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stator mount upgrade


By blueyonder, Section Mechanical
Posted on Fri Aug 29th, 2008 at 12:30:00 AM MST
 and mod for pulling off rotor

  with a bit more work done on the mill .i had to make sum new mods.
  with the second rotor finished and fitting on the shaft i was now ready
 to start with testing coils.
   in fact i was itching to test the coils and check it all out for cut in.
   my coil winder was ready to go.

    but i had to sort sum things out.  things that needed welding grinding etc.
   i thought it best to leave the coil winding a stator building to last.

    so got on with the dirty work cutting and welding.
    i made sum new mounts for the stator. and also made from 316 stainless
  new studding .
  this had 12mm thread on the frame and 10mm thread on stator.
    i made from a scrap shaft i made for the mark one .so that was lucky.

     with all the new bits welded i gave it a coat of paint(again)
    i had no blue left so used yellow. (now its called the yellow  peril)
    happy with what i done i started to think about the new stator.

    now i run into a problem. whare i had the jacking screws fitted
  it fualed on the inside of the stator.
    and as its only a mini gen with a 9" rotor i had no room on the inside of the
 stator  to allow for jacking screws.  what a pain this was turning out to be.

     the jacking screws worked well with just the two rotors in position
   but the hole in the middle was now to small.
    but after a nights sleep i got the idea to use the same jacking screws but in a different way .
  so i made up a puller with scrap bits.
  used the same threaded holes.  and now fitted into the end of the shaft,
    so i had a bit luck there.
  shaft was a bit on the short side so had to make a small extension .
   and now i can pull the rotor off till its past the pull of the other rotor.

 i forgot how little room there was inside the small stator.

  also i played about with balancing the two rotors on there shaft.
  it needed a bit added. why you ask did it need a bit added.
   well when i cut out four mags i had in the wrong way.  i don't think i got them back in right.
   couldn't use the magnet jig now. wouldn't fit.
   or just maybe sum thing else.
    but im happy with the balance now.(considering)
    sorry for all the text and no pics.
   will now add pics.
   i am now working on stator. just finishing it off. so will add that later.

   











stator mount upgrade | 7 comments (7 topical, 0 editorial)

Re: stator mount upgrade (3.00 / 0) (#1)
by frackers (g8ecj at *nospam* gilks dot org) on Thu Aug 28th, 2008 at 07:07:15 PM MST
(User Info) http://www.gilks.org

I know just how you feel about the small hole in the stator!! I had a similar experience and a lucky escape.

I used a blank hubbed trailer stub axle and drilled the hub for 6 studs to that I could have 2 studs per blade. To get a wide spacing of the studs I went as far out as I thought prudent on the hub flange and totally forgot that the stator hole was fixed as I'd bought it from here (Otherpower) and its full of wires!

By shear luck I had about 2mm clearance between the rotating studs and the stator hole - that increased to about 3mm after I cleaned up the stator a bit. phew :-)

Its been flying OK since Easter and is due to move from its temp mast to its permanent one in 2-3 weeks time so I'll give it a good check over while its down.
Robin - Down Under (or are you Up Over)



Re: stator mount upgrade (3.00 / 0) (#2)
by TheCasualTraveler (a.miklos@yahoo.com) on Thu Aug 28th, 2008 at 07:32:15 PM MST
(User Info) http://thecasualtraveler.com/wind.htm

Once again Blue, great work.

     I really look forward to your progress posts. Your way of doing things suits me. Methinks I will use your reverse engineered jacking screw thing my own self and your stator mounts look more than sturdy enough now.

Andy



Re: stator mount upgrade (3.00 / 0) (#3)
by tecker on Thu Aug 28th, 2008 at 09:08:07 PM MST
(User Info)

Yes impressive



Re: stator mount upgrade (3.00 / 0) (#4)
by electronbaby (roy<at>windsine.org) on Thu Aug 28th, 2008 at 09:29:42 PM MST
(User Info) http://www.windsine.org

Yes, very cool. I used to use a puller similar to that arrangement when I used to build machines out of brake discs. Mine just slipped inside the inner center hole and used a stop turned up against the top of the threaded rod studs passing through the bearing hub. It worked well, but there is no substitute for nicely placed jacking screws. :-)

Well thought out solution :-)

I also like your cooling fins (channels) cast into the rotors. Do you have a hole in the center of the rear disc to allow air to get in? If not, you might want to think about drilling some toward the center of the rear rotor. It has to be the rear rotor because in most instances the front rotor is blocked up by the prop that is installed.

Just a though.

Very nice project though. Thanks for sharing :-)
Have Fun!! RoyR KB2UHF



Re: stator mount upgrade (3.00 / 0) (#5)
by DanB (danb@*no spam*otherpower.com) on Fri Aug 29th, 2008 at 07:24:44 AM MST
(User Info) http://www.otherpower.com/

Good ideas, it looks quite nice and very robust.
I wonder about the position of the tail pivot...  it seems quite different than what I would do, or what Hugh would call for in his design.



Re: stator mount upgrade (3.00 / 0) (#6)
by Flux on Fri Aug 29th, 2008 at 07:49:58 AM MST
(User Info)

Dan, I think I can answer that one.

I saw some of his earlier pictures and he has mounted the prop one side of the hub and built the alternator on the back. Not a bad idea in that it removes all the gyroscopic blade forces from the alternator discs. It does mean a through shaft and extra flanges to mount the prop, but when you see where the prop is intended to be mounted then the furling becomes conventional.

Flux

[ Parent ]



Re: stator mount upgrade (3.00 / 0) (#7)
by blueyonder (windwoodgood at yahoo dot co dot uk) on Sat Aug 30th, 2008 at 03:46:32 PM MST
(User Info)

 
 hi all. this was just a few mods i had to do before i move on to the stator.
  but i see i can make the hole in the stator what size i want.
  it will just let the air flow the bigger it is.

   so i have made the stator but kept the hole as big as i could.
  and in doing that gave myself a few problems with the wiring.
   i done a bit damage getting the island out the centre of stator.
    but done a few small repairs to it ok.
   twas my fault . rushing to get it out the mould like a man possessed.

   thanks for kind comments all.
   and thanks flux.  i wasn't sure about the giro effect   . but from what you say
  it sounds ok.
   will be interesting to watch as it furls (clang clang)
its a ill wind that dos no good



stator mount upgrade | 7 comments (7 topical, 0 editorial)
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