ohh wow!!
I am rambling on regarding my public thread on how to test the limits of coils / magnet arrangements.
depending on how one winds a coil one can get 300 winds easy to pull apart. So that iron powder can creap easily into every space in between the individual wires. Yet also be compacted really thinly like 8mm high only once compressed in isolation. So no resin and powder around it.
please see on the left 150 winds and on the right 300 winds. on the 300 coil I opened up the back and the front is somewhat compressed.
These are wound in a narrow fashion rather that a wide fashion like the coils I wound earlier.
This tells me 2 things;
* That I still should see if I can get the heat dissipation ability back (like I demonstrated earlier with a single non stacked powdered coil) even in a 20mm thin stacked configuration. I think I can do it.
* That there is a lot of unused copper in the leg bends.. But I am putting on hold any attempts of also harvesting there as I already see that this alternator in its current configuration is going to generate far too much volts if the goal is 52 at 3.3 m/s.
So I am at a crossroads and I could really use some advice / opinions.
Do I keep pushing this concept and end up with voltages in the 200s and use a Midnight Classic MPPT controller to deal with that?
Or do I scale down to a more economical size as to reach the 52 volts at 3.3m/s?
I am leaning towards scaling down to give this design a chance to contribute to the world by reducing the bill of materials considerably.