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Author Topic: Machining the Rotors  (Read 1395 times)

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Murlin

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Machining the Rotors
« on: July 05, 2006, 01:43:09 PM »
I found some spare time this weekend to do a little machining.


I have lots of photos, but am hesitant to post them all so I will put up a couple of the last ones.


Since the local water jet wanted 600 bucks plus materials to cut two easy dough nuts, I decided to go over to the track torch shop and got a couple .630 plates for $53 each.








Fun....fun.....


Murlin

« Last Edit: July 05, 2006, 01:43:09 PM by (unknown) »
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dinges

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Re: Machining the Rotors
« Reply #1 on: July 05, 2006, 11:15:06 AM »
Looks very nice.


600$ to cut a few plates? I have mine laser cut by a local company; I explain my purposes, that it's a hobby project, no rush, etc.etc. They usually let my small orders (I give them complete CAD drawings that they just have to copy and paste in their own software) run along with another, bigger one.


First few times it cost me only a pie (so they something extra during lunch break :) ). Last few times they just charged material cost. 20$ or so at most have I paid for my rotor plates...


Guess I'm a lucky guy. We have in my (small) village a motor rewind shop (cheap wire! and other tidbits for motorconversions) and a laser cutting company. I'm happy :)


Peter.

« Last Edit: July 05, 2006, 11:15:06 AM by dinges »
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“Research is what I'm doing when I don't know what I'm doing.” (W. von Braun)

WXYZCIENCE

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Re: Machining the Rotors
« Reply #2 on: July 05, 2006, 12:11:06 PM »
to cut two easy dough nuts,


Murlin, did you have the wave edge cut into the plate by the torch shop. Looks good.   Post more pictures. Joe.  
« Last Edit: July 05, 2006, 12:11:06 PM by WXYZCIENCE »
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stevesteve

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Re: Machining the Rotors
« Reply #3 on: July 05, 2006, 12:14:41 PM »
I take it the angled slots are for cooling? It looks like a modern sculpture!

Nice work.
« Last Edit: July 05, 2006, 12:14:41 PM by stevesteve »
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Murlin

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Re: Machining the Rotors
« Reply #4 on: July 05, 2006, 01:01:38 PM »
Couple more pics....the angled fins are for cooling...











Murlin

« Last Edit: July 05, 2006, 01:01:38 PM by Murlin »
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stevesteve

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Re: Machining the Rotors
« Reply #5 on: July 05, 2006, 01:18:47 PM »
OK that cross-posted!

Still meant what I said though. It looks like a Porche component... beautiful.
« Last Edit: July 05, 2006, 01:18:47 PM by stevesteve »
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Murlin

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Re: Machining the Rotors
« Reply #6 on: July 05, 2006, 01:26:25 PM »
oops :) ...ment to reply to this one and get em all with one post muh bad.....


Thanks for the compliments...


Murlin

« Last Edit: July 05, 2006, 01:26:25 PM by Murlin »
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amiklic1

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Re: Machining the Rotors
« Reply #7 on: July 05, 2006, 03:05:11 PM »
I am amazed with your design. It looks like some expensive hi-tech stuff. How many watts do you expect to get from that turbine? It's 20 magnets per rotor (I suppose 2 rotors, 15 coils...


What voltage are you looking for. As it's large machine, I guess it's 48 V generator.


Also, is there any chance for me to get the cad drawings of those rotors (I have no knowledge in cad drawings at all). I think those angle holes are going to improve the air circulation.

« Last Edit: July 05, 2006, 03:05:11 PM by amiklic1 »
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Murlin

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Re: Machining the Rotors
« Reply #8 on: July 05, 2006, 04:55:59 PM »
"How many watts do you expect to get from that turbine"


Well I am not sure :) I am just doing this by the seat of my pants so-to-speak.....


I think about 2500 watts @ 20 MPH wind. 48 volt 3-phase..


Cut in is going to be low like Danb's around 60.  He seemed to have the right approach to harvesting energy vs design.


Although Flux says it will produce alot more (3500 watts) more if I skip the low winds and go for the gusto and use a hand full of wires to wind the coil with....


It took me a couple of days to make the rotors.  As far as cost goes, I had $106 in the material and my time.  Maybe $50-100 added manufacturing costs IE electricity, perishables ect...


It is fun to have your own Machine shop in your back yard.. :)  I am very lucky to have the means.....


I will supply CAD drawings to anyone who wants them, providing they just want to use them for their own personal use, and does not sell or give them to anyone for commercial use.


I did not do anything special with the design, it's Homebrew all the way. I wouldn't even know how to make it if I hadn't found this site...


I just added some stuff that made it more complicated...


Murlin

« Last Edit: July 05, 2006, 04:55:59 PM by Murlin »
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Shadow

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Re: Machining the Rotors
« Reply #9 on: July 06, 2006, 11:55:25 AM »
Your rotors look very nice, I'm trying to follow your design. It appears you cut out pockets for the magnets and will be putting a screw/pin on the end to keep from sliding out? Then I see two holes between each magnet? If so what is their purpose? I like the cooling fins.
« Last Edit: July 06, 2006, 11:55:25 AM by Shadow »
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SmoggyTurnip

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Re: Machining the Rotors
« Reply #10 on: July 06, 2006, 12:58:49 PM »
I did alot of testing on different shapes of cooling fins

on my gennie and I think if you left those holes open instead

of angled you would get better air flow.  I know it doesn't

look that way at first but I think the angles actually restrict

the air flow by having ending up with a smaller opening for the

air to enter.
« Last Edit: July 06, 2006, 12:58:49 PM by SmoggyTurnip »
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Murlin

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Re: Machining the Rotors
« Reply #11 on: July 10, 2006, 05:45:42 AM »
The holes are going to be for bolting the mags down, refer to other Diary entries for details.


Murlin

« Last Edit: July 10, 2006, 05:45:42 AM by Murlin »
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Murlin

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Re: Machining the Rotors
« Reply #12 on: July 10, 2006, 05:49:21 AM »
You maybe right, I was going to get a bee smoker and do some testing first but decided to just go for it.  If it doesn't work the way I want it to, I will weld on some SS ram scoops to force the air through.


Murlin

« Last Edit: July 10, 2006, 05:49:21 AM by Murlin »
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