My little Sparky so far

[vawtman]

 In his early life he was a 3ph baldor and was a oddball 2speed.

 Since I adopted him which he might regret Hes been totally gutted and probably did more damage to me.

 I decided not to let his lams rust or coat them with anything thanks Flux and Zubbly

Here a pic hopefully with his newly skewed stator and play coil no liner yet and 1 of the 24 1.5x1x5/16 arcs

 Im a little concerned about his skew angle.I can easily adjust it if needed.Thanks

 What gauge wire do you think Zubbly and how many turns for heating elements?

 Do you wind the coils with the same rotation?Here goes.....

[vawtman]

Oops hes a little fuzzy at the bottom is the mag causing that or puburty? Is the pic sized right?

[kurt]

you forgot to leave the .jpg file extention on the file name when you uploaded the pic to the server.

[oztules]

The Zubbly one should be proud...... keep up the effort Vawtman..........oztules

[vawtman]

Sorry Kurt im a total dumbbutt with this pic thing.The little guys pic was only 2x2 in my files.

[oztules]

No vawtman... I think he means that you need to go back into "your files" and rename the stator pic with the same name but add the .jpg suffix on the end .... same as the ones above it (go look)... youll see what i think he means there.

..........oztules

[zubbly]

high vawtman!

lams look great!.  how close did you get it to 10 deegrees skew?  easy way to ckeck is put a heavy weight on a string. hold the string right in the centre of one of the stator teeth. the bottom of the string should be right in the middle of the next tooth over.

i now would put in a complete 1 turn winding. all 3 phases. it will look like a wave winding. connect your 3 starts or finishes together (that is your start point) the other 3 are your lines.

insert rotor with bearings on, assemble. you now need to spin at a "known" speed. 300-400 rpm is good to get a steady volt reading from 2 lines (it will be quite low)

you now have the info to calculate your winding for what ever voltage you want and ar what ever speed you want.

just my opinion, i think 600 rpm is a good max speed to have the genny run. calculate the voltage you want for 600 rpm to match elements.  mine will likely be 240 volt, (perhaps 600volt). you do loose a little voltage under load.

i hope you counted turns and took wire size from the original winding. that tells you what the slot fill is. if you didn't, you will have to make a few dummy coils at the required turns and adjust wire size from there.

wind individual coils. i suggest you put all of phase A in first. make all the connections. do phase B, connect, and then phase C.  it won't be so overwelming that way.  just look at my winding diagram, one phase at a time-put in one coil, skip 2 slots, put in thenext coil, continue.

have fun!

zubbly

[dinges]

(wiping drool of his chin)

Very nice... Looking forward to the rest of the story.

Despite the description of Zubbly on how he skewed the stator, I'm still not entirely getting how it's done. If you should happen to have any pictures of the phases that led to the current situation, I'm interested. Zubbly tells me it's easy, but then, so is anything if you have done it several times... Still think I would skew the magnets, at the price of slightly smaller airgap, but maybe I'm worrying too much about the difficulty & work of skewing the stator.

As far as you being worried about skew angle; I know the rule of thumb is 360deg/#slots = skew angle; but I don't think more angle than this would hurt, as far as cogging is concerned.

One thing I'm beginning to notice that, once one has made a coil, it has to be pushed into the slot. The slot is big enough, but the gap at the top of the slot is usually quite small. Better be careful not to damage the lacquer of the wire.

Don't think Sparky regrets being adopted. Maybe he's looking forward to generating power, as opposed to consuming power, as he (she?) has done so far.

Can't wait to see the first sparks fly.

(BTW, Zubbly, you once mentioned in that .pdf-file about having the stator commercially rewound; I asked about this at my local friendly rewind-shop, and they charge at least 500Euro (say, 600US$) for such a job. Minimum. Yikes... Better roll up my sleeves for some DIY rewinding, I guess.)

[wooferhound]

You can rename the file with the .jpg extension in Your Photo Uploads area. I am having trouble viewing this file as it is named now.

[WXYZCIENCE]

A diary of a fun day    

By vawtman, Section Mechanical

Posted on Tue May 30th, 2006 at 01:06:51 AM MST


I think? Here's the progression of removing windings and lams the hard way,

6. :00 am, Check in with the board to see what Zubblys thoughts were on a ?.
   
   
6. :39 Decide to fire up the oven and open windows. Just has I was walking out the door I here this why you are starting the oven,I said sorry I must have accidently touched it.(she knows I dont know how it works.)
   
   
7. :OO Go out and fire up the fire pit.
   
   
7. :30 Oh no!!! She's not sleeping in. Asks why I'm starting the pit, My reply was I wanted a good layer of coals for a nice dinner I'm cooking? Once she said that's nice, I thought I had a window of opportunity to burn the windings out.
   
   
8. :00 Hot fire and stick the stator on the grill 15 minutes later just has the lacings where starting to burn. I here this get that %^$#@ thing away from there from the bedroom window.
   
   
8. :01 Back to the shop in a short hurry with my smoking 8in brat.
   
   

 I knew from then on I was going to have to pick at the windings. What fun and the wife came out and said some more bad things like I went all the way to town to get the parts you need (honeydoo list) and your still playing with this? Hands bloodied I asked for a bandaid. I think I started gaining ground the nurse in her got me patched up.

3. :00 pm All the windings out and Zubbly A needle nose vicegrip with an open stance worked awesome to pull the lams came out nice. It seemed to just loosen 1 at a time.
   
   
4. :00 The neighbors brought their kids over for a swim and they wanted me let the turbine fly. The first thing out of their dads mouth was how are you going too stop it. I just showed him my bandaged hand and said where there's a will there's a way.
   
   

 I need to take more days off. Thanks for all the info over time guys.


8:00 My wife says its bath time. Does viagra really work?

Vawtman Had to post your Fun day.

I think you need some, Dacron-Mylar-Dacron on your stator.


Looks good should work. Joe  

[vawtman]

thanks oz here goes again

[vawtman]

hello Zubbly looks to right on using your string method(good idea)

 I would like to keep his rpms has low has possible since im dealing with vawts.

 Im in the process of redoing his rotor yet.Thanks for all your help to this point.

[vawtman]

Hello Joe

 Thanks for bringin back that lovely day.

[willib]

i did read that

very funny !

and sort of sad that with the honeydoo list you cant work on what you want to .

[vawtman]

Go for it Peter its not that hard

 I woulnt do it the way i did though.......

 Zipstrip does a good job of loosening the varnish and the outer lams maybe 10 on each end are really packed in but after that it goes easy.

 On the reinstall i noticed little cogs on the o.d of them and a couple trips with the bench grinder until they where gone allowed me to easily adjust them with a tool i made that fit the tooth gap snuggly and lightly coated it with oil.Not sure what Zubbly thinks about that but once the coils packed in there nothing should move and also revarnished.

 The new lam stack is 3in to accomodate my mags i just added about 1/4in extra lams and compressed them with a big c clamp and locked in with rollpins ill weld them yet.

 One motor i played with had no varnish cant remember what Zub called the process but was able to remove the whole stack quit easily.

 If you like to tinker give her.....

     Sparky says hi.

[vawtman]

Zubbly could i sneak a quikie in?

I cut one endring off the rotor and low and behold the aluminum only goes has far has the width of my mags.Would i be ok to turn it till the aluminum is gone and just the steel lams left or would solid steel be better.Thanks

[zubbly]

hi vawtman,

if your needed material removal from the rotor face brings it under the depth of the aluminum bars, the rotor lams will basiclly fall apart. even if you clamp the ends of the lamonations after it has fallen apart, you will not be able to thread holes into the lams to screw mags down if that is your intent. simple solution then is a solid rotor.

zubbly

[vawtman]

Zubbly thanks for your reply im just wondering if the leftover lams would be better than solid steel if not screwing down.Sorry to be such a bother.Many more thanks. I owe you.

[vawtman]

Zubbly i decided to just replace the rotor with solid steel thanks.I should have known if scarfed lams where better you would try it.

  Whats left of Sparky says hi!