EduGrid - Wind Turbine

3D-Printed Wind Turbine – Open-Source Educational Project (EduGrid)

This wind turbine is designed as an educational tool to demonstrate the principles of wind energy, aerodynamics and mechanical power generation. The fully open-source project allows students, educators, and hobbyists to explore renewable energy through hands-on learning.

Learning Objectives:

1. Understand the basic principles of wind energy and how turbines convert kinetic energy into mechanical or electrical power.
2. Explore aerodynamic design, including blade shape, angle, and efficiency.
3. Develop problem-solving and engineering skills by assembling, testing, and modifying the turbine.
4. Encourage experimentation and innovation by allowing users to customize and improve the design.
5. Foster learning through discovery, where students actively investigate how different variables affect turbine performance through hands-on testing and observation.

The design will be accessible and easily fabricated using widely available 3D printing technology. All files and assembly instructions are provided for free, therefore making it an ideal project for classrooms, workshops, and independent study.

Disclaimer:

The information provided in this tutorial is intended for educational and informational purposes only. The author does not assume any responsibility for any harm, injury, or damage that may arise during the construction, assembly, or operation of the wind turbine or its associated components. All activities should be carried out with the utmost care and attention to safety protocols.

Co-Authors: Maximilian Hock, Lukas Rau

3D-Files: (...)

Notes

:

TO_DO’s Wind Kit

1.

Copper Wiring Gerät: Öffnung in der Mitte größer machen, damit Ring besserruntergeht

2.

Rotor – Löcher auf der Rückseite etwas größer machen und “disassembly” toolmitbringen, falls Magneten falsch eingedrückt wurden

1.

eventuell noch Bild Frontalansicht Wind Turbine ohne Blades Step 10 hinzufügen

2.

Theorie Magnetfeld Rotor

3.

Theorie/Erklärung Sinus (letzter Step)

4.

Theorie/Erklärung LED (letzter Step)

1.

alle Bilder & Videos sind im Teams zu finden

1. 1 Axle
2. 1 Tape
3. 1 Stator
4. 1 Rotor
5. 11 Hex nuts
6. 6 Ball bearings
7. 1 Pipe (Tower)
8. 1 Foot stand
9. 32 Magnets 3x10mm or 16 Magnets 6x10mm
10. 3 Blades
11. 2 Hub (Front and back part)
12. 1 Nacelle
13. 1 Yaw
14. 1 Copper Wire
15. 1 Wiring Device
16. 2 Small caps
17. 1 Big cap
18. 3 Screws (M6 x 10)
19. 1 Screw (yaw fixation) - (M6 x 5)
20. 1 Screw (long - M6 x 20)
21. 2 Banana plug sockets 12 mm outer diameter

Estimated Time: 5 minutes

Parts & Tools Required

1. Spacer
2. Wiring Device
3. 2 Ball Bearings
4. 2 Caps
5. Copper Wire
6. 1 Screw
7. 1 Nut
8. Wrench

1. Prepare the Spacer: Take the Spacer and place one ball bearing on each side.
2. Attach the Caps: Position the two caps so that they face inward.
3. Fasten the Screw and Nut: Thread a nut onto a screw as depicted, then fasten them slightlywithout tightening them completely.
4. Place the assembly into the opening, ensuring a tight fit.
5. Insert another Hex Nut: Place a hex nut into the appropriate middle opening of the wiring device.
6. Final Assembly
7. Attach the Spacer and Wiring Device using a longer screw.
8. Important: Tighten the screw securely so that the assembly holds firmly but remainsmovable.

Estimated Time: 15 Minutes (Requires a minimum of two people)

Parts & Tools Required

1. Screwdriver
2. Fully Assembled Wiring Device
3. Safety Gloves
4. Axle / Stick

1. Attach the Screwdriver: Take a cordless screwdriver and attach it to the fullyassembled wiring device by holding the screw in the middle with the screwdriver.
2. Secure the Copper Wire: Insert the copper wire through the opening of the Spacer. Wrap itaround the middle screw and secure it with a knot (as shown in the reference image) toprevent it from slipping off easily.
3. Insert the Axle: Pass an axle through the copper winding so that it can rotate smoothly while unwinding the wire.
4. Hold the Axle Firmly: Secure the axle with one hand, ensuring it can rotate freely without falling off.
5. Control the Wire Feed: With your other hand, hold the end of the copper wire and keep it slightly tense so that it unwinds smoothly.
6. Start the Screwdriver: A second person carefully! Start the screwdriver to begin winding.
7. Count the Rotations: The person operating the screwdriver counts every full rotation of the Spacer.
8. Ensure Even Distribution: The person holding the copper wire spool ensures that the wire unwinds smoothly and distributes evenly from left to right to fill the entire device uniformly.
9. Complete 700 turns: Continue the process for 700 turns to achieve the required winding.
10. Cut the Copper Wire

Estimated Time: 10 Minutes

Parts & Tools Required

1. Wrench
2. Fully Wired Device

1. Prepare the Tape Strips: Cut 16 small tape strips, each approximately 3 cm long.
2. Apply the First Tape Strip: Take the Wiring Device and wrap one tape strip around the opening (refer to the picture for correct placement).
3. Loosen the Screw Slightly: Loosen the screw slightly to make the copper ring easier tomove.
4. Adjust the Copper Ring Position
5. Rotate the copper ring slightly so that the edges of the outer ring align perfectly with the middle of the taped spot.
6. Important: As you progress, turning the ring will become increasingly difficult. If you can’t rotate it anymore, loosen the inner nut slightly.
7. Apply Additional Tape Strips: Wrap another tape strip around the copper ring to secure it in place.
8. Repeat for All 16 Tape Strips: Continue this process until all 16 tape strips are applied evenly around the ring.
9. Remove the Copper Ring
10. Once all tape strips are in place, fully loosen the device and carefully remove the copper ring from the Wiring Device.
11. ⚠ Note: This step requires patience and precision as it is a delicate process (a fiddly job!)

Estimated Time: 15 Minutes

Parts & Tools Required

1. Copper Ring
2. Stator
3. Rotor
4. Magnets

1. Prepare the Copper Ring
2. Take the copper ring and fold an edge between two tape strips (see picture 1).
3. ⚠ Note: This requires some strength!
4. Insert the Copper Star into the Stator
5. Place the stator on a flat surface.
6. Carefully insert the copper star into it (see picture 3).
7. ⚠ Delicate work (fiddly work!): This step requires patience.
8. You can also use a flat-head screwdriver to firmly push the edges – but be CAREFUL!
9. Take the Rotor
10. Insert the Magnets
11. Important!
12. Place two magnets in every second hole of the rotor.
13. Now, flip the entire stack of magnets upside down and fill the remaining empty holes between the magnets you just placed.
14. Complete the Magnet Insertion: Repeat this process until all 32 magnets are used, meaning all holes are filled.

Checking the Magnet Placement

a. Test the Magnetic Polarity

1. Take a magnet and hover it above the rotor.
2. Every second magnet should either be pulled towards or pushed away from it.
3. ✅ If this happens, you have installed the magnets correctly!

b. Fixing Incorrect Magnet Placement

1. ❌ If the test does not work, you may need to reposition the magnets.
2. Locate the small holes on the back of the rotor.
3. Use a hammer and a steel pin (that fits into the small hole) to carefully push.

Estimated Time: 15 Minutes

Parts & Tools Required

1. Hot Glue
2. 3 Screws (long)
3. 3 Nuts
4. 2 Ball bearings
5. 1 big cap

1. Secure the Copper Star
2. Use hot glue to fix the Copper Star in the middle so it no longer moves.
3. Apply glue to both the center and the side parts for stability.
4. Insert Screws and Nuts
5. Take three screws and nuts and insert them through the designated openings (see picture 3).
6. Install the Ball Bearings
7. Place one ball bearing in the middle.
8. Insert a second ball bearing on the other side as well.
9. Attach the Cap
10. Secure the cap on this side (see picture 6).

Estimated Time: 15 Minutes

Parts & Tools Required:

1. Axle
2. Assembled Rotor
3. Nuts
4. 2 Slip Rings
5. Wrench
6. Lighter

1. Insert the Nut and Axle
2. Take the rotor and place a nut into the designated recess.
3. Insert the axle through the rotor. (see picture 1.)
4. Assemble the Stator and Rotor
5. Insert the axle through the fully assembled stator.
6. Secure them together by tightening the screws. Ensure the rotor fits close but can still rotate.(See pictures 2 and 3.)
7. Attach the Bushings with Contacts: Insert the bushings with the electrical contacts through the two holes on the side of the generator housing.
8. Prepare the Copper Wiring: Burn off the insulating lacquer from the copper wires to expose the bare metal.
9. Clean the Wires: Use a towel to remove the resulting soot.
10. Connect the Copper Star: Take one end of the copper star and wrap it around the nearest bushing contact. (See picture 5.)

Estimated Time: 10 Minutes

Parts & Tools Required

Solder the prepared copper wire to the contact on the generator, as shown in the pictures.

Estimated Time: 5 Minutes

Parts & Tools Required

1. Nacelle
2. Tail Fin
3. Yaw
4. 2 Ball Bearings

1. Assemble the Tail Fin and Middle Section (Nacelle) as depicted
2. Insert the Ball Bearings: Take the yaw and insert two ball bearings into it.

Estimated Time: 5 Minutes

Parts & Tools Required

1. Tower
2. Foot Stand
3. Assembled Yaw

1. Cut the Tower and Attach the Yaw
2. Attach the tower to the stand.
3. Place the yaw on top of the tower.

Estimated Time: 5 Minutes

Parts & Tools Required:

1. Blades
2. Hub (Front / Back)

1. Prepare the Blades: Break off the flat platform-like structure from the blades.
2. Assemble the Blades: Attach the blades in the Hub.

Estimated Time: 15 Minutes

Parts & Tools Required

1. Fully assembled Generator
2. Fully Assembled Tower
3. Fully Assembled Nacelle
4. Fully Assembled Hub
5. Wrench
6. 5 Nuts
7. 1 Screw (Yaw)

1. Attach the Generator to the Nacelle: Secure the generator onto the nacelle using three nuts. (see picture)
2. Mount the Nacelle on the Tower: Place the nacelle on top of the tower and fixate the yawmechanism with a screw.
3. Attach the Blades to the Axle:
4. First, screw one nut onto the axle.
5. Take the hub with the attached blades and place it onto the axle.
6. Secure the blades with another nut.

Stabilize the Tower Stand: Screw the tower stand onto a piece of wood to ensure stability.