For constructing the blades, we will use an ABS/PVC pipe. It is to note that we are making a small sized windmill and thus will incorporate all the things that are easily available at home. However, if someone doesn’t have a spare ABS pipe, it can be easily bought from a nearby hardware shop. A 6 inch thick and 24 inch long pipe piece would suffice for making the blades. Take the PVC pipe and cut the pipe into 4 equal pieces. The blades should be cut in the shape as shown in the figure. The best procedure for this is to cut one piece and make the rest keeping the first one as reference. Once done, make the surface and edges of the blades smooth using a sand paper, so that they don’t hurt the handler and also increase the efficiency of the blades.
The second step is to make a hub on which the blades will be attached. For this we will take an aluminum disk which is approximately 5 inches in diameter and 0.25 inches thick. Also we will need a device such a toothed pulley or a gear to attach the aluminum disk to the motor shaft. The blades and aluminum disc should be drilled and bolted together as shown in the figure. Then bolt the aluminum plate to the toothed device to complete the hub. Cover the side of the hub with bolt heads with any kind of covering such as vent cap as shown in the figure.
The third step involves mounting the hub assembly on the motor shaft. However, for this we need to make a motor assembly. Cut a wooden strap of appropriate length and fix the motor at one end of the wooden strap using jubilee clips or thin aluminum clamps. Also cut a PVC or any material pipe from the center to make a semi-circular covering for the motor to protect it from rain water and adverse weather. On the other end of the wooden strap attach the tail of the windmill. For this, cut an aluminum sheet into an appropriate size and attach it the wooden strap by making a slit and using an adhesive.
One can also make a tower for attaching the windmill on it. This can be done by using any iron pipe and floor flange and fixing it to the base of the windmill apparatus as shown in the figure. The tower of the mill will ensure that the unit is high enough to catch wind.
Once done, mount the blade and hub assembly on the shaft of the motor and clamp it. The mechanical part of the windmill is now ready and all that remains is to attach the batteries to the motor. Connect the batteries to the motor for storing the extra power generated. Once this is done, your windmill is ready for use. However there is one more very important device that needs to be attached to the windmill and that is the controller. A Controller is easily available in the market and is not at all expensive. The controller controls the voltage generated by the windmill and accordingly sends it to the batteries for storage.
With the prices of the electricity soaring high and everyone trying to save their hard earned money, a windmill is the best option for making a humble effort at home to save energy.