My daughter got a co-curricular school activity in early September about
renewable energy models. The students were tasked with making a model
depicting one of the three renewables: solar energy or wind energy or
hydroelectric energy. A link to a
sample video
was provided for some inspiration too. Included was also a reminder note:
The model can be non-working. (Emphasis was the school’s.)
We chose wind energy and decided to make a non-working model with a couple of
windmills, a house and farming land around it. As she and her mother started working
on making the actual model, I started wondering, “Can a working model be
made?”. I mean it seemed like just sticking a pinwheel fan on a dynamo
generator should do the trick of lighting up a single measly LED! How hard
could it be, right? As it turns out, it is actually quite a pain to make a
working model of a windmill out of just those 3 things! I list here all of my
failed attempts to make a working “windmill” with the help of a ceiling fan
providing the required wind.
Attempt 0: Her mother likes my “grand” idea for the
“project” and agrees to source the electronics components. She gets 10 green
LEDs, wires and two motors used in toy cars (cuboid shaped with a red plastic
end). As it turns out, this motor can be used as a generator (the same working
principle in reverse) but I did not know this fact at that time so I ask her
to source a generator specifically. She gets two dynamo generators similar to
those used in bicycles (I guess), one of which we use till the end of this
“project”. (As it turns out, the red one could not have worked for our
purposes anyway!)
Attempt 1: We make a couple of pinwheels (we discard the idea
of a 3 blade proper-looking windmill quite early on because we can not make it
aerodynamic enough!) and source a plastic stub from Sakura’s toy collection (a
kids’
science kit for electrical stuff) to fix the pinwheel to the generator’s axle. We switch on the ceiling fan,
turn it to max and let the pinwheel rotate away. The LED does not turn on. No
surprise there!
Attempt 2: I search about what can be done and settle on
Gemini’s suggestion to spruce up the pinwheel to make it more sturdier and
rotate faster and even use gears to rotate the axle of the generator even
faster so that enough voltage is generated to light up the white LED.
As it turns out, these LEDs need ~3V to turn on and no way was the pinwheel’s
rpm enough to generate any voltage close to that. I buy a
toy gear set
and make a cardboard enclosure for the gear mechanism but at the end of the
day the pinwheel does not rotate the geared generator at all. This is because
(it is obvious now) more power is required to turn a 5:1 gear set than just
the generator’s axle directly. So this is a complete failure.
Attempt 3: I am back to the pinwheel directly attached to the
generator’s axle. I finally “painstakingly” use a battery tester to measure
the voltage being generated by the generator and it is a disappointing ~0.6V!
The 5:1 gear box idea was quite good as it would have really given ~3V to
light up the LED if the pinwheel had rotated as required. Another idea
strikes: let me replace this bulky generator with a sleek drone motor (which
can also be used as a generator). Another day, another order for
the drone motors
and while I am at it, let’s buy a proper
multimeter
too.
With 4 drone motors in hand, I make a smaller pinwheel for this smaller
generator and no prizes for guessing, this also does not work because the
voltage generated now is measly ~0.06V… 10× lower! Arrgh! But then it is
post-priori obvious that this would not have worked because these drone motors
are rated for very high rpm (~50K) for ~3.5V and the bulky generator is rated
for just ~5K worth rpm for ~12V so from pinwheel’s low (100-500) rpm, no
wonder the voltage drops so drastically. (The “red motor” mentioned above
would not have worked either exactly for this reason.) This is utter disaster.
Attempt 4: Back to the pinwheel directly attached to the
bulkier generator which is happily generating ~0.6V at max ceiling fan speed.
Gemini finds technical specifications of this generator and “calculates” from
the generator’s 0.6V that the pinwheel must be performing ~150 rpm, which is
nice to know but utterly unhelpful for my purposes! Because the rpm of the
pinwheel cannot be increased any further so I need to boost 0.6V to 3V. I ask
Gemini for simple DC voltage step up circuits. It talks about “Joule thief” circuit and suggests a
ready-made circuit
to buy. This circuit requires minimum input voltage of 2V so I call it quits
on sourcing another product that might not work! Also there is no way of
making a Joule thief circuit on my own as I am not salvaging a ferrite core
and transistor from anything in my surroundings in a million years.
Joule Thief Circuit Video Tutorial
Attempt 5: After having a few sleepless nights with
ever-increasing urge to get this “windmill” light up a single LED, I decide to
follow the maxim: Go Big or Go Broke! I order ₹4K worth of
electronic components
(including the
Arduino Uno board kit
for later use by Sakura, hopefully!). With the above tutorial video running in
loop in front of me and having ransacked Sakura’s toy closet to get my hands
on two ring magnets (instead of the ferrite core), I cobble up this JT circuit
and with a “dead” AAA cell, it lights up the red LED (to “match” with the red
ring magnets)! WOW! So this circuit is definitely boosting 1V to 3V.
Now is the moment of truth. The moment way past the actual co-curricular day
where Sakura had to present her non-working model. The moment
when I replace the cell by the “windmill”: WHhhaaattt!!! WHhhyyyy??? The LED
does not light up. So apparently, this circuit is not able to boost 0.6V to
3V or was it just luck that the magnet “worked” with the AAA cell. Anyway, we
now know what needs to be done.
Attempt 6: I order the final missing component: the
ferrite core. What’s ₹400 more having spent ₹4K already? They arrive in a pack of 5 after
what seems like ages. I pick out one, wrap wires around it (in a
slightly different way) and remake the JT circuit. It works with the dead AAA cell. Good!
Now again is the moment of truth. Nothing else matters because this is the
brink of all that has transpired for the last few weeks. This is the moment
when I replace the dead cell with the live “windmill”…
Our faces light up along with the red LED!
The final setup is shown below with a green LED to match the colour scheme of
the ferrite core and the overall theme of green energy.
Finally, we should take stock of what all we did and what all we spent to
achieve that. We did make a Joule thief circuit (barely worth ₹200) to boost
low voltage output of a generator (~0.6V) powered by a “windmill” to a level
that can turn on a standard (green, red, white) LED requiring ~3V. As for what
we actually spent to get there, here is the itemized breakdown:
Motors, LEDs, wires – ~₹400
Toy gear set (unused) – ~₹350
Multimeter – ~₹1400
Electronics components – ~₹4000
Ferrite cores – ~₹400
Project time – ~1 Month
-
Sakura’s lit up face when windmill worked – Priceless
Here’s the proper finale for those who have reached till the end.
Windmill with Joule Thief Circuit
Next order