Wind Turbine(Fully Functional Mechanics)

thingiverse

Before you build this read through everything below. Very complicated project. This was a project for a local project fair. I designed it taking inspiration from real full-size wind turbines. It has a gear selector, Brake, Blade angling system, and Pointing Mechanism. For this project, I made it Remote Control so that I wouldn't have to worry about programming. It was more of a learning project rather than an efficient design the generator is quite small and only generates a fraction of a volt on average. There are a lot of intricate parts, some requiring supports, rafts, and brims; that being said, use your judgment for each part. This is a very hard project for an experienced 3D printer/ builder. Please read: For the brake disk I used a plasma cam to cut out the circle, (don't remember the gauge), If your using plastic, be ready for breaks. Parts list: Filament: Creality PLA (your color choice) Hatchbox PLA+ Esun LW- PLA Electronics: -Ar-620 (Spektrum) -2x Winch servo (W5513-6T JX Servo 6 turns) -2x mg90s (or something of the same shape) -4 AA battery pack(2x2 configuration) -Transmitter (6 channels min) Bearings: -11x: 8mm x 22mm x 7mm -2x: 17mm x 23mm x 4mm Shafts: -8mm Aluminum tubing, 1mm wall thickness, 300mm length 4x(minimum, recommend more) -5.5mm Aluminum tubing 1mm wall thickness, just buy one -4mm Brass rod 300mm (must not be hallow) Screws: Used Virgue brand -m3 -m4 -I suggest buying a box of each type make sure there are at least 6, 25mm -Will need a variety, and may have to tinker with different lengths to make parts work and fit. -Other stuff: -2 paperclips -18 gauge wire (This is what I used, builder discretion) -Tape (embedded string type), (for covering blades) -2x2ft plywood board -4in PVC sections (2x, +connector) -Toilet flange (I'm not joking, 4in id) -RC Airplane control rods (1.2mm, you will want 2 packs) Generator: Use a 12volt DC motor Tools: (approximation) -Drill (bits as well) -vice -pliers -Allen wrenches ( m3, m4) -Hand Saw (be careful) -Calipers(or ruler) -A lot of time -place to build -may need to solder some connections -Super glue Instructions: This is more of a tinkerers project, so be prepared to try things. -Print all the parts -Use LW-PLA for the blade skin and cowl (not the nosecone!!!) and use PLA or PLA+ for the rest of the parts. Using the nose cone hammer in 8mm id bearings onto shafts, ensure they don't come off by pulling. There is a 3mm screw that fits between the two bearings on each blade, insert one of the angling arms in and drill a 3mm hole, insert a 3mm screw. -The Gear selector is really weird, it has a lot of moving parts, two major issues I solved in post-production were: 1 the sliding part of the mechanism would freeze up, put some grease on it; 2 the gears could be pushed back because there is nothing holding them in place, I glued some pieces to the main shaft to maintain their position, (they should be able to spin freely from the main shaft when not engaged). -For the secondary shaft (above the main shaft) use the 5.5mm shaft, use small 7mm sections of 8mm shaft to adapt to 8mm id bearings. -The connection from the worm gear pusher assembly to the pusher shaft is the most difficult part of this build. You will have to cut small sections of RC airplane pushrod and drill them into the brass rod, use a Vice, and some sort of guide for the drill bit(1/8th inch). -The connection to the winch servos is a tricky one, drill a (1/16, or 1/8inch) hole through the side of the rotating part of the drum,( remove the outer portion, you won't need it) and a small 8mm shaft (attached to worm gear). Insert the paper clip, either twist it or put some glue in there and cut it somehow. -Drill holes in the 8mm shaft that correspond with the holes in the inner blade piece (there are so many pieces I can't remember what I called it, looks like a giant paddle) Have fun and good luck!!!