How to make a controller for a wind generator with your own hands: device, principle of operation, assembly diagram

The mechanical design of a wind generator in its pure form is only part of a complete wind power plant. A fully usable system, in addition to the mechanical structure, also has a number of electronic components.

For example, a controller for a wind generator is required - a device functionally designed to stabilize the battery charge parameters during the operation of the wind turbine.

Let's figure out what functions the device performs and provide diagrams for assembling the controller yourself. In addition, we will outline the features of the work and the advisability of purchasing a Chinese electronic unit for a windmill.

Wind generators and battery charge controllers

If it is quite possible to make a mechanical windmill yourself, is it possible to make a windmill controller yourself?

In order to have some idea about wind generator controllers and successfully reproduce such equipment with your own hands, basic information about these devices will not be superfluous.

The controller that serves batteries is primarily designed to control the battery charging process. This is its main function, but it should be conditionally divided into a number of subfunctions.

For example, one functionality monitors the charge current and self-discharge current. Another functionality implements actions aimed at measuring temperature and pressure. The third is responsible for compensating for the difference in energy flows when the battery is charged simultaneously with the current consumption by the load.

Battery charge controller for a low-power wind generator. Control of some system parameters is carried out through a built-in LCD display

Industrially manufactured devices are equipped with full functionality. But the same cannot be said about amateur designs. Devices made on the basis of simple circuit solutions at home with your own hands are controllers that are far from perfect models.

Nevertheless, they work and allow you to operate quite productively different types of wind generators. As a rule, homemade designs implement only one function - protection against overvoltage and deep discharge.

One of the many variations of controllers for wind turbines, made by yourself. Such designs are distinguished by simple technical solutions and simple installation.

Why is the introduction of a controller into a wind turbine system a must?

Because in the mode of energy replenishment of the battery without using a controller, unpleasant consequences should be expected:

1. Degradation of the battery structure due to uncontrolled chemical processes.
2. Uncontrolled increase in pressure and electrolyte temperature.
3. Loss of battery charging properties due to the long-term discharge taking place.

The charge controller for a wind turbine circuit is usually made in the form of a separate electronic module. This module is removable and quickly disconnected. Industrially manufactured devices are necessarily equipped with an indication of modes and states - light or visually transmitted through a display.

In practice, two types of devices can be used: those built directly into the wind generator housing and those connected to the battery.

Circuit solutions for DIY assembly

For all the time since the appearance of the first homemade windmills the number of controller circuit solutions has increased many times over. Many of the circuit designs are far from perfect, but there are some options that you should pay attention to.

For domestic use, of course, simple schemes that require little financial investment, are effective and reliable are relevant.

Based on these requirements, you can start with a controller for a wind generator, created on the basis of car relay regulators. The circuit uses both relays with a negative control contact and relays with a positive control contact.

This option attracts with a small number of parts and simple installation. You only need one relay, one power transistor (field effect), one resistor.

A controller diagram drawn by a certain electronics engineer with his own hands. Everything here is simple and clear without unnecessary words. Actually, as in the manufacturability of the solution itself. Minimum parts – maximum savings (+)

The circuit is called “ballast”, since it uses an additional load in the form of an ordinary incandescent light bulb. Thus, the list of parts will be replenished with one more element - a lamp.

A 12-volt automotive lamp (or several lamps) is used, depending on the power of the system. It is also permissible to use a different type of load resistance instead of this element: a powerful resistor, an electric heater, a fan, etc.

Operation of the “ballast” circuit with a minus

The action of an automobile relay-regulator is directly related to the charge level of the battery. If the voltage at the battery terminals rises above 14.2 volts, the relay is activated and opens the negative circuit of the power transistor.

In turn, a transition opens on the transistor, connecting the direct incandescent lamp to the battery. As a result, the charging current is discharged through the filament of the incandescent lamp. When the voltage at the battery terminals decreases, the process is reversed. This ensures a stable battery voltage level is maintained.

How does a “ballast” circuit with a plus work?

A slightly modernized version of the “ballast” charge controller for a windmill is the second circuit on a relay regulator with a positive control contact. For example, relays from VAZ cars are suitable.

The difference from the previous circuit is the use of a solid-state relay, for example, GTH6048ZA2 for a current of 60A instead of a transistor. The advantages are obvious: the circuit looks even simpler and at the same time has greater reliability and efficiency.

Another simple circuit design solution for assembling a wind generator battery charge controller. The efficiency and reliability of the circuit is increased due to the use of a solid-state relay (+)

The peculiarity of this simple solution is the direct connection to terminals wind turbine generator battery. The conductors of the charge controller are also “planted” directly on the battery contacts.

In fact, both of these parts of the scheme are in no way connected with each other.Voltage from the wind generator is supplied to the battery constantly. When the voltage at the battery terminals reaches 14.2 W, the solid state relay connects the load to reset. This way the battery is protected by the device from overcharging.

Here, not only an incandescent lamp can act as a ballast load. It is quite possible to connect any other device designed for a current of up to 60 A. For example, an electric tubular heater.

What is also important in this circuit is that the action of the solid-state relay is characterized by a smoothly increasing amplitude. In essence, the effect of a professionally manufactured PWM controller is evident.

A complicated version of the controller circuit

If the previous version of the circuit design for the battery charge controller only resembles a PWM (pulse width modulation) device, here this principle is implemented specifically.

This controller circuit for a windmill with a three-phase generator has some difficulties, since it involves the use of microcircuits - in particular, operational amplifiers on field-effect transistors as part of the TL084 assembly.

However, on the circuit board everything does not look as complicated as on a piece of paper.

Circuit solution for assembling a controller with your own hands, using the TL084 microassembly. The operating principle is also built using a relay to switch modes, but it is possible to adjust the cut-off points (+)

Just as in previous solutions, a relay is used as a switching element for the ballast load. The relay is designed to work with a 12-volt battery, but if desired, you can choose a 24-watt model.

The ballast resistor is made in the form of a powerful resistance (winding on nichrome ceramics).To adjust the operating voltage range (11.5-18 W), the circuit uses variable resistors included in the control circuit of the TL084 microelectronic assembly.

This windmill battery charge controller works as follows. The three-phase current received from the wind generator is rectified by power diodes.

A constant voltage is generated at the output of the diode bridge, which is supplied to the input of the circuit through relay contacts, an additional diode, a battery, and then to the in-circuit stabilizer (78L08) and to the input of the TL084 assembly.

The moment the trigger switches to one of the states is determined by the values ​​of the variable resistors (Low V and High V) of the lower and upper voltage thresholds.

As long as there is a voltage at the battery terminals that does not exceed 14.2 volts (meeting the R High V setting), charging is performed. As soon as the values ​​​​change upward, the operational amplifier TL084 supplies a signal to the base of the transistor, which controls the relay.

A do-it-yourself product based on the microassembly scheme TL084. Everything is extremely simple, even instead of a high-quality printed circuit board, a board for surface mounting was chosen. Homemade designs always make us happy with moments like these.

The relay is activated, the power circuit of the circuit is broken and shorted to the ballast resistor. The ballast reset occurs until the battery is discharged, close to the Low V variable resistor setting value.

Once this value is reached, the second operational amplifier TL084 switches the circuit to the reverse state. This is how the controller works.

Chinese electronic alternative

Making a wind generator controller with your own hands is a prestigious matter.But given the speed of development of electronic technologies, the meaning of self-assembly often loses its relevance. In addition, most of the proposed schemes are already obsolete.

It turns out cheaper to buy a ready-made product, made professionally, with high quality installation, using modern electronic components. For example, you can purchase a suitable device at a reasonable cost on Aliexpress.

The range of offers on the Chinese website is impressive. Controllers for wind generators for various power levels are sold at prices starting from 1000 rubles. Based on this amount, in terms of assembling the device with your own hands, the game is clearly not worth the candle.

For example, among the proposals of the Chinese portal there is a model for a 600-watt windmill. The device costs 1070 rubles. Suitable for use with 12/24 volt batteries, operating current up to 30 A.

Quite a decent, Chinese-made charge controller designed for a 600-watt wind generator. Such a device can be ordered from China and received via mail in about a month and a half

A high-quality all-weather controller housing measuring 100x90 mm is equipped with a powerful cooling radiator. The housing design complies with protection class IP67. External temperature range from – 35 to +75ºС. On the housing there is a light indication of the wind generator state modes.

The question is, what is the point in spending time and effort assembling a simple structure with your own hands, if there is a real opportunity to buy something similar and technically serious?

Well, if this model is not enough, the Chinese have some really cool options. Thus, among the new arrivals there was a 2 kW model with an operating voltage of 96 volts.

Chinese product from the new arrival list. Provides battery charge control, working in conjunction with a 2 kW wind generator. Accepts input voltage up to 96 volts

True, the cost of this controller is already five times more expensive than the previous development. But again, if you compare the costs of producing something similar with your own hands, the purchase looks like a rational decision.

The only thing that confuses us about Chinese products is that they tend to suddenly stop working in the most inopportune cases. Therefore, the purchased device often has to be brought to fruition - naturally, with your own hands. But this is much easier and simpler than making a wind generator charge controller yourself from scratch.

For lovers of homemade products, our website has a series of articles dedicated to the manufacture of wind generators:

1. Do-it-yourself wind generator from a car generator: wind turbine assembly technology and error analysis
2. How to build blades for a wind generator with your own hands: examples of self-made wind turbine blades
3. Do-it-yourself wind generator from a washing machine: instructions for assembling a windmill
4. How to calculate a wind generator: formulas + practical example of calculation

Conclusions and useful video on the topic

The desire to make equipment for home use with your own hands is sometimes stronger than the simpler solution - buying an inexpensive device. See what came out of this in the video:

Assessing the prospects for manufacturing electronics on our own, regardless of its purpose, we have to face the idea that the age of “homemade” is coming to an end.

The market is oversaturated with ready-made electronic devices and modular components for almost every household product.Amateur electronics engineers now have only one thing left to do - to assemble home construction kits.

Do you have anything to add, or do you have any questions about assembling and using controllers for a wind generator? You can leave comments, ask questions and add photos of your homemade products - the contact form is in the lower block.