📄 windmeter - anemometer by infidigm.htm
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<H1 align=center>Windmeter / Anemometer by <A
href="http://www.infidigm.net/">Infidigm</A></H1>
<HR>
<H2>Overview</H2><A
href="http://www.infidigm.net/projects/windmeter/windmtr.jpg"><IMG height=310
src="Windmeter - Anemometer by Infidigm.files/windmtrs.jpg" width=250
align=right></A>
<P>The Windmeter is an anemometer designed to measure and record wind speed
distribution from 0 to 17+ meters per second. It was designed for high
reliability, ease of construction, and for a wide environmental range. Data is
logged over a period of 30.46 days (1/12 of a year), and then saved for 11
months. The data can be retrieved with a laptop computer any time within the 12
months of logging. The Windmeter is self-powered by a solar pannel and battery.
Calibration of the Windmeter can be done against a car's speedometer or better
yet a GPS receiver. The Windmeter should cost you under $300 Can. to make.</P>
<P>Here is an example of <A
href="http://www.infidigm.net/projects/windmeter/sample1.xls">Actual Data</A>
that the Windmeter generates!</P>
<H3>Skills Required</H3>
<UL>
<LI>General Electronic Knowledge
<LI>SMD Soldering
<LI>PCB Prototyping (Single layer)
<LI>General Mechanical Knowledge
<LI>Wood working / power tool / hand tool usage </LI></UL>
<H2>Mechanics of the Windmeter / Anemometer</H2>
<H3>Description</H3>
<P>The Windmeter / Anemometer is constructed from common parts and supplies. The
design is simple and easy to build. The internal frame is made of wood and the
external moving parts are plastic and metal. All electronics are housed inside
the Windmeter and thus protected from weather. The only difficult part to get is
the MAXI Kinder surprises. They are available at Christmas and Easter or all
year from a specialty store listed in the parts list. The rotating assembly
rides on two standard <B>shielded NOT sealed</B> roller blade bearings. Shielded
bearings have less friction than sealed. Replacement roller blade bearings are
available at most sports stores.</P>
<H3>Assembly</H3>
<P>Read the entire document before beginning construction. Complete the circuit
board first before the making and assembling the mechanical parts of the
Windmeter. If serious problems arise during construction, re-read the entire
document again. If this fails to solve your problem you can email me at "drwho
<I>at</I> infidigm <I>dot</I> net". I may not respond to all questions.</P>
<TABLE cellSpacing=5 cellPadding=5 border=0>
<TBODY>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step1.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step1s.jpg"
width=115 align=right></A> <B>Step 1</B> Begin by cutting the following
pieces out of the ply-wood as shown.</P>
<UL>
<LI>(1) piece 4.5" x 5.5".
<LI>(1) piece 3.5" x 4".
<LI>(2) pieces of 10.5" x 4" x 6.5" x 5.5". The 10.5" and 6.5" sides
form the longest sides and in parallel. The 5.5" side is a 45 deg.
cut.<BR></LI></UL>Pre-drill 8 holes in the ply-wood for the screws as
shown.<BR><BR></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step2.jpg"><IMG
height=99 src="Windmeter - Anemometer by Infidigm.files/step2s.jpg"
width=115 align=right></A> <B>Step 2</B> Screw the pieces together with
8-1.25" screws.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step3.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step3s.jpg"
width=115 align=right></A> <B>Step 3</B> Drill 4 holes in the wooden
assembly, 2 in each side, 3/4" from the edge and 1.75" from the corner
with a 5/16" drill bit.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step4.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step4s.jpg"
width=115 align=right></A> <B>Step 4</B> Slide the wooden assembly down
the pipe so that the top of the pipe is 13.25" from the top of the wooden
assembly. Be sure that the pipe is square to the wooden assembly and that
the 45 deg side touches the pipe. Re-drill the holes in the wooden
assembly to go through into the pipe. Mount the wooden assembly to the
pipe by inserting the 5" x 1/4" bolts though the holes and tighten the
nuts.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step5.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step5s.jpg"
width=115 align=right></A> <B>Step 5</B> Mount the Solar panel as shown
with the same 8-1.25" screws.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><B>Step 6</B> Drill a 1/4" hole in the side of the pipe, just below the
wooden assembly for the wires for the solar panel. (See Step 4
picture.)</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step7.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step7s.jpg"
width=115 align=right></A> <B>Step 7</B> Using a compass, draw two 3"
circles on the ply-wood. Cutout the circular shapes with a jig-saw and
then sand them so they will fit in the 3" pipe.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step8.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step8s.jpg"
width=115 align=right></A> <B>Step 8</B> Draw a line along the diameter of
one of the cutouts. Mark for drill holes at the center and at a 1/4" from
both sides along the diameter.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step9.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step9s.jpg"
width=115 align=right></A> <B>Step 9</B> Clamp the two cutout pieces
together so the edges are flush. Place the marked one on top. Drill 3 1/4"
pilot holes through both pieces.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD><BR>
<P><A href="http://www.infidigm.net/projects/windmeter/step10b.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step10bs.jpg"
width=115 align=right></A> <A
href="http://www.infidigm.net/projects/windmeter/step10a.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step10as.jpg"
width=115 align=right></A><B>Step 10</B> Drill the center hole with a 7/8"
wood bit. Do not go all the way through. Drill just deep enough so that
half of the 608 bearing sits inside the wood as shown.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step11.jpg"><IMG
height=85 src="Windmeter - Anemometer by Infidigm.files/step11s.jpg"
width=115 align=right></A> <B>Step 11</B> Now drill out the three holes
with a 1/2" drill bit. Their should be no wood left between the outside
holes and the outside of the 3" cutout.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step12.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step12s.jpg"
width=115 align=right></A> <B>Step 12</B> Drill another 1/2" hole 90 degs
to the others to allow the wires to pass through the cutouts.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step13.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step13s.jpg"
width=115 align=right></A> <B>Step 13</B> Cut 2 pieces of 1/2" wooden
dowel to 6" long. Mark measurements on the dowels as shown.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD><BR>
<P><A href="http://www.infidigm.net/projects/windmeter/step14b.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step14bs.jpg"
width=115 align=right></A> <A
href="http://www.infidigm.net/projects/windmeter/step14a.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step14as.jpg"
width=115 align=right></A><B>Step 14</B> It is necessary to glue the
assembly together inside the pipe so that it will easily slide in and out.
Insert one of the circular cutouts with the bearing notch facing out. This
cutout will now be called the bottom cutout. Slide it three inches into
the pipe. Place the two 1/2" wooden dowels down though the bottom cutout.
Now pass the top remaining cutout through the dowels to just above the
7/16" markings. You should have something that looks like the left
picture. Apply epoxy to the both dowels at the top 7/16" markings. Slide
the top cutout overtop of the 7/16" markings. Slide the whole assembly
into the end of the pipe as shown in the right picture. Be sure that the
upper cutout is square to the pipe and that the dowels are still in the
right place. Wait 15 minutes for the epoxy to harden.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step15b.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step15bs.jpg"
width=115 align=right></A> <A
href="http://www.infidigm.net/projects/windmeter/step15a.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step15as.jpg"
width=115 align=right></A><B>Step 15</B> Remove the assembly and re-insert
the opposite way with the top in first. Put the bottom cutout part way
into the pipe as shown in the left picture. Apply epoxy to both dowels at
the bottom 7/16" markings. Slide them down until they are flush with
bottom cutout as shown in the right picture. Be sure that the cutout is
square to the pipe. Wait 15 minutes for the epoxy to harden.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step16.jpg"><IMG
height=154 src="Windmeter - Anemometer by Infidigm.files/step16s.jpg"
width=115 align=right></A> <B>Step 16</B> Mount the electronic circuit
board to the assembly as shown with the hall effect sensor facing the
5/16" shaft. Try to keep the hall effect sensor center around the 5/16"
shaft. Space the board 3/16" away from the 1/2" dowels. Be careful that
the board will clear the pipe when the assembly is inserted into the
pipe.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step17.jpg"><IMG
height=93 src="Windmeter - Anemometer by Infidigm.files/step17s.jpg"
width=115 align=right></A> <B>Step 17</B> Cut a piece of 3/16" x 1" wood
to 3.5" in length. Epoxy the piece flush to the top of the 1/2" dowels,
opposite the circuit board. Wait 15 minutes for the epoxy to harden.
Insert the assembly into the pipe until the 3/16" x 1" wood piece catches
the top of the pipe. Mark the pipe where the piece touches. Cut one notch
on each side of the pipe, 1" deep. The assembly should now slide flush
into the pipe as shown.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step18.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step18s.jpg"
width=115 align=right></A> <B>Step 18</B> Cut the 5/16" steel rod to 7" in
length. Put a M8-1.25mm thread on one end of the 5/16" rod. Make the
threads about 1" in length.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step19.jpg"><IMG
height=153 src="Windmeter - Anemometer by Infidigm.files/step19s.jpg"
width=115 align=right></A> <B>Step 19</B> Destroy the third 608 bearing by
crushing it in a vise. Only the inner race is needed for the next step.
Epoxy the inner race to the 5/16" shaft 2.5" down from the threaded end.
Epoxy the magnet in place with the NORTH pole facing out. Be sure that the
magnet is directly in front of the hall effect sensor with the shaft in
place.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step20.jpg"><IMG
height=153 src="Windmeter - Anemometer by Infidigm.files/step20s.jpg"
width=115 align=right></A> <B>Step 20</B> Epoxy the two 608 bearings in
place in the wood. Slide the 5/16" shaft in place to align the bearings.
Try to keep the bearings as centered as possible in the 7/8" cutout. Be
sure that no epoxy runs down into the inner race or it will destroy the
bearings.</P></TD>
<TD width=100></TD></TR>
<TR>
<TD width=100></TD>
<TD>
<P><A href="http://www.infidigm.net/projects/windmeter/step21.jpg"><IMG
height=86 src="Windmeter - Anemometer by Infidigm.files/step21s.jpg"
width=115 align=right></A> <B>Step 21</B> Take the 4" PVC pipe cap and
mark the exact center. Drill a 5/16" or 11/32" hole in the center. (What
ever size will fit the 5/16" shaft the best.)</P></TD>
<TD width=100></TD></TR>
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