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Non-cast stator
By clflyguy, Section Mechanical Posted on Tue Apr 10th, 2007 at 11:05:33 PM MST
Finally got the photos for those who asked about it...

Several folks asked how I was going to mount the coils, so this is how it was done.
First I laced the coils onto the stator plate. Then I cut 5" long pieces of
1/2"x1/4" aluminum stock to fit between each coil. I cleaned up the plywood ring
left over from making the stator mold and obtained a piece of waxed paper which I
waxed again with mold release wax. The stator was layed flat face down on a piece
of 1/4" steel plate and the aluminum pieces were fitted radially between each coil.
between the face of the stator plate and the steel.Sika epoxy anchor bolt adhesive
was liberally applied about the perimeter of each coil. Wax paper was layed over
the assembly and plywood ring layed over that. Large C-clamps were applied tightly
at the cardinal points to force the stator plate and coils respectively to level, each at their own plane.

Non-cast stator | 13 comments (13 topical, 0 editorial)

Re: Non-cast stator (3.00 / 0) (#1)
by RP (russp located-at fidnet (dot) com) on Tue Apr 10th, 2007 at 05:13:00 PM MST
(User Info)

Please explain a little more about the aluminum bars. I don't understand that part. Are they embedded in the stator between the coils?

Re: Non-cast stator (3.00 / 0) (#2)
by clflyguy (sidney.raiford@gmail.com) on Tue Apr 10th, 2007 at 05:45:03 PM MST
(User Info)

No, they were simply used as spacers while epoxy set up to hold the stator plate at one level and allow the coils to be pushed down onto the steel table 1/4" lower
than the face of the stator plate.

[ Parent ]

Re: Non-cast stator (3.00 / 0) (#7)
by rpcancun (hobbyshopmx@hotmail.com) on Tue Apr 10th, 2007 at 09:23:21 PM MST
(User Info)

Nice work,...how do you determine the spacing between coils?

I just finished my coils and Im kinda doing the same thing but I am going
to use 1/2 Ply, I'm using 2x2x.5 mags, coil center hole is 2" at the top and 1" at the bottom, leg width is 1 inch, which came out at 180 turns 16 gauge.
Flux called it a megavolt coil,...anyone care to take a guess at the volts?
I wont be ready to test for a while....

Thx

[ Parent ]

Re: Non-cast stator (3.00 / 0) (#9)
by clflyguy (sidney.raiford@gmail.com) on Tue Apr 10th, 2007 at 10:08:35 PM MST
(User Info)

RPCancun-
I'm really not the right guy to ask about that end of the deal, I would suggest
you read and read and read for hours and hours and then and only then ask either
Nando, Flux or Jimovonz (Our Resident Electrical & Electronics Geniuses)

Gus

[ Parent ]

Re: Non-cast stator (3.00 / 0) (#3)
by vawtman (vawtman(at)charter(dot)net) on Tue Apr 10th, 2007 at 06:50:27 PM MST
(User Info)

Nice work lacing the coils and the plate having that outer ridge to reduce or eliminate warping is also a good idea.

Thanks for sharing and best wishes for your hard work.

Re: Non-cast stator (3.00 / 0) (#4)
by ghurd on Tue Apr 10th, 2007 at 07:21:57 PM MST
(User Info)

It is projects like this that make me feel 100% completely insignificant.

"Get a haircut, you hippy!" ;-) That's what they tell me.
Now I feel a little better, just a little, but good enough to ask a question or 2.

Is the stator `frame' reinforced with fiberglass? (not my strong point)
Earlier photos look like it could be pure epoxy?

Looking forward to the photos of the finished blades.
G-

Re: Non-cast stator (3.00 / 0) (#5)
by hiker (hiker.wild[at]yahoo[dot]com) on Tue Apr 10th, 2007 at 08:06:30 PM MST
(User Info)

nice work..

looks somthing like my plywood stators..
i just cut the holes out for the coils then press them in with a lot of epoxy..
then coat the whole works with a good water proof paint or varnish..
so far ive had one for over a year with no problems...
of course as soon as i say somthing like that --the whole thing will blow up.. :}
WILD IN ALASKA
[ Parent ]

Re: Non-cast stator (3.00 / 0) (#8)
by clflyguy (sidney.raiford@gmail.com) on Tue Apr 10th, 2007 at 09:30:10 PM MST
(User Info)

Hiker,
I seriously thought about plywood for stators but eventually decided on glass
based on what I have seen happen to even the highest quality marine plywood.
About the only way I can think of to protect the wood well enough to suit
my overly anal standards would be to lay it in a pan of marine grade polyurethane
for a few days to let it really soak in, then pull it out and let it harden in
a hot attic for a week or so- and I'd probably still worry!

Gus

[ Parent ]

Re: Non-cast stator (3.00 / 0) (#6)
by clflyguy (sidney.raiford@gmail.com) on Tue Apr 10th, 2007 at 09:16:05 PM MST
(User Info)

Hey Ghurd,
Come on, don't even go there man. I look through your files too, ya know? You're
way ahead of me on the solar end of the deal, I haven't even started yet. I was
big and hairy for my age and started working in boat factories when I was fifteen
so the fiberglass end of it comes easy- it's all the rest of it that intimidates!
The stator plate definitely has glass in it. It is 3/16" of alternating layers
of 10oz. cloth and chopped strand mat with just barely enough resin to wet it out.
The white paint is to help with UV resistance.
And oh yeah- you already have turbines in the wind while I'm still building!

Gus

[ Parent ]

Re: Non-cast stator (3.00 / 0) (#10)
by tecker on Wed Apr 11th, 2007 at 03:03:40 PM MST
(User Info)

I really like this technique I 've seen it in a couple of machines . Potting the coils in place is so easy I opt for that instead . I get a little closer to this method every time .I would be very cool to be able to replace bad coils so that's where I well end up . Good stuff.

Re: Non-cast stator (3.00 / 0) (#11)
by bob golding (photoman290 at yahoo dot com) on Wed Apr 11th, 2007 at 04:26:32 PM MST
(User Info)

nice work, i am thinking of doing something simular but using something like g10 garolite. its very strong so 3/8" would be plenty strong enough. you can get it from mcmaster carr. look under sheet materials for the spec.

bob golding

Re: Non-cast stator (3.00 / 0) (#12)
by hvirtane (hannu_markus_virtanen(at)yahoo(dot)com) on Thu Apr 12th, 2007 at 12:21:29 AM MST
(User Info) http://web.archive.org/web/20050404022706/www.cc.jyu.fi/~hvirtane/cooker/

It looks really good.

Did you measure the resistance? Have you tested it already to see, how much coils will heat?

- Hannu

Re: Non-cast stator (3.00 / 0) (#13)
by clflyguy (sidney.raiford@gmail.com) on Thu Apr 12th, 2007 at 05:37:21 AM MST
(User Info)

No, I haven't, but I figure it will be in the ballpark with all the others which
is why I'm trying for better cooling in the first place.

[ Parent ]

Non-cast stator | 13 comments (13 topical, 0 editorial)

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