Permogator II was pretty much a failure because of the alternator design. But it was a beneficial exercise in bearing and motor construction. The motor actually worked great, spinning that big old disk full of magnets around at over 230 rpm, up to 270.
I took a break and worked on a magnetic motor. No luck with that project, but again a beneficial experience in constructing a model and an idea emerged for an alternator outrigger that I will get into later involving spinning magnets in tubes.
Permogator III is up and running. Sorry, no pics yet because we don't have a digital camera yet. So, when I finish this roll of film and take it to town, I'll post some pics.
Instead, I have drawings.
Permogator III is basically a bigger Permogator I. It uses 8 coil sets and 8 magnet sets for the motor. The alternator uses 18 coil sets and 36 magnet sets mounted on the edge of the rotor, which is a single .236-inch by 8 inches in diameter acrylic disc. The stators are two laminated .236 inch by 10-inch discs and these were purchased from Tap Plastics. This unit doesn't get the torque that it would if the motor were place on the rim, as was the case with Permogator I. Oh well, got to put things where they fit, I guess.
Pockets were drilled in either side of the rotor disc and magnets placed in the pockets where they hold themselves in very tightly. Half inch round by eighth inch disc magnets induce the alternator coils and three quarter inch rounds by eighth inch discs induce and are accelerated by the motor coils.
The coils are identical for the motor and alternator. They are pried out ferrite chokes that I bought from All Electronics for fifty cents each. With the bobbin and magnet wire and the machine winding, I figured it was cheaper than trying to wind my own coils. The bobbin is just shy of 7/8" diameter and the hole is 7/16". The winding is ½" inside and ¾" outside. Nicely made round coils.
The alternator coil sets are oriented so the windings are opposite in hand. This seems to facilitate their mutual induction for flux flow. On the other hand, the motor coil sets are oriented so the windings are in the same direction. The idea here is to have the mutual induction increase the field for a stronger attraction of the magnets. As it turns out, the EMF waveform is advantageous as well. It resembles the wave surfers ride on. The up slope is longer and less inclined, while the down slope is short and drops off quicker. Since the magnet is being attracted back toward the coil on the down slope, this lessens the time it is retarded.
One thing I want to clear up is about the alternator coil sets. The waveform is induced through each coil exactly as shown. This is verified by the frequency calculated by the rpms against what is shown on the scope. The wave also alternates in polarity each cycle. In fact, if one places a magnet in the end of a free spinning tube, sideways the tube will spin at about half the speed of the cycle due to the polarity switch. This is 9 times faster than the Permogator rotor is spinning. It would be fairly simple to mount some magnets to a flywheel disc rotor, using the spinning tube as a shaft and place some coils to generate some free energy off the main stator.
Holes were drilled in the stator discs for the coils and the coils were placed in the holes and then grouted in with Smooth On plastic. The leads then are soldered together in series.
The bearings hold the ¼ " shaft in alignment and are mounted to the stator, top and bottom, in one-piece aluminum shaft collars. The bearings are stainless steel abec-5 precision bearings and press fit the shaft. I purchased all of this from McMaster Carr. The rotor is suspended between the two stators and held in place with another one-piece aluminum shaft collar, which is screwed to a fender washer that is screwed to the flat face of the rotor. The fender washer is drilled and tapped for the screws and there is some adjustment in the clearance holes to get everything finely aligned. I used very tiny stainless steel "1-72 machine screws to hold the rotor in place. Good thing I bought some reading glasses, or I never would have been able to see well enough to do this. All in all this arrangement does a fine job of keeping the alignment perfect and holds the rotor absolutely parallel to the stators allowing for a very close air gap between the magnets and coils. The gap is about 1/32". There is absolutely no vibration, when running, which is a first in Permogator construction.
I am using 4 AA batteries for the primary voltage source through a 555 chip as I have done before. Thanks to GeoM (finsawyer) I learned how to place a one-ohm resistor in the circuit to measure the amps. The motor circuit operates at 530 milliamps. The batteries powering the motor are delivering 4.9 volts to the circuit. The power being supplied by the batteries then, is 2.61 watts. These measures are taken before spinning up the rotor. I don't think this battery drain ever stops, even with the rotor spinning and the coils are delivering their EMF into the circuit. The moving magnets induction of current into the circuit adds to the power of the motor, of course, but doesn't ever stop the batteries from discharging. I have gone into how the motor operates elsewhere and won't repeat it here.
The Ohms measured in the alternator circuit are 5.2.
With freshly charged batteries the device ramped up to 234.5 rpm after a light twisting of the shaft to get it going. A bridge rectifier was installed on the alternator output and a measurement of 6.55 rectified volts was obtained. With the Ohms as measured, that is 1.26 Amps and 8.25 watts with the circuit open. At this speed the potential is 315% in power output over the battery power input. The volts per rpm are .028, the amps per rpm are .005, and the watts per rpm are .035.
I am now charging batteries with the output. I have two sets of 4 NIMH batteries. I'll see how long I can run it, by charging one set while discharging the other. No special charging circuit, just plugging the batteries to be charged into the leads off the bridge rectifier.
I made a bunch of steel wire coils to juice the system, but sadly that was a wasted effort. The steel wire coils bring the device to a halt.
That's all for now. More later.
Chester