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Forum Index : Windmills : Recycled Items used to generate power.
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MrDelanco Senior Member  Joined: 12/11/2011 Location: United StatesPosts: 101 |
I used recycled items to enlighten the minds of others. I tried to show that we are not limited by the resources around us only in the way we perceive the use of them. I started this project to supplement my electric usage because of high electric bills and continued price increases by the suppliers. I started with solar and found that the technology just was not invented yet, the panels only worked well or as advertized by the manufactures and suppliers on sunny days and to make solar economical or even affordable to the average homeowners without taking out a loan was not going to happen anytime soon. I then looked into prebuilt wind systems and found that all were over priced and not very well constructed to be environmentally friendly with Nature and or people with the noise of the blades, parts falling off and low pressure effects ect. I then decided that if I was to reduce high electric bills I would need to design and build a vawt design windmill and a low speed alternator-generator. Now this was going to be a great project, I took inventory of the items needed and what was laying around that could be used for this project. And with the help of some of the children around town the project was infused with resources. The videos I have posted here are the results of the resources that were available for the successful completion of this project. The Vawt worked better then I thought it would I am totally off the power grid. The output voltage is steady at 26.3 - 27.7 volts dc on the 24v side after rectification with a 2-12 mph wind. I charge into an ultra-cap bank using the wind to charge this power source using charge equalizers installed between each ultra-cap bank to charge from the wind and have a stable output depending on how many ultra-caps you use you can obtain an output with high amps and watts. I use 36-2600uf ultra capacitors recycled from the electric buses when they upgraded to 3000uf. I am charging the battery storage banks that are recycled forklift batteries from part of the output of the ultra-cap banks. I also us a bank of ultra caps before entering the three inverters that are used to power the house. From the batteries to the inverters I again enter a boost cap bank each cap is 2500f at 8000 joules, there are 6 banks with 6 caps in each bank. This gives the bank of inverters a stable current input to handle multiple start-up loads and places less of a strain on the battery cells. I used recycled items to open the minds of others. I tried to show that we are not limited by the resources around us only in the way we perceive the use of them. View Project Videos Building the Alt-Generator Up n Running Cycloturbine Darrieus Giro-mill Vawt Windmill machine Working Cycloturbine Ultra Caps-Boost Caps MrDelanco:Project Videos It is not only too know what it does but to understand how it does what it does. |
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Rastus Guru  Joined: 29/10/2010 Location: AustraliaPosts: 301 |
Hi Mr Delanco, Congratulations on the success of your projects.To be Grid free is quite something!I think additional education will help unlock the dark recesses of my mind.If I recycle what I've got,I probably couldn't raise enough for a beer.But then again  Cheers Rastussee Rastus graduate advise generously |
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| MrDelanco Senior Member Joined: 12/11/2011 Location: United StatesPosts: 101 |
I use the cycloturbine to generate the motion to run the 1st alt-generator. From the 1st Alt-Generator the output goes into a bank of four(4) full bridge rectifiers. I rectify the voltage and charge a Maxwell ultra capacitor bank setup to 24 volts. From this I enter the charge controllers that charge three banks of 24 volt wet-cell forklift batteries. From this battery bank I use a bank of Maxwell ultra capacitors to run a 2nd Motor-Generator-Flywheel pma that charges a bank of 36 Maxwell ultra capacitors "Boostcaps" before entering the charge controllers that charge another battery bank of seven(7) 12 volt forklift gel-cell batteries. From the 12 volt batteries I use another bank of 36 Maxwell ultra capacitors "Boostcaps" before entering the inverters that are used to power the house. Each Maxwell ultra capacitor is 2.5 volts 2600f at 8000 joules, there are 6 banks with 6 caps in each bank to build a voltage of 15vdc. This gives the bank of three(3)10,000 watt inverters a stable current input to handle multiple start-up loads and places less of a strain on the battery cells. There are two(2) more 6,000 watt inverters that run my lab and workshop. and another 6,000 watt inverter to run the computer rack. To keep the Maxwell ultra capacitors "Boostcaps" from charging over 2.5 volts I built a charge equalization circuit for each row in each bank. 
MrDelanco:Project Videos It is not only too know what it does but to understand how it does what it does. |
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| MrDelanco Senior Member Joined: 12/11/2011 Location: United StatesPosts: 101 |
Here is a block view of the setup. 
MrDelanco:Project Videos It is not only too know what it does but to understand how it does what it does. |
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| Air Bender Senior Member Joined: 25/01/2011 Location: AustraliaPosts: 206 |
Hi MrDelanco, I like the way you have the Vawt set up, a big slow spinning mill with a shaft through the roof with all your gearing and generating system in easy reach for maintance and lubricating it all looks to be running like clock work. That is the way I always thought a big Vawt should be set up. It is good to see that you have taken on something this size and made it work. All the best Dean. |
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| MrDelanco Senior Member Joined: 12/11/2011 Location: United StatesPosts: 101 |
Thankyou Air Bender I only tried to supplement my electric usage at first, but I over built the system and now generate more electric then I can use. I installed dump loads by building HHO generators so I have a supply of burnable fuel that I am storing to use in-place of natural gas for cooking and heating. I already supplement my fuel usage in my work truck with HHO. I used to fill up the gas tank once a week now it's once a month. Cheers Bob MrDelanco:Project Videos It is not only too know what it does but to understand how it does what it does. |
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Perry Senior Member Joined: 19/11/2009 Location: Posts: 190 |
Wow, that's a lot of steps. Aren't you losing power at each conversion/storage stage? How is this better than running alternator-rectifier-battery bank-inverter? What function does the second motor and flywheel serve? And all the ultra caps. Those are all energy storage devices. Why have 3 different types in series generating heat and wasting power? Perry |
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MacGyver Guru Joined: 12/05/2009 Location: United StatesPosts: 1329 |
[Quote=MrDelanco] I already supplement my fuel usage in my work truck with HHO. I used to fill up the gas tank once a week now it's once a month. I'm curious to know how you store HHO without it turning back into water. I found that its partial pressure was enough to make the phase changge, if I let it sit in a closed system any longer than a few minutes. I'm also curious to know how you use it as a fuel replacement without blowing yourself to kingdom come. Poppet valves don't seal well enough to contain pure compressed hydrogen and it's been my experience an engine won't start on HHO. In fact, if the engine is not hot, it fouls the plugs. If it is indeed burning, how does it affect the useable horsepower of your engine and how are you measuring it? If you are using it as a "mileage booster" I'd be interested in knowing how you are measuring that as well. Are you comparing apples to apples, meaning, are you driving the same path under the same conditions each time you use the vehicle/. Also, is your truck running on HHO only or does it still require as least a portion the fuel recommended by its manufacturer to operate? I've dabbled with HHO (Brown's Gas) as well as pure hydrogen and I, for one, have never found a safe-enough way to handle it. If you think I'm talking out my hiney, ask me to tell you about the day the city bomb squad paid me a less-than-cordial visit! I had ignited about a cup full of HHO in a zip-lock bag to see how much of a boom it would make. It shook windows for about 7 blocks and the police got more than a dozen calls! Oops! Sorry for all the questions, but your claims run somewhat counter to my hands-on experience. Be careful out there! . . . . . Mac Nothing difficult is ever easy! Perhaps better stated in the words of Morgan Freeman, "Where there is no struggle, there is no progress!" Copeville, Texas |
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| MrDelanco Senior Member Joined: 12/11/2011 Location: United StatesPosts: 101 |
Hello Perry; It is not a lot of steps for a complete electrical power generation setup for my home use. I have found no lost power at conversion only increase's in amp's and watt's. I am running alternator-rectifier-battery bank-inverter but with two systems combined. I only require a low 2-12mph wind speed to keep the storage batteries charged and the system in motion. The function of the 2nd Motor-Generator-Flywheel pma is described in a past post. Understanding the wind stops from time to time the 2nd compensates for times without wind by providing a ups input. The motor/generator draws power provided by part of the 1st battery bank to spin the rotor of the flywheel. The kinetic energy stored in the rotor is transformed to DC electric energy by the generator, and the energy is delivered at a constant frequency and voltage into the storage system. This also helps to prolong the life of the batteries. The ultra-capacitors provide strong steady power. By combining ultra-capacitors with a battery-based uninterrupted power supply system, the life of the batteries can be extended by reducing the cycling duty on the battery cells. I have found no heat being generated and have an abundance of extra power. This is a recycle project about a small mill made from recycled items for home power. Perry do you operate a small home unit or just work on the large commercial mills? Regards Bob. MrDelanco:Project Videos It is not only too know what it does but to understand how it does what it does. |
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| MrDelanco Senior Member Joined: 12/11/2011 Location: United StatesPosts: 101 |
I'm also curious to know how you use it as a fuel replacement without blowing yourself to kingdom come. I've dabbled with HHO (Brown's Gas) as well as pure hydrogen and I, for one, have never found a safe-enough way to handle it. If you think I'm talking out my hiney, ask me to tell you about the day the city bomb squad paid me a less-than-cordial visit! I had ignited about a cup full of HHO in a zip-lock bag to see how much of a boom it would make. It shook windows for about 7 blocks and the police got more than a dozen calls! Oops! Sorry for all the questions, but your claims run somewhat counter to my hands-on experience. Be careful out there! . . . . . Mac This HHO topic if for another forum Mac. As I stated I supplement my fuel usage in my work truck with HHO, the HHO generator in the truck supplies 2 liters per min. I still need the petrol fuel to start the engine and run at idle and low speeds I turn on the HHO generator when I get on the highway. They should have given you a new coat with long sleeves that tie in the back. 
Cheers Bob MrDelanco:Project Videos It is not only too know what it does but to understand how it does what it does. |
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| Perry Senior Member Joined: 19/11/2009 Location: Posts: 190 |
Hi Bob, I think I understand now. You are using 3 storage methods, batteries, caps, and a flywheel. Then again, maybe I don't understand by looking at your block diagram above. Are all those things connected in series? Sure your flywheel provides energy when the wind isn't blowing but that's what the batteries are for. Man your recycled parts bin must be nice. Aren't Maxwell Ultracaps and flywheel backups UPS's expensive? I like your videos. Since you asked, I build smaller turbines just as a side hobby. Have a couple I 'fly' in my garage since it seems I get absolutely no wind at the house. Frustrating for sure. Perry |
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| MacGyver Guru Joined: 12/05/2009 Location: United StatesPosts: 1329 |
[Quote=MrDelanco]They should have given you a new coat with long sleeves that tie in the back. This is the second time you've stated this on the 4m; the first time was amusing. I agree the HHO topic should be taken up in another thread. Why don't you start one in "Other Stuff" and begin it by answering all my above questions? . . . . . Mac Nothing difficult is ever easy! Perhaps better stated in the words of Morgan Freeman, "Where there is no struggle, there is no progress!" Copeville, Texas |
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Tinker Guru Joined: 07/11/2007 Location: AustraliaPosts: 1904 |
I'm curious why you use a LED and a zener. Is the LED telling you when the cap is fully charged? BTW, I enjoyed watching your super cap video, unfortunately these are a trifle expensive to start experimenting with and recycled ones are not available AFAIK. Klaus |
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| MrDelanco Senior Member Joined: 12/11/2011 Location: United StatesPosts: 101 |
Here is a Tid-Bit of information. About 35 years ago, Fradella and two of his brothers who owned a machine shop developed the brushless regenerative DC motor shown below. Fradella very successfully demonstrated it to colleagues where he worked as a consultant, at the Navy weapons development center and at Hydropower in San Diego, also JPL and Aerojet; each issued purchase orders for various diverse applications. It was also demonstrated at Parker-Hannifin. Fradella was not able to finance motor manufacturing, and therefore could not accept the motor purchase orders. The left photo shows the portable motor demo, with its 48vdc battery pack, power interface electronics (including a plug-in battery charger), the motor assembly, and user control box. The next photo shows the motor prior to assembly, with its rotor and stator disks and supporting parts. RPM's brushless regenerative ultra-efficient DC motor. 
This motor technology is closely related to the DC generators and flywheel batteries, plus the RPM EV motor-wheel developments that followed. It is tested and proven. Source Info MrDelanco:Project Videos It is not only too know what it does but to understand how it does what it does. |
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| MrDelanco Senior Member Joined: 12/11/2011 Location: United StatesPosts: 101 |
For a quick visual scan at the panel, and to indicate when the ultra-caps are charged or that they are charging. MrDelanco:Project Videos It is not only too know what it does but to understand how it does what it does. |
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| MrDelanco Senior Member Joined: 12/11/2011 Location: United StatesPosts: 101 |
This is the second time you've stated this on the 4m; the first time was amusing. I agree the HHO topic should be taken up in another thread. Why don't you start one in "Other Stuff" and begin it by answering all my above questions? . . . . . Mac Hello Mac; This was the 1st time the other forum was the 2nd time , guess you read that one 1st. Now this topic on HHO will be saved for another forum and another day. About the boostcaps I posted that in the other forum. Regards Bob MrDelanco:Project Videos It is not only too know what it does but to understand how it does what it does. |
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| MrDelanco Senior Member Joined: 12/11/2011 Location: United StatesPosts: 101 |
Hi Perry; My system is comprised of several sub system's combined into one. There are several sources of recycled parts available too me. I have quite a few friends in several area's that stay in contact with me and what I am doing, they are always asking for my help and always offering items too me. The Maxwell caps came from public bus upgrades and I purchased them from Electronic goldmine's online store, by buying 100 of them I got a better price per unit. The Motor-Generator-Flywheel ups unit is an integrated component of my system and uses part of the earth's rotation to assist the flywheel's rotational motion this was a plus. It took me awhile to build the unit and getting it to work on a smaller scale took considerable inventive research on my part. Material strength has increased over the past decade and is found in all types of recycled items. Permanent magnets like Neodymium are up in cost, but I had bought my supply 3 yrs ago when they were cheaper, and by using smaller magnet's and improvising other components I was able to produce a working unit fairly cheap in cost. Flywheel Basics I setup my system to be supplemented by the wind not to totally rely on the wind. I also have 12 230 watt solar panels that charge and run the 24 volt side of the system during daylight hrs. I find I enjoy teaching the science of recycling to others. .....Bob MrDelanco:Project Videos It is not only too know what it does but to understand how it does what it does. |
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fillm Guru Joined: 10/02/2007 Location: AustraliaPosts: 730 |
This is where I would think 95% of the power is comming from , and its the frst time you have said that you have solar system of this size "2760W". From the start of the post it seemed as though you were saying the wind was supplying all your power, as nowhere in your block picture of your system does it show 2760W of solar comming in. This would easily account for over 10kW/H a day . What size Batt bank do you have? If the 24V Battery bank is not large enough to handle the solar burst effect of 1.4 to 1.6 x when the cloud edge effect happens , at those times you would be getting 140A+ hitting the Batts then thats what the 'Boost Caps" are good for absorbing large amounts of power quickly, I would think they would need to be in paralell or you would risk turning those caps into loud exposions. Did you design the Cap balance circuit? PhillM ...Oz Wind Engineering..Wind Turbine Kits 500W - 5000W ~ F&P Dual Kits ~ GOE222Blades- Voltage Control Parts ------- Tower kits |
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| MrDelanco Senior Member Joined: 12/11/2011 Location: United StatesPosts: 101 |
The solar side is spit into four(4)sections, three panels per charge controller and battery bank. There are four(4) large wet cell forklift battery units for the 24 volt side, each with it's own charge controller. I built and installed a auto circuit between the solar and the system that separates the solar. When the batteries are charged the solar dumps all it's output into the power grid through six(6) grid-tied inverters. I don't rely on the solar that much it's not reliable during cloudy or rainy days or snow cover, plus the trees have grown and shadow the arch of the sun at certain times during the day. I stated in the beginning I used solar and found it was not reliable. .Bob MrDelanco:Project Videos It is not only too know what it does but to understand how it does what it does. |
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| MrDelanco Senior Member Joined: 12/11/2011 Location: United StatesPosts: 101 |
I know enough about electrical circuits that there will be no explosions. The balance circuit is a standard design available from several sources, I customized a circuit design to meet my needs. .Bob 
MrDelanco:Project Videos It is not only too know what it does but to understand how it does what it does. |
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