As I finished moving the last of about 150 - 200 tons of manure, Anybody need unobtainium for over unity projects? I think I found its source!
I though about it and I am going to repair the one blade that ripped out, being its actually completely intact other than the tear spot, and make a plaster negative of it and cast a set out of aluminum.
I have experience with aluminum smelting and can build a smelter easily. Been wanting to justify building one for years too!
All I need is the blade shape for the mold forming process.
So what do you guys think, should I go cast aluminum blades next?
The hub took me about an hour to make so no big loss there. The shaft is bent about a 1/4 inch off center so its done for.
I took the gear box apart this morning and the sudden stop apparently striped the gear teeth off the main drive gear right in one spot too.
If it had been the driven gear on the motor I would have suspected a catastrophic over spin did in the blades but when the drive gear losses teeth in one single area it shows it stopped so suddenly the driven gear had enough motor momentum going to over power it.
Well now I have a reason to rewind the big Getty's 5 kw servo to put out 200 volts at 1000 RPM instead of 50 volts per 1000 RPM.
That has a 1 7/16 inch shaft so I doubt it will bend during a 20 ft fall!
Actually I am going to put an anti lift off locking ring on the center pivot with the next design.
Never needed one in 20 years of home made generator experiments but now its going to be standard after this.
Wind Max is the blade manufacture by the way.
I did some searching last night and found several others that gave them a bad review due to exactly the same manufacturing defect causing them to have a blade come apart at a speed and load well within its rated working range.
So my incident is not a random manufacturing flaw apparently. At least I did not pay several thousand dollars for my gen set that got knocked down after one week of run time!