Helical Plus Six Belt Driven Nema Turbine - Free 3D Print Model

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Rumbling Werewolf

Education>Engineering

IP Report

Print Profile(1)

All

H2D

H2C

P2S

H2S

H2D Pro

X2D

A2L

0.2mm layer, 6 walls, 25% infill

Designer

85.6 h

15 plates

5.0(1)

Open in Bambu Studio

Boost

149

445

107

Released

Description

Hi!

This is my Helical Plus Six Belt Driven Nema Turbine. This is a step up from my previous wind turbine design with a six blade main blade and a helical center blade. I have also included my tri blade mount, six blade center blade and post top mount so you can use them as well if you like. If you check out my Instagram profile you will find reels of the turbine in action. (Link in bio or just search for rumbling.werewolf)

The turbine is now geared up with a small belt drive. The ratio is 3:1 so one turn of the blades creates 3 turns of the Nema motor. This spins the motor faster for an increased power output. The phases of the motor are connected to a custom built rectifier, you can see the layout in the attached drawings.

I'm currently feeding the output of the rectifier into a DC-DC converter with an input range of 20-60v and an output of 12v to power a light. There are a lot of converters out there with different inputs and outputs to choose from, this one suited my needs for testing.

I have added a parts list to one of the attached drawings, it also shows exploded views and part locations to help you put it together. As alway be careful, remember its an experiment and have fun!

R.W.W.

Update 19-03-26

I Made a new rectifier and photographed the board layout at each stage of construction. Photos are now available on my instagram profile.

I used the following purchaced components to create my turbine along with th 3d printed parts.

Linear Rod 2pcs 10mm x 400mm & 1pcs 10mm x 300mm for the vertical shaft but a 400mm would work too.

https://amzn.eu/d/iitnFZC

M5 x 25mm Hex Head Bolts Set with Nylon Nuts and Washers

https://amzn.eu/d/a05frST

Thrust Bearing's F10-18M

https://amzn.eu/d/5CFx6VP

1N5408 Rectifier Diodes General Purpose Silicon Rectifiers, 3A, 1000V

https://amzn.eu/d/fy13OsN

***Electrolytic Capacitor 1000uF 50V Aluminum*** Update 13-03-26, Im upping these to 1000uF 100v after spotting the originals have started to show signs of over heating. It could be age with mine, I have been using them for over a year now but better safe than sorry.

https://amzn.eu/d/018hO0Rd

Nema 23 Stepper Motor 57x56mm Body 1.8 Stepper Angle 2.0A 2 Phase 4-Lead

https://amzn.eu/d/d1QF5ha

6000RS Deep Groove Ball Bearings 10 x 26 x 8mm High Carbon Steel Double Sealed Bearings

https://amzn.eu/d/atyC81h

Double Sided Prototype Universal Printed Circuit Board

https://amzn.eu/d/hfFBlew

The protototype board size that fits the model is 50mm x 70mm

https://amzn.eu/d/0daFcd22

M4 Nut and Bolt (pan head with hex) set 500 pcs + M4 spring washers

have a look at the parts list for sizes and quantitys, i cant find the exact set I purchased as its not in stock but this set looks similar.

https://amzn.eu/d/0cGUaw5h

Belt and Pulleys - 60 Teeth:10mm Bore,20 Teeth:8mm Bore

2pcs 2GT 60 Teeth Synchronous Wheel, 2pcs 2GT 20 Teeth Synchronous Wheel, 2pcs Length 200mm Width 6mm Belt , 4pcs M4 screws, 1pcs Allen Key

https://amzn.eu/d/08Peqjzb

DC-DC converter 20-60v in 12v out ( check out RS components for lots more)

https://amzn.eu/d/0e4zD8Jd

Documentation (7)

Assembly Guide (7)

Helical Plus Six Belt Driven Nema Turbine-1.png

Helical Plus Six Belt Driven Nema Turbine-2.png

Helical Plus Six Belt Driven Nema Turbine-3.png

Helical Plus Six Belt Driven Nema Turbine-4.png

Helical Plus Six Belt Driven Nema Turbine-5.png

Helical Plus Six Belt Driven Nema Turbine-6.png

Helical Plus Six Belt Driven Nema Turbine-7.png

Comment & Rating (17)

@user_2311659620

I would like a version to store energy in batteries

The designer has replied

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@rumblinwerewolf

:D So would I! Its getting there :)

@user_2311659620

Replying to @rumblinwerewolf :

I'm waiting for new filaments to arrive to start the project, I'm already eager to see how it turns out!!!

Show original

@rumblinwerewolf

I hope it goes well for you. I’m still waiting on some wind here to test out some new ideas. 🐺

@user_64792689

how many megawatt of engery does this wind power building produce? per minute

(Edited)

The designer has replied

@rumblinwerewolf

Hi so 0MW :D, Megawatt turbines are way way bigger than my turbine. I have tested it with a 10w load in 20mph winds which it runs quite happily.

@user_64792689

Replying to @rumblinwerewolf :

so i will need like 100.000 of them to power the death beam. that are plenty of wind power buildings.

@user_2311659620

How is the electrical connection made?

The designer has replied

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@rumblinwerewolf

Hi so from the Nema motor its two phase so four wires, two for each phase or atleast thats how I understand it. The wires are connected to a rectifier. Theres a drawing of my one in the assembly guide. The rectifier converts the AC electric from the motor into DC electric. The rectifier is connected to a DC to DC converter this take the higher voltage DC and makes it a lower voltage. The lower voltage is fixed or it can be variable depending on the type. The one I listed is fixed so it only outputs 12v with I think a 20-60v input. Im currently testing a different DC-DC converter which is variable and has a wider input range, 10.5v-60v input. It has an varible output voltage and current which you can set by adjusting some screws and measuring with a multimeter. When the wind here picks up again I will be able to test it and see if i can get it to power an old solar battery charger I have and a car battery. I will post my results on my insta page. (link in my profile)

@user_2311659620

Replying to @rumblinwerewolf :

👍🏻👍🏻👍🏻

@user_1570839055

Thanks for the great model! I'm almost done printing and all the electrical parts are ready. How do you prevent the cable from constantly winding around the pole? Eventually, it gets so wrapped around the pole that the turbine can no longer turn into the wind, right?

(Edited)

The designer has replied

Show original

@rumblinwerewolf

Hi yes it does occasionally but I turn mine back by hand. It would need a slip ring inbetween the turbine and the mounting post to stop it twisting up. 🐺

@user_1143105281

Thank you for all your hard work and testing. This is why we 3D print.

The designer has replied

@rumblinwerewolf

Thank you! 😊🐺

@stonerhino

i plan to build this, but just a bit of a note; its better to move AC over long distances. the voltage drop for DC is very bad past 1-2m.

(Edited)

@Tomy061165

Print Profile

0.2mm layer, 6 walls, 25% infill

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