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Need a Rotor Layout
By valterra, Section Mechanical Posted on Tue Aug 07, 2007 at 04:58:17 PM MST
or a program to map out all the holes

I have some buddies who will fabricate my rotor discs for me. Does anyone know of a good (hopefully free?) program to draw a template for all the mounting holes?
I basically need a full-sized drawing on paper, and I don't trust my own drawing skills enough to lay the holes out correctly.
Also someone told me the rotors should be at least 5/8 inch thick. What is your take on that?
Resectioned

Need a Rotor Layout | 10 comments (10 topical)

Re: Need a Rotor Layout (3.00 / 0) (#1)
by valterra on Tue Aug 07, 2007 at 02:17:22 PM MST

I'd thought of this before, but didn't menton it to my fab shop guy... he brought it up on his own. He said he could rout out rectangle "divots" into the discs where the magnets are supposed to go.

My thinking is that slipping the magnets into, say, a 1/16 inch square indentation would work better than using tape or banding around the outside edge. That way, the magnets would have to try a lot harder to come off, and no template would be necessary: just plug and play.

Would that work? If I'm crazy, please tell me! :)

Re: Need a Rotor Layout (3.00 / 0) (#2)
by DanB on Tue Aug 07, 2007 at 04:20:35 PM MST

5/8" seems rather thick but it depends on the size of machine and which magnets you're using.
Cutting rectangular slots for the magnets to fit in would be fine. Not 'easy' - unless you have the equipment to do it. (A CNC milling machine?... even then probably not easy) It's been done here before. You can make life as complicated as you like ;-)

[ Parent ]

Re: Need a Rotor Layout (3.00 / 0) (#3)
by valterra on Tue Aug 07, 2007 at 04:48:03 PM MST

It's a good design though, right Dan? I'm not worried about the mill guy's time. He's more than willing to take a diversion from his regular work. :-)

[ Parent ]

Re: Need a Rotor Layout (3.00 / 0) (#4)
by Shadow on Tue Aug 07, 2007 at 06:12:01 PM MST

Its a good idea. But what works just as well is to just machine down the outside 2 inches, (or whatever size magnets you use). The same as you would turn down brake rotors. Leave a 1/16 inch lip around the outside edge to help keep the magnets from sliding off.

[ Parent ]

Re: Need a Rotor Layout (3.00 / 0) (#5)
by valterra on Tue Aug 07, 2007 at 06:20:16 PM MST

roger that. I don't plan to vary from your guys' proven design, as demonstrated in the "our current way of doing things" section on Otherpower.

I think I've seen enough pictures of that same design being put together to get the idea once I start actually handling parts. I have been waiting a long time to feel like I could afford this. Then a recent job loss and salary dip really put the damper on things.

Then someone offered to make me the steel. Good deal then. That's a start. I also work around people who spend all day welding (which I've never done and was my other setback). So this is all starting to come together nicely. Hopefully will be ordering some magnets soon.

[ Parent ]

Re: Need a Rotor Layout (3.00 / 0) (#6)
by finnsawyer on Wed Aug 08, 2007 at 08:44:27 AM MST

I've been thinking of doing a head to head test of my generator design versus the three phase by building them both on a single rotor. This would eliminate a number of issues. I don't like the idea of committing the expensive Neos to something that would be used once for a test, so I came up with the idea of using a plywood or plastic form or template around the magnets, relying on their natural magnetism to hold them down for the test (I don't need any power out). The template would be held down with stainless steel screws. This way I could use the 16 or so magnets over. Any comments?
GeoM

Re: Need a Rotor Layout (3.00 / 0) (#7)
by pepa on Wed Aug 08, 2007 at 01:31:06 PM MST

good for testing, i will be following your progress, keep us posted, i am very interensted in any system that will use low wind speed. pepa.

[ Parent ]

Re: Need a Rotor Layout (3.00 / 0) (#8)
by finnsawyer on Thu Aug 09, 2007 at 08:16:53 AM MST

Don't hold your breath. This will take time. I have a circle cutter device for the oxy-acetylene torch that I never used. Maybe it's time to try it.
GeoM
[ Parent ]

Re: Need a Rotor Layout (3.00 / 0) (#9)
by etownlax on Thu Aug 09, 2007 at 06:42:49 PM MST

I've been thinking of that before too.haha

Never got around to making it though. We have 3 or 4 at my work but I dont' know what the boss would think of it if I went and made it.lol

Oxy-Fuel is the best. Welding or cutting... doesn't matter.

-Randy

[ Parent ]

Re: Need a Rotor Layout (3.00 / 0) (#10)
by finnsawyer on Sat Aug 11, 2007 at 08:39:06 AM MST

Turns out the guy I work for part time can cut perfect circles in steel plate. There goes my incentive for learning a new skill.
GeoM
[ Parent ]

Need a Rotor Layout | 10 comments (10 topical)

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