Stators ready to cast.

[Jerry]

This may be the first dual rotor disc alt out of 4 diferant sizes ready for the star VS "Jerry Phase" alts test?

This one is 5.125" od. It uses 8 each 1"X1/2"X .25" NEOs. 8 per disc. ^ coils 3 phase.

I'm getting ready to cast 2 stators. One has coils wound with 18 gage at 40 turns each and the other stator has coils wound with 24 gage with 150 turns each coil.

The 24 ga. is the "Jerry Phased" stator.

Here are a few picture prier to puring the reson. The stator are made from fiberglass sheet. They should be about 5/6" thick after compressing.

                            JK TAS Jerry

[Jerry]

I was able to give star a few turns extra. The idea here is the star with wire 4 time the circlar mils would have 1/4th the turns as :Jerry phase". Because this alt is an 8-6 combo. Wich means in star there are 4 coils in sires. One coil of "Jerry Phase" equals all 4 of the star coils in turns count.

However it has been sugjested the star needs a handicap to make up for its loses, so I was able to do 40 turns rather then the 37.5 or 1/4th the 150 turns of "Jerry Phased".

The yellow discs are left over rounds of 3/4" MDF from speaker cabnets we make.

MDF is much smoother then plywood. I primered then painted it with glose enamel. Then I melted toilet bowl wax on it as a relief agent. There is a top piece that bolts on.

More to follow.

                       JK TAS Jerry

[s4w2099]

Thats Sweet man. I am wondering how fast would you have to spin the 40 turn coils one. Is the airgap going to be small enough for the thinkness of those magnets.

If I do my math right, 0.25 + 0.25 (dual rotor) = 0.5" so the airgap should not be much bigger than that. Maybe its a picture magnifying thing, I see the coils very thick.

Correct me if I am Wrong please

[Flux]

With those magnet spacings and coil sizes you should have a waveform that is well removed from a sine wave. I suspect it will favour your Jerry connection.

Keep up the good work Jerry, I am particularly interested in looking at the versions of Hugh's baby alternator where I have a good idea what it will do in its present form.

Flux

[Norm]

  Jerry.. something I've been thinking about for

a couple of years.....

 That white material that you have placed the

coils in are marked pie-shaped ....a person could

possibly mark into pie-shaped divisions....each

coil could be a replacable unit....

  ....Maybe just a dumb idea that others have

thought of an rejected as a bad idea ?

        (  :>) Norm.

[DanB]

Hi Jerry -

this will be interesting...

How does the weight of these coils compare?

Looking forward to your next posting!

[Jerry]

Hi Dan B.

I've weighed these coils and they are 1 oz. each. Both the 18 gage and the 24 gage.

I have a very nice GE dc motor to drive these smaller disc alts with.

The motor name plate says 48v armature/48v feild, 1.4a armature/2.2a feild, 930 rpm, I think then it is compund wound, it weighs 32 lbs.

When I've powered it up befor it seems to have alot of tourque. It has a 5/8" shaft.

I will couple it direct to the alt shafts via. love joy conectors. I will supply a varyable DC voltage with a 10 amp 60 volt DC supply and my 5KW variac. For 0 to 60 volts.

The loads will be battery and fixed resistor values.

I'll be useing amp & volt meters on the drive motor to track power going in. I'll be useing amp and volt meters on the disc alts as well as a lazer tach and an infer red remote thermomitor to track coil temperature. I will lock the thermomiter into a set position so the coil temp reading are accurate.

I will be doing the same for the other sizes of alts. However on the larger alts I'll use my 100 LB 2.5 hp DC motor for  higher power readings.

I'll try to report all findings here with text and picture data.

Another thing about the fiberglass stator is the coils are in the exact same location/posistion. Holes were cut through all stator forms at once then the 2 stacks of wafers were seperated.

I'm trying to keep all aspects of the 2 stators exact, coil weight, coil position, coil thickness.

I work on this project as time permits.

                        JK TAS Jerry

                     

[Jerry]

I belive the test results here are scaleable. The results should apply to the very small as well as the very large alternators.

I'm also doing these tests on round coils, wedge coils, rectangle coils, dual rotor and single rotor, and the 12-9 as well as the 8-6 configuration. I also hope to do some odd configuration. Something like my propossed 14-11 or 14-9? I know these will only work "Jerry Phased" where coil count dose not matter. Other then proper under magnet posistion and room.

I've all ready done these tests on car alternators and AC motor conversions. Those tests were very promesing.

                         JK TAS Jerry

[Jerry]

I've rechecked the stator/coil thickness. Its 1/4" thick. I'm thinking maybe the gap between the magnets to be 3/8".

One nice thing about the 150 turn coils, when useing a fullwave bridge rectifier per coil, there is no importance on conection to coils in regards to start or end coil conection. It don't matter.

I got to thinking about the turns ratio between these 2 systems. Jerry Phased 150 turns VS star at 37.5 turns.

Since I've used 40 turns per star coil, star ended up with 10 more turns total.

                              JK TAS Jerry

[cyplesma]

not a dumb idea, I'm getting close to getting my coils mounted for my first windmill, and I've been thinking the same thing.

I would even go so far as to have the slices be made so that on the outside and inside diameter edges would overlap the pie slice next to it so they would get screwed / bolted together.

The section of the pie where the coils are almost touching would have to be straight though.

[cyplesma]

not to mention the terminals for the coil would also be terminated for each coil module.

this would allow for delta and wye connections and who knows what other configurations just to play with.