Clear Labeling Helps Brake the Wind Generator

Not so very long ago, exchanges like the following were all too common in our cabin:

“Stand by the brake, and turn it on as soon as I tell you!”

“Wait, turn it on? Do you mean turn the brake on, or—”

“NOW!”

“Wait! Am I turning the brake on or off?”

“What? Wait, don’t turn it on, there’s a gust!”

“What?”

Trying to brake the wind generator in high winds is a difficult job. It’s a two-person process, as one stands in the cabin corner at the brake, while the other stands at the window, or, more often, out on the porch, watching for a moment when the wind generator is not furled (turned sideways to the force of the wind). To safely brake the blades, the generator needs to be normal (not furling), and moving slowly enough to stop within 30 seconds. This made for a very narrow window of opportunity, one that accommodates no confusion.

The confusion is caused by semantics: the brake turns on, the wind turns off, and vice versa. The watcher, waiting for a short opportunity, usually says something like “turn IT off,” which doesn’t clarify anything.

That doesn’t happen anymore, since we found a solution.

labeled brake switch

Even the most panicked person should be able to interpret this switch (Photo: Mark Zeiger.)

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Building a Homemade Wind Generator Brake

Our home wind generator features a charge controller with a regulation feature, which the manufacturer claims eliminates the need for an actual brake for the mechanism. When charging reaches a preset voltage level, the prop slows itself, and will eventually stop, if the wind is not too strong.

In practice, I find that a brake is an essential back up to this feature. There are many situations when the generator must be stopped completely. To do this, I built my own brake.

brake switch insides

It’s nothing more than a simple double-pole light switch. Yellow tips are capped pigtails coming off the main lines. (Photo: Mark Zeiger.)

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