Another way of winding the stator

[Reno]

I have read alot about coils and stators and

it seems the ideal stator wound be wound in one

continuous wire. Someone might have posted this before

but I will throw it out see what everyone thinks.

based on a childs homebrew pinwheel.

-You layout on a piece of wood the stator you will make

-plot on it the inside corners of your coils and any holes

you will need

-drill out the holes

-At these points hammer in smooth finishing nails (no heads)-(four per coil)

-Lay down a sheet of fiberglass and push the nails through so glass is against wood

-start winding you first coil using conventional hold

 together techniques (hot gun, crazy glue...)

-once first coil is done advance wire to next coil

(making sure the wire goes to opposite side of next coil)

-continue this all the way around the mandrel

(If three phase more nails)

once the winding is complete and you feel confident it will work

-make a side wall to create a mold

-pour resin making sure all of the fiberglass is soaked

-complete filling the mold.

Once mold is dry

-drill holes again from back side of wood

-Pull all the nails out

-take mold apart and remove backing plate

-Fill holes left by nails with more resin

I laid out a couple of coils just to try it and it seems

it might work well and the concern of wich way the coils go

is eliminated as well as all those connections that might fail.

One other thing you might want to put some protection on the nail so

when it is pulled it does not scratch the wire.

Well let's here it, any thoughts

[Jerry]

Reno I like this idea. Bravo give yourself a pat on the back.
I'm thinking something like Eds sloted stator. First you put down the metal laminations next you do your nail wire thing and then you poure in some iron powder/resen mix between coils and coil holes keeping this mix just below coil surface.
It like making slots without the milling machine. ? Good job AH.
                     Jerry

[Reno]

Glad it sounds good

I am working on getting some free mag wire

so I have to be patient.

I have never made a stator before and want to

make it three phase but want to make sure

I get it right. Using this pinwheel idea

can someone comment on wiring in three phase.

the way I am visualizing this is one coil would

go over the nail for the next coil.

i want to use 1 magnet per 3 coil set.

[windstuffnow]

  Hi Reno,

     Your idea will work quite well, its how I made my single phase alternator shown below.  I laid out the pattern and hammered brads in place, wound the whole thing poured resin over the coils and pulled the nails after.  Took about an hour....

Have Fun

Ed

[Reno]

hello

I was wondering if you still have some of those neos on your webpage

If so can you tell me the demensions I want to see if they fit on my newly acquired

rotor mandrel