# Windkit contruction manual V1.1

[TOC]

tack-welded

# Introduction

# System overview

# Tools and materials

## BOM - Bill of materials
"D:\ERNI-Nextcloud\ERNI\05_Projekte\windkit-prototype-fund\Dokumentation\SKL_windKit_221118.ods"

## BOT - Bill of tools

# Let's build

## Painting Job No.1

Some parts need to be painted before!
???Put painting jobs into construction manual section of each component/subassembly.

## Rotor blades
The rotor of the windkit consists of 3 wooden blades each 900 mm long.



### Materials needed:
* ???Insert table with parts when BOM is ready

### Tools needed:
* ???Insert table with tools when BOT (Bill of tools) is ready

### Construction manual: Rotor blades
A step by step manufacturing guide for the wooden blades can be found in the master thesis ["Performance analysis and improvement of a small locally produced wind turbine for developing countries"](http://resolver.tudelft.nl/uuid:e186338b-87eb-4baa-8280-a7940b83db14) by N. Hosmann in "Appendix G: Blade manufacturing manual for the new rotor design".


As surface treatment we recommend linseed oil. Other coating solutions like epoxyd based varnish are to rigid for the flexible blades. The main issue is that the blades will bend due to the aerodynamic forces acting on them. After some operational time a varnish solution which is to rigid will start to become brittle which leads water to enter the cracks. So the blades will become mouldy. Linseed oil gets absorbed by the wood and is therefore no issue for the blades bending forth and back in the wind.

Follow our recommended instructions below for the surface treatment with linseed oil:
* ??? Put text from [INF_Rotorblatt-Oberflaechenbehandlung_19-12-17.docx](["D:\ERNI-Nextcloud\ERNI\04_Workshops\06_Anleitungen\03_Holzstation\INF_Rotorblatt-Oberflaechenbehandlung_19-12-17.docx"](https://cloud.erni-kollektiv.org/nextcloud/index.php/f/123121))

???Our blade length is 1050 mm in CAD. N.Hosmanns construction manual is 900 mm. Define our blades as 900 mm as well. results in 2 m diameter of the windkit. Currently diameter is 2.2 m.

## Alternator

### Alternator Stator

#### Materials needed:
* ???Write part slist when BOM is ready

#### Tools needed:
* ???Write tool list when BOT (Bill of tools) is ready

#### Construction manual: Coils
The 9 coils are build according to the ["2F Wind Turbine Construction Manual"](http://scoraigwind.co.uk/2014/06/ebook-plans-for-2f-turbine-now-finally-published/) by [Hugh Piggot](https://scoraigwind.co.uk/contact/).

???Insert coil picture.

#### Construction manual: Coil array
Follow the instruction for the electric connection of the coils as explained in the ["2F Wind Turbine Construction Manual"](http://scoraigwind.co.uk/2014/06/ebook-plans-for-2f-turbine-now-finally-published/). The only difference of the windkit coil array is that the electric connection inbetween the coils is realised within the coil circle and NOT on the outer rim.

Coil array

Electric connection of the coil array in the inner circle.


#### Construction manual: Alternator stator
Follow the process instructions of the ["2F Wind Turbine Construction Manual"](http://scoraigwind.co.uk/2014/06/ebook-plans-for-2f-turbine-now-finally-published/) but use the windkit stator mould to cast the stator.
???Insert stator mould image.

### Alternator Rotor

#### Downwind Magnet Disk
1. 
2. 
3. 

#### Upwind Magnet Disk
1. 
2. 
3. 
4. 
5. 

#### Taper Bush

> Mount the Taper Bush on the frontside of the Upwind Magnet Disk
1. 
2. 

### Nacelle

1. Cut the Yaw Pipe
2. Place and spot-deld Upper Spacer on to the Yaw Pipe
3. Place and spot-weld Bearing Mounting Plate and Lower Spacer
4. Weld the Nacelle
5. Place the Wind Vane Socket
6. Weld the Wind Vane Socket
7. Paint the Nacelle
8. 

New Renderings


### Shaft
> There is nothing to do here actually. ???Needs to be cut to the correct length.

### Wind Vane
1. Cut the Vane
2. Drill holes into the Vane
Place the *Vane Mounting* ontop of the Vane and drill 7 holes @ 6mm
3. Cut the Vane Pipe
400mm length
4. Paint all parts
5. Screw Vane onto the Vane Mounting
7x M6x25-Screw
6. Connect Vane Mounting and Vane Pipe
2x U-Bolt Clamp M10

## Painting time

## Set all together (the marriage)
> Nacelle - Alt.Stator - Alt.Rotor - Rotor - Wind vane -> DONE!
### Nacelle - Alt.Stator
1. Place the Alternator Stator front facing down
2. Place Bolts underneath
4x M12x60-Screw without washers
3. Place first Housing Bearing
Mounting side up
1x UCF205
[](https://i.imgur.com/ihAUYmc.png)
Take care of the grease nipple

4. Place Nacelle
5. Place second Housing Bearing
1xUCF205
Mounting side down
6. Mount all together
1. Loosly tighten the Nuts
4x M12-Washer
4x M12-Nut
2. Place the Shaft and tighten the setsrews of the bearing
3. Tighten the Nuts
4. Next we add the Alternator Rotor

### Add Alt.Rotor

#### Assemble the Upwind Magnet Disk
1. First we take the assembled Alternator Rotor

3. Add the Taper Bush by screwing it with the setscrews loosly
4. Place the Alternator Rotor on the Shaft
Note: Magnets touching the Stator is fine
5. Fasten the Taper Bush Setscrews

#### Measure and Calibrate

1. Measure the gap
2. In case calibrate with
Passscheiben DIN 988
https://cloud.erni-kollektiv.org/nextcloud/index.php/f/157853

#### Assemble the Downwind Magnet Disk

6. Place the assembly upside down
7. Add M6x85-Screws and washers
9x M6x85-Screw Stainless Steel
8. Add Spacer Sleeve
9x Stainless steel sleeves 8x6x1 mm (up to M6), 50mm Length
9. Place the Downwind Magnet Disk on top
Caution: Because of the magnetic field there is a strong force, place pieces of wood between the Stator and Rotor
10.Tighten the Nuts
9x M6-Nut

Finished ALternator

### Assemble the Rotor
Each blade is connected seperatly to the upwind magnet disk to form the rotor.

#### Attach the Rotor Blade
Needs to be done three times
3 x M6x50-Screw
3 x M6 Nut (Not true needs to be a )
3 x M6 Washer

#### Measure and calibrate the Rotor


### Assemble the Wind Vane

1. Place the Wind Vane down wind facing side of the windturbine
2. Attach the WInd Vane
2x U-Bolt Clamp M10

### Done