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Drive train

Direct drive, no gearbox

A gearbox multiplies generator speed and, with it, every vibration and every failure mode. Our rotors turn a three-phase permanent-magnet generator at rotor speed, so there is no oil to change, no seal to leak and one moving assembly instead of three.

Neodymium magnets and class-H insulation let the generator run hot without derating; the stator is potted against moisture and salt spray. The result is a drive train with a design life of 20 years and a single scheduled service item: the main bearing.

Topology
Three-phase PMSG, direct drive
Magnets
NdFeB, N38SH grade
Insulation
Class H, vacuum potted
Protection
IP54 nacelle, IP65 junction box
Technicians assembling a wind turbine nacelle in the workshop

Power electronics

The controller does the hard work

A turbine without proper control burns itself out in a storm or cooks its batteries in a week. Ours tracks the maximum power point, protects the battery and stops the rotor when it must.

MPPT tracking

Continuously adjusts load to hold the rotor at its optimum tip-speed ratio, harvesting 15–25% more energy than a fixed-load controller.

Three-stage charging

Bulk, absorption and float stages with temperature compensation, so lead-acid banks are not over-gassed and lithium packs stay balanced.

Dump load

Surplus energy is diverted to a resistive heater rather than dumped into the stator, keeping the generator cool when the battery is full.

Fail-safe stop

Over-speed, over-voltage, over-temperature and vibration triggers short the stator and apply the brake — no operator needed.

Safety

Two independent ways to slow down

Passive furling

The tail hinge is set at an angle to the rotor axis. As wind approaches the survival limit, thrust on the rotor overcomes the tail restoring force and the machine turns out of the wind on its own. No sensors, no actuators, nothing to fail.

Electromagnetic braking

Shorting the three generator phases creates a strong braking torque. Controllers apply it automatically on over-speed or over-voltage, and there is a manual stop switch at the tower base.

Above 10 kW the two systems are backed by a mechanical disc brake, and the yaw system holds the rotor at 90° to the wind in storm mode.

Load cases we design for

Normal operation3–25 m/s
Rated output11–12 m/s
Cut-out / furling14–18 m/s
Survival gust50–59.5 m/s
Design life20 years

Load cases follow IEC 61400-2 practice for small wind turbines. Test reports available on request.

Installation

Tower height beats model choice

Wind speed rises with height, and power rises with the cube of wind speed. Moving from a 6 m pole to a 12 m tower at a tree-lined site can double annual output — usually for less money than a bigger turbine.

Guyed pole · 6–12 m

Cheapest option, needs a 15 m radius of clear ground for anchors. Standard for cabins and monitoring sites.

Lattice tower · 9–24 m

Rises above tree lines and small buildings, small footprint, climbable for service. The usual choice for farms and telecom.

Monopole / rooftop

For tight sites and urban roofs. Requires a structural check and vibration isolation on the building frame.

Questions

Frequently asked

What average wind speed do I need?

For a realistic payback, 5 m/s or more at hub height. At 4 m/s a turbine still works, but the economics are marginal unless the alternative is diesel or no grid at all. We will model your actual site before quoting.

How loud is a small wind turbine?

Our horizontal axis models measure below 45 dB(A) at 20 m, roughly the level of a quiet conversation. Vertical axis units are quieter still at low wind but produce more mechanical noise at high speed.

How much maintenance is required?

One visual and fastener inspection per year, main bearing grease every 2–3 years, and a blade inspection after any severe storm. No oil changes, because there is no gearbox.

Can it connect to my existing solar system?

Yes. Hybrid controllers accept a wind input and one or two PV strings on separate MPPT trackers, sharing the same battery bank and inverter.

What is the warranty?

Standard warranty is 2 years on the turbine and controller, 5 years on the tower structure, with an extended 5-year drive train option. Terms are stated in the quotation.

Do you support OEM and ODM orders?

Yes. We produce under customer brands with custom paint, nameplates, packaging and manuals. Minimum order for OEM is 10 units per model.

Want the design file?

Power curves, single-line diagrams, foundation drawings and test reports — send one email and we will reply with the technical pack.

Request technical pack