New dual rotor project.

[Jerry]

My first and previus dual rotor alt was 10" with Lowes ceramic magnets. It did 200 watts plus. I'm hoping for around 400 watts this time. The NEOs are about the same size as the ceramics.

There actully coffin shaped. I'll cut them in half with my wet tile cuting saw.

This makes a wedge shape aprox 1/2" X 1" at 1.5" long. They are about 1/4" thick.

I'll be doing the standard 12 magnets 9 coils 3 phase. Stator will be the same design as the Lowes ceramic dual rotor.

If it works and there not to big here is a sires of pix in the beginings?

This is a 6" pice of 1.5" Galv. pipe. I've used a dremmel to make the ID accept a bearings. The flange part will hold the stator mounting plate.

                    JK TAS Jerry

[Jerry]

This pix shows the plastic pipe inserts used to keep the bearings in there place, a spacer.

This is the shaft and its bearings.

This is a bearing partialy inserted into the pipe.

                    JK TAS Jerry

[Jerry]

This is the shaft and bearings installed into the pipe.

This is the front shaft collar installed. Theres 1 on the rear also. These collars keep the shaft secure and in the right position.

This is the rear shaft collar and stator mounting flange installed.

This is a plastic cap. It keeps the rear bearing dry.

                  JK TAS Jerry

[Jerry]

So far in all of the above pix the only tools used were a dremell and an alin rench.

After some further assembly. The yaw bearing and stator mounting plate. Small muffler clamps were used to hold the pipe assembly to the yaw bearing.

This is the yaw bearing. No furling on this genny.

This is the stator mounting plate. It doesn't look it but it is 1/4". It just has an ugly coating of powder coat of somthing that didn't want to come off. Also the 8" steel discs 1/4" thick. I'll shine the up befor I install the magnets.

The littel hole in the muffler clamps are for the tail wing boom. It will be bolted on top of these clamps.

Thats all the pix for now. I have started the stator. I have more work to do on the magnet disc also.

This unit will be powered by one of my plastic 3 blade 49" props.

I'll post more pix as the project progreses.

                        JK TAS Jerry

[Jerry]

A couple notes. After everthing is cut, drilled and sized the unit will get a good coat of paint to keep the rust down. The yaw bearing mounting board it that composition plastic wood. Weather has no effect on it and it will last forever.

Now for some coil winding.

                        JK TAS Jerry

[para t8]

love to see more pic.you got all that from lowes?{cool}you guys come up with some good plans.i like that one,wind them coils nice and tight,do you put glue and accelerator on your coils?

[Experimental]

Hello Jerry,

    Pretty slick and done with out a lathe !!

   This may get some of the guys without fancy machinery going on a project, but I,m curious where you are going to hang it -- you have so many flying, I,m wondering where you will find room !! Ha, Ha !!

   Looks great and very inventive, Bill H....

[Jerry]

Hi para t8.

Everthing accept the yaw bearing, aluminum stator supporting plate and muffler clamps.

The referance to Lowes has to do with my first dual rotor disc alt I built 1 year ago.

I posted a diary on Jan 30, 05 about it. I just searched back and took a look at it. Most of the 35 pictures are missing.

You can look at it but be WARNED it takes a long time to load. I didn't have the right camera setting.

If you have the time its at http://www.fieldlines.com/story/2005/1/30/4118/94606

Many of the pix are missing but I think there are enough to see how it was built.

I'll be using the same stator build.

                      JK TAS Jerry

[Jerry]

Hi Bill.

I've got about 1.2 acer here at home. I've room here for a few more. At one time there were 14 flying at my store on the roof top. The roof is flate and measure about 60ftX60ft.

After that big crash a while back there are only 7 up there now. Some had been flying 5 years. I've made many improvements since the early units and had planed on replaceing them 1 at a time.

Mother nature and my mistake speeded up my replacement schedual. However I have very littel time to build and replace.

I think I figured out what heaven is. Once you get there you'll have a shop just like Dan Bs and all the time and wind you could ever want.

I like to try many ideas and I have a bunch. Just not enough time to impliment them.

Hope things are flying well up north and say hi to your wife. May see you in the spring?

                     JK TAS Jerry

[hiker]

looks real slick their JERRY...

might have to try some of your ideas the next time around..

[theTinker]

thanks for much for the post, very informative on the bearing. ive been looking for some information on it. hope ur other pics are as detailed and story lined

[Jerry]

A few more pix. Stuff I did today.

This is the $59 Harbor Freight wet tile saw. I had to space the magnet away from the steel table with a few sheets of shower fiberglass panel stuff. The magnets didn't want to slide on the saws steel deck.

Here the coffin shaped NEO is cut.

Its easy to clean the magnet chunks and dust of the magnet with duct tape.

Magnet templates and 1 magnet.

Magnets on 8" steel disc with templates.

                     JK TAS Jerry

[Jerry]

After cutting the magnets some of the paint chipped of. These magnets are cheap $1 each.

A littel more work on the discs then build the coil winder form. The actul magnet size after cutting 9/16"X 1"&1/16"X 3/16" thick. The coils will be small for a littel magnet like this. Because of this I'll be using the same 20 or 22ga. wire I used on the Lowes dual rotor. That worked quite well.

I've collected around 1000 garbage disposal motors over the last 4 or 5 years. Most are AC induction but about 20 are PM. These have a nice littel 8 amp fullwave bridge diode on a small heat sink.

As I did in the Lowes alt each coil will have its own fullwave bridge then all DC outputs combined.

The justification for this is the very small coil wire. The fine wire permits many turns. This brings the voltage up per coil.

If I see just a few amps from each coil multiply that by 9. This worked very well on the Lowes alt.

The stator support plate is a 10"X1/4" aluminum disc, a very nice heatsink. The small wire from each coil will go directly to its own bridge.

As in the Lowes alt the stator will be a stack of shower fiberglass paneling with the coils resind into cutouts.

Pix will follow when done. I think I don't go by the book sometimes?

                      JK TAS Jerry

[hiker]

hey jerry where did you find your neo mags for a buck each?

alt looks great as usual......

[Jerry]

Hi Hiker.

I goofed. I'm sorry I rechecked the price. After shipping there $2 each. Still not too bad.

All Electronics. Cat# Mag-93 $3.75 each + shipping. But you have to cut them in half with a diamond wet saw.

So maybe aint so cheap after all. And the saw takes a littel lingth away.

I just wanted to build a small dual rotor with NEOs befor I went on to the big wedge NEOs from our hosts here.

                         JK TAS Jerry

[Jerry]

OK the discs are just about ready for the magnets. Drill a few holes clean em up and start gluing.

I'll try to do that tomorrow and make the coil bobin to?

                         JK TAS Jerry

[para t8]

hows the project?going good im sure.how long was the shaft or dose it matter?better to have more than not enough i gess.lookin good.  para t8

[Jerry]

Hi para t8.

Total shaft lingth 12" and .75 dia. Looks like after the alt is done there will about 3"s of shaft available for the blade hub. The blade hub I'll use only needs about 1.25" shaft lingth.

I did some drilling on the stator today and made 2 discs for the coil winder. Maybe a littel more progress tommorow?

As soon as the coil winder stuff is ready I'll try to wind 1 or 2 coils after work

in the evenings?

                          JK TAS Jerry

                       

[para t8]

jerry,is your coil winder going to be elecric or one like i made...wooden?my mag.wire should be coming today,ill be winding coils too.sorry im asking all these questions,but this little project is perfect for me,{living in an apartment},something to keep  me workin and learning more about wind power,i will talk to you later...........parat8

[Jerry]

Hi para 8t.

I'll try to load a picture. I built it a year ago for my firs dual rotor alt.

Check my update diary post.

                           JK TAS Jerry