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A method to make coils


By hvirtane, Section Homebrewed Electricity
Posted on Mon Jun 14, 2004 at 01:46:27 PM MST
I made some drafts how to form coils

directly on the stator disk.

These drafts are made for six magnets
and this method will have six coils
in one phase. The number of the magnets
is the same as the number of the coils
with these drafts.
(You can as well make the number
of coils different of the number
of the magnets.)

The same method will of course work
for any number of magnets.

First a picture of the method how to make the
coils of the wire. I got the idea
by reading about 'WindstuffEd''s generators.



So all the coils of a phase can be made
of one single wire piece. In practice
it is maybe often good to put many thin
wires in parallel instead of using one
thick wire, because it is easier to bend
a few thin wires than a single thick wires.

To make it three phase we need to have
two other phases 20 degrees from
the first one and from each other.
This will give 120 degrees phase difference.



For making these coils on the stator
I think that it is good to make
the stator disk so that the place where
the coils will reside is thicker than
the center part of the stator. Then the
loops outside the area of the magnets
will have room to make the stator flat.
For the wires it is good to make slots
or another possibility is maybe to use
some kind of tubes where to put the coils?
One more picture of the first phase.



One advantage of this method is that
you can get quite easily three overlaid
phases without making
the stator unnecessary thick?

You can get lots of wires
on the stator so that the
alternator can be made
with low RPM.

For the stator one good material is
industrial formica, good quality
plywood can also be used.

This method will suit to air core
stators and for stators with
laminates, too.

One disadvantage with this plan is maybe,
that when the coil number of one phase
is the same as the number of the magnets
the alternator might vibrate more than
such an alternator, which has got
different number of the coils from
the number of the magnets?

- Hannu

A method to make coils | 8 comments (8 topical)

Re: A method to make coils (none / 0) (#1)
by Tom in NH on Tue Jun 15, 2004 at 09:34:55 PM MST

Hi Hannu,
You know, I was thinking about almost exactly the same winding pattern as you except instead of running your wire back at the end, I intend to just keep going around again and again.

I know practically nothing about making generators and alternators, but it seems like your method should work, in theory anyway.

I am still some time away from actually trying this method because I am up to my elbows in a solar hydrogen project that needs lots of work, but we should definitely compare notes after we try the method out. Please keep me informed of your progress. You can email me: woods at ncia dot net.

--Tom Woods



Re: A method to make coils (none / 0) (#2)
by wayne on Thu Jun 17, 2004 at 11:50:59 AM MST

Hi Hannu

Nice thought and just making a wood stator 5" test right now. will try this method vs making a large loop and putting into the slots. Will use a rotor to cut the slots at 1/4" wide and 1/4" deep. Will see what happens soon.

Wayne



Re: A method to make coils (none / 0) (#3)
by wayne on Thu Jun 17, 2004 at 01:38:49 PM MST

opps spelling I mean Router. Bought a bit last night using a Rotor Zip tool seems good. Just have to make jig to keep the lines straight for each slot. I made a paper template then cut out each slot, then stuck paper on wood. Sprayed with paint now have a nice template to cut into. Will take pics at each stage.

Wayne

[ Parent ]



Re: A method to make coils (none / 0) (#4)
by hvirtane on Thu Jun 17, 2004 at 02:51:52 PM MST

Sounds nice.
Please post a picture of your tool, too.

Are you going to make it with air coils
or with laminates?

I've been thinking that an angle grinder
might work to cut through laminates easily...

- Hannu

[ Parent ]



Re: A method to make coils (none / 0) (#5)
by wayne on Thu Jun 17, 2004 at 09:46:21 PM MST

Hi Hannu

Well I started out with router and cutting slots 1/4" wide usind the bit and set the depth to 1/4". I cut 18 slots and one of the pieces in between broken off. The job didn't look to bad but was not happy with it. Tried to wire it up as a test using your method. I think it would take some time for 50-100 turns, but it works. Found the wire would go into or under the wood. Needs to be very smooth and no indents. Going to try another way friday, is to cut the center pieces with a band saw and glue them on at the right space. Would be nice to pour a mould but need a template first.If get time will show my results from tonight this weekend and my 6" and 8" Lenz Turbine, Ed would love to see it! Must be a easy way of doing this? More later

Wayne

[ Parent ]



Re: A method to make coils (none / 0) (#6)
by wayne on Fri Jun 18, 2004 at 08:49:26 AM MST

Hi
Here are the first few of what I did last night. One is the spray paint on 5" dia wood, and the other was the go lucky router job. Not happy with it. Going to try the other way by cutting out little traingles on band saw and glueing around the stator. Should look cleaner. Tonight I see if all goes well?

Wayne

[ Parent ]



Re: A method to make coils (none / 0) (#8)
by wayne on Fri Jun 18, 2004 at 08:52:19 AM MST

try again



[ Parent ]


Re: A method to make coils (none / 0) (#9)
by wayne on Fri Jun 18, 2004 at 08:53:22 AM MST

opps wrong order



[ Parent ]


A method to make coils | 8 comments (8 topical)
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