional. It can be easily done but the mount will need a spring to bring the fan back or the wiring may entangle and break.
(d) An angle iron (one with a number of holes along its length) was bent at 90 degrees. At one end the Ghee tin with the motor inside was secured and the other end was fixed inside the GI pipe.
(e) The wiring was extended and the fan fixed onto the motor.
(f) The GI pipe was secured, making sure that the fan faced the wind.
(g) Immediately the turbine started working and the current was measured to be from 12 to 20 Volts.
Utilising the power
Wiring
(a) The positive wire was cut and the diode inserted so as to keep the current uni-directional (for this, the positive side of the diode was connected towards the turbine).
(b) The wires were then joined to the 12V secondary battery to charge it. The only thing is not to overcharge it, so the battery voltage needed to be monitored regularly. A charge controller will make it automatic but that will need some more effort.
(c) The battery was then connected to the portable DC to AC converter available in the market for Rs 800. This can either charge a laptop or a cell phone or light a CFL. One can even connect a bigger battery and inverter to the turbine to do all of these simultaneously.
Cost effect
8. Itemised cost of materials used
(a) 24V PMDC 300rpm motor Rs 2000/-
(b) 3’piece of 6” PVC pipe Rs 100/-
(c) 10 feet piece of 2” GI pipe Rs 600/-
(d) 12 Volts, 4.5 AH battery. Rs 600/-
(e) 24 volts Diode. Rs 10/-
(f) Some flexible wire for wiring. Rs 50/-
(g) Some binding wire. Rs 10/-
(h) A metal hub will cost approx Rs 250/-
(j) Nuts and bolts Rs 20/-
(k) DC to AC convertor Rs 800/-
9. As it can be seen from the list that the total cost (if everything is bought from the market) will be approx. Rs 4500/-. If the post has an inverter, then it can be used, it will bring down the cost to approx. Rs 3000/-
Wind power is an non polluting, easily available source of energy. Using the kind of wind turbine shown above, our quest for power at almost all inaccessible places can be solved at a fraction of the cost of conventional generators.




