Thoughts of not paying electric bills dance through our heads most likely on a daily basis but questions run wild. How about a closer look?

The beginning steps in the assembly of a Wind Turbine system is the Hub. The rotor is the blades and the hub together. It is the part that holds the blades to the main shaft of the turbine. Slight differences in turbines are characterized by the type of blade attachment and pitch mechanisms applied by manufacturers specifications.

The hub is usually cast in a strong iron alloy, a mix of composite compounds and cast iron. Because of the unusual shape, which is difficult to make in any other way, it is convenient to use cast iron moldings. In addition, the hub must have be resistant to metal fatigue since it is exposed to the climate elements and doing work.

It is for these reasons that the hub is also one of the most costly parts during the manufacturing process of a wind turbine system. Thanks in part to the wind tunnel research done by NACA (National Advisory Committee for Aeronautics) designs were catalogued for use as reference for the best shaped blades to be used in the designing process. They are very aerodynamic.

Blade attachments are usually attached by bolts and is critical they are correctly installed to prevent the risk of a blade falling off especially when in operation. The blades are sharp so caution must also be taken when handling them during the assembly process. They are not attached until the turbine is mounted on the tower.

Small and residential wind turbines have direct drive (alternators or generators) motors. The speed of the blades’ rotation causes a fast spinning of the shaft inside the generator, producing AC (alternating current) electricity which is captured by the Rectifier and converted to DC (direct current) and sent to the battery banks.

Advantages of the direct drive generators or alternators is they drive directly with the rotor and do not require oil, other part changes or frequent maintenance. Generators come in various sizes, relative to the output you wish to generate.

PM (permanent magnet) alternators are designed with use of powerful ‘neodymium’ permanent magnets and are most popular since they eliminate the need for replacement and are more compact and lightweight, produce less noise, cheaper to produce and manufacturers can offer them at competitive prices. A disadvantage is the ‘wild’ three phase AC output that needs to be immediately rectified to the desired DC battery bank voltage due to high speed winds and do require higher torque to start.

The alternator can be designed to produce power at low speeds, eliminating the need for a speed-increasing gearbox. It’s output is usually a three phase AC and goes to the Rectifier which are all embodied within a nacelle. Voltage is generated whenever the rotor is turning. Torque is important to start the generator/alternator from a stopped position.

A Rectifier operates like a diode. It is a device that converts AC to DC and allows electrical flow in only one direction. It sends the electricity that is produced to a safety disconnect switch –> then to the charge controller –> the battery banks –> through the inverter –> AC loads such as the computer, refrigerator, T.V. etc.

DC generators are no longer being used in new wind turbine systems. They are assembled with a armature containing wound copper wire spinning in a magnetic field. This magnetic field may be created with a coil of wire or magnets mounted in the housing of a generator. New designs are created each year.

Induction generators are used for utility sized wind turbine systems linked to a grid and with rotors greater than 10 meters in diameter usually found on wind farms for delivery to a larger population. A helicoptor can actually land on one these behemoth sized wind turbines!

I hope you have enjoyed exploring and learning about the inner parts and systems of a Wind Turbine system and it's accompanying language. I would prefer that we at least have basic knowledge when exploring the idea of venturing into our own energy management project. Read related --> here and there.

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