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RACA Stator Update
By WXYZCIENCE, Section Mechanical Posted on Thu Oct 19th, 2006 at 01:55:24 AM MST
Cooling the Stator

I was going to build a solid stator but after seeing Ed's work on his four pole I got to thinking. I came up with this cool idea, literally speaking. Air flowing from the rotating rotor will pass through the coils of the stator.

The coils will be vented and will also be used for the structural support of the stator. As you can see one of the draw backs to this design is the inability to easily access the rotor. The stator end plates are made of a 1/8" nylon. Here is a top view of one stator end plate. The bearings will be added to the end plates and a water tight plastic housing will cover the entire assembly.

The coils were wound and glued then removed from the winder, an epoxy coating will be added to the wire too strengthen the coils.

After a few tries I used a thin mylar electrical tape between each of the coil layers. This helped me get very uniform windings. There are 42 turns of 22 gauge wire on each of the 16 coils.

Joseph.

RACA Stator Update | 9 comments (9 topical, 0 editorial)

Re: RACA Stator Update (3.00 / 0) (#1)
by windstuffnow (elenz(at)windstuffnow(dot)com) on Wed Oct 18th, 2006 at 09:08:51 PM MST
(User Info) http://www.windstuffnow.com/main

Very Nice Joseph ! How deep are those coils? or the distance from the top of the coils to the magnets?

I've been pondering the enclosed rotor problem and really haven't come up with any concrete solutions. In reality, as long as the rotor is built properly, there should be no real need to remove it at any point.

Started another one, larger - 18 poles and 54 coils. I was so impressed by the little one I couldn't help myself. I also remembered that winding them the way I did I needed to reverse the 2nd phase. It worked pretty well but it works much better now.

I found some 6 inch sch 40 pipe and made some end plates from some 1" thick nylon, 1" shaft with a key and pressed them into the pipe section. I finished drilling the end plates today. I plan to use an external bearing set up similar to my 500 watt kit so the plastic stator won't have to support anything but it's own torque.

I like your design as well, is that going to be a single phase? If I recall, you were using 16 poles on a 5 inch drum.

It looks like its together enough you could spin it up for a quick test... did you? ;o) I probably would have - I'm kind of impatient like that. Can't wait to see the end result!!! Impatient like that too! Oh, by the way, those are about the nicest coils I've seen.. far better than most of mine.
.

Have Fun! Windstuff Ed

Re: RACA Stator Update (3.00 / 0) (#2)
by WXYZCIENCE on Wed Oct 18th, 2006 at 10:32:49 PM MST
(User Info)

Ed, the coils a 1/2" in depth 4 layers of 10/11 wraps. Might be a little tall but I wanted the 42 wraps maybe 8x5 would work better, but tight. I wrapped them on my winder and made a small 1/2"x 3/8" plastic stick flat on one side and beveled on the other. Used the stick to flatten the wires after each row then taped each layer with mylar tape. Used up lots of instant CA glue. I am trying to get .04 " between the magnets and the wire.

Yes it is a single phase unit. May try two 180 degree, depends on the volts. My first test in the lathe with two magnets and one coil were impressive. .75 amps at 1.5volts. Don't have an exact rpm. 250-400. Suspect to have bearing mounted by the weekend, should have results then.

My problem: I keep building it in my sleep, waking up and having to do twice the work. I read that Tesla had the same problem.
Thanks for the feed back, Joseph.

[ Parent ]

Re: RACA Stator Update (3.00 / 0) (#5)
by windstuffnow (elenz(at)windstuffnow(dot)com) on Thu Oct 19th, 2006 at 08:53:42 AM MST
(User Info) http://www.windstuffnow.com/main

That is impressive with only two magnets installed!

My problem is I go to bed with all these ideas floating around my head and I lay there flopping around like a fish out of water. Sometimes I wake up with some good solutions other times I wake up with more questions and/or ideas. In any case my nights are short.

Can't wait to hear more about it this weekend!

.
Have Fun! Windstuff Ed
[ Parent ]

Re: RACA Stator Update (3.00 / 0) (#3)
by DanB (danb@*no spam*otherpower.com) on Thu Oct 19th, 2006 at 08:34:31 AM MST
(User Info) http://www.otherpower.com/

Very cool Joseph -
My thinking is that you'd do lots better to have the coils not so tall. I wonder if you used fewer coils that were shorter/wider - and maybe go with a 3phase setup if you'd see lots more output. Lots of possibilities...

It reminds me of a much nicer version of this thing I built a few years back.

Re: RACA Stator Update (3.00 / 0) (#7)
by WXYZCIENCE on Thu Oct 19th, 2006 at 11:47:08 AM MST
(User Info)

Dan, after winding 16 coils and placing them in the stator I realized that they could have been made flatter and wedge shaped. I am going to try a wedge that will fit without the gaps between each coil. Have some other ideas also. We need a thumbnail gallery for these projects of the past. Something that can show say 24 at one time. Just a thought. Thanks for the input
Joseph.

[ Parent ]

Re: RACA Stator Update (3.00 / 0) (#4)
by wayne (wayne.jones@sait.ab.ca) on Thu Oct 19th, 2006 at 08:52:11 AM MST
(User Info)

Nice work Joseph and see it coming along very well. I hope the coil width is not to much. A spin test you will know for sure.Looking forward for your results. And going with single phase like mine. I have 12 poles and 12 coils, #21 gauge wire. Going for 30 turns. Mine looks like Ed's but last night used stainless steel threaded rod. Found out it clogged so back to Home depot and get some brass rod for now. I did make end plates from MDF for first test and now cut plates from lonnie store cutting boards. The problem is make sure your rotor is done before it gets locked into its cage! there is no escape.

Wayne

Re: RACA Stator Update (3.00 / 0) (#8)
by RP (russp located-at fidnet (dot) com) on Thu Oct 19th, 2006 at 07:14:46 PM MST
(User Info)

If you lock all the coils together with resin and glass you could saw out the plastic from one end. The stator would then be shaped like a drinking glass on its side with a bearing in the closed end and open on the other.

You could then support the open end from the outside rather than the inside.

[ Parent ]

Re: RACA Stator Update (3.00 / 0) (#6)
by Stonebrain on Thu Oct 19th, 2006 at 11:04:23 AM MST
(User Info)

Cool,
I'm following your and eds raca's with great interest.

Maybe I would make the coils as flat as possible to put
the wire as close as poossible to the mags,but maybe
there are structural reasons for your rather thick coils.

I think my first genny will be a radial air core.

cheers,
stonebrain

Re: RACA Stator Update (3.00 / 0) (#9)
by electrondady1 on Thu Oct 19th, 2006 at 07:50:08 PM MST
(User Info)

i love long legs.
joseph your machine is looking good.

[ Parent ]

RACA Stator Update | 9 comments (9 topical, 0 editorial)

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