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First coil winding dissapointment
By gotwind2, Section Wind Posted on Wed Dec 31, 2008 at 12:09:20 PM MST
Coil design wrong?

Continuing from my diary entry
http://www.fieldlines.com/story/2008/12/20/18329/862
My first attempt at winding a coil for my latest axial flux alternator was a bit of a dissapointment.
it is an 8 pole 6 coil arrangment with square rotors mounted on a bicycle hub.

I was attempting to get 200 turns of 20 gauge(0.9mm)wire into a 55mmm circle with a 19mm hole for the magnet.

I managed to get 150 turns in the space allowed, and measured a coil reisistance of 0.8 ohm. So thinner wire is probably the answer.

The annoying thing is - I wanting the coil to be 8mm thick, and it was until I released it from the winding jig. It then sprung out to 12mm - no good with the 6mm magnets I am using, the air gap would be too big.
Maybe its the coil design,or my winding jig?, it was made fairly quickly in my shed that is unheated and 0 deg C at the moment.
Ben.

First coil winding dissapointment | 5 comments (5 topical)

Re: First coil winding dissapointment (3.00 / 0) (#1)
by Janne on Wed Dec 31, 2008 at 08:00:44 AM MST

Hi,

I've found, that a good trick is to tie the coil together with magnet wire, while it's still in the winding jig. Then, after removing it from the jig, use electrical tape to tie it together, and remove the magnet wires holding it together. Then cast the coils with the tapes in place.

Good luck with it
contact: #otherpower @irc.otherpower.com

Re: First coil winding dissapointment (3.00 / 0) (#2)
by wdyasq on Wed Dec 31, 2008 at 08:23:37 AM MST

I did a bit of calculation and came up with this. The 55mm X 19mm X 8mm coil has "18mm per side" and is 8mm tall. .9mm wire will only get 8 turns in the 8mm 'height' and 20 turns in the 18mm width. You did very well getting 150 out of 160 theoretical turns. I doubt the varnish/enamel thickness is included in the .9mm.

Being sneaky, I would probably have built the coil form out of a material I could cast and remove the form so the coil would be a solid chunk when it came out of the winder.

Ron
Adventure is just bad planning." -- Roald Amundsen

Re: First coil winding dissapointment (3.00 / 0) (#3)
by jlt on Thu Jan 01, 2009 at 09:36:53 AM MST

it looks like you can move your magnets out a bit farther. to make room for larger coil. i compress each coil after removing from winder. i use .about teaspoon of resin and clamp them between two pieces of metal.i use a plastic bag to keep from sticking i mix the resin very rich in hardener.it will set up in 10 minutes, or less.

Re: First coil winding dissapointment (3.00 / 0) (#4)
by hiker on Fri Jan 02, 2009 at 12:01:12 AM MST

that works--i use a couple of pieces of 3/4" plywood--coil in the middle--
then toss in a vise--they come out nice and compact. after that they dont really
want to expand at all!!

WILD IN ALASKA
[ Parent ]

Re: First coil winding dissapointment (3.00 / 0) (#5)
by KilroyOdin on Fri Jan 02, 2009 at 02:22:32 AM MST

Hi, really nice graphics. I am puzzled, how do you have your coils connected?

First coil winding dissapointment | 5 comments (5 topical)

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