Big Boss Box
Windmill Energy
EF 152
Report
Elias Askins
Jerrika Hall
Caroline Sneed
Raphael Onwzuruigbo
Overview
The purpose of the project was to bring a team of four engineers together to construct a
windmill generator that could produce enough electricity to light a small LED bulb. The device
could be constructed with any resources available as long as the finished product’s net worth did
not exceed the budget of $40. Though the actual design of the project was left up to each group,
copper wire and magnets were necessities in order to construct the actual “generator” component
of the project; this part was necessary to generate the electric field necessary to light the LED.
This field, in a simple context, is created by moving a strong magnetic source through hoops of
wire (or vice versa). Using this concept as a foundation, the team constructed a device that
would allow this process to take place, unaided, with a proper source of wind.
Design Process
To begin our design process, we first brainstormed. Our brainstorming included designs
for the blades of the windmill, type of wiring, and layout of the generator as a whole. We had to
choose whether we would use large or small blades, the shape of each blade, and the amount we
would use. However, the biggest question was how we would effectively create a generator.
Since no one had made a generator before, we looked on You Tube for examples. Once we got
an idea of what we actually were suppose to be doing, we decided to go to work. The first piece
of our project we focused on was the generator. We first stripped the enabled coating off the end
of three different wires, connected them, and wrapped them around a Pringles can. We used the
volt meter to check the resistance and voltage of our first generator. The resistance was too high
and we hardly received any voltage, so we decided to start over. Next, instead of scrapping the
wires with scissors and sand paper, we melted the wires together by soldering to ensure all the
coating was off. This did not work, and gave us similar results to our first generator. We came to
a conclusion that the result of the high resistance and low voltage was due to the connection of
the various wires, so we decided to use one long wire. Also in the process we decided to wrap
the wire vertically and horizontally around the Pringles can to receive a higher voltage. We
positioned four magnets horizontally inside of the Pringles can to optimize the voltage. To
capture the most air, we decided to use small wooden rounded blades that we positioned at angle
for our windmill. Through trail and error, we created the best possible way of making our
generator.
Description of Device
Our final device’s structure is a plexi-glass box raised by a few
scrap pieces of wood to allow extra room for our fan’s radius. We guled
our generator on the inside of it with hot glue. Our generator consists of
a Pringles can, wrapped both lengthwise and circumference-wise in one continuous enamel
covered wire. We wrapped it both ways in order to maximize the
capture of electrons.
The windmill part of our project came from an old Christmas
decoration used to capture heat from candles. We transformed this
old decoration by disassembling it, then gluing the propellers into
place, and attaching the entire piece to the metal rod. The magnets
are glued to the other end of this metal rod (which goes
through the ball bearing). So, when the fan spins, so do the
magnets. The magnets extend into the Pringles can,
completing the generator.
Estimated Efficiency
Bill of Materials
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
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Pringles can
Plexi-glass box
Windmill Wood
Wire
Magnets
Metal Rod and Ball Bearing
Scrap Wood
Hot Glue
Total
$0.75
$15.00
$5.00
$10.00
$3.00
$5.00
$1.00
$0.25
$40.00
Conclusions
In the end, our group was successful in the creation of our windmill and the generation of
electricity. Individually, we each took away different learning experiences. For instance, some of
us learned what a generator even was and how they work. We learned how to position the
magnets and the wire to optimize the generator performance. We had the chance to use new tools
such as the soldering iron. As a team, we all learned about various types of wires, and what to do
in order to minimize resistance in an electrical circuit. We also were able to practice working
together through frustration while we sorted through all of our wire complications.
References

“Ultra-Simple Electric Generator”
William Beaty
amasci.com/coilgen.html

Dr. Arazi’s lecture notes

Professor Schleter & Dr. Bennett

YouTube.com