Author Topic: axial generator with lamination core  (Read 110338 times)

0 Members and 8 Guests are viewing this topic.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
axial generator with lamination core
« on: November 07, 2017, 06:41:45 AM »
Windmill friends,

This forum seems to me the right place to exchange ideas on a test setup of an axial generator.
Now I have 2 magnet rings and an axle.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #1 on: November 07, 2017, 11:15:45 AM »
Got 51 lamination packages now ( 20 x 8 x 8 ) cut out of transformer sheets.

I think of gluing  49 magnets 20 x 10 x 5 mm on the magnet backing rings ( thickness 4 mm)
« Last Edit: November 07, 2017, 11:24:56 AM by mbouwer »

joestue

  • Hero Member
  • *****
  • Posts: 1759
  • Country: 00
Re: axial generator with lamination core
« Reply #2 on: November 07, 2017, 02:21:59 PM »
Got 51 lamination packages now ( 20 x 8 x 8 ) cut out of transformer sheets.

I think of gluing  49 magnets 20 x 10 x 5 mm on the magnet backing rings ( thickness 4 mm)

odd numbers don't work for magnets.
My wife says I'm not just a different colored rubik's cube, i am a rubik's knot in a cage.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #3 on: November 07, 2017, 03:18:05 PM »
Of course.
Then I can go to 48 or 54 magnets.
Or does it make sense to go to the maximum of 80 magnets?

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #4 on: November 08, 2017, 05:04:01 AM »
With 51 packages the space for the coil-legs is 8 mm.
I tend to 48 packages with coil-legs 9 mm.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #5 on: November 08, 2017, 09:52:53 AM »
the mold to position the 48 blocks in the polyester of the stator.
« Last Edit: November 08, 2017, 09:58:51 AM by mbouwer »

SparWeb

  • Global Moderator
  • Super Hero Member Plus
  • *****
  • Posts: 5452
  • Country: ca
    • Wind Turbine Project Field Notes
Re: axial generator with lamination core
« Reply #6 on: November 09, 2017, 01:18:13 AM »
Can you give us a reminder of the turbine specification you intend to build, please?
Blade diameter, airfoil type...
Generator number of magnetic poles, number of phases, expected power output...
No one believes the theory except the one who developed it. Everyone believes the experiment except the one who ran it.
System spec: 135w BP multicrystalline panels, Xantrex C40, DIY 10ft (3m) diameter wind turbine, Tri-Star TS60, 800AH x 24V AGM Battery, Xantrex SW4024
www.sparweb.ca

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #7 on: November 09, 2017, 05:00:22 AM »
Inspired by the professional windmills around, the idea is that I first need to create test setups,
 
to, together with windmill builders on this forum, search for a design of a light direct drive generator with operational reliability.

In doing so we must be able to build that generator with stuff that is common and easy available for me and windmill friends on the forum.

It seems to me that the generator is the most difficult component.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #8 on: November 10, 2017, 07:21:09 AM »
If we could manage to get more collaboration we also can use each other's molds.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #9 on: November 11, 2017, 05:14:01 AM »
Detail of the mold with attachment point and cutouts for the stiffening rings and the terminal of the stator.
« Last Edit: November 11, 2017, 05:21:43 AM by mbouwer »

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #10 on: November 12, 2017, 05:58:17 AM »
The packets are now pressed in a layer of polyester. Now ajusting my coilwinder to shape 24 coils of wire 0,5 mm.
« Last Edit: November 12, 2017, 06:03:13 AM by mbouwer »

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #11 on: November 22, 2017, 05:32:59 AM »
modified coilwinder.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #12 on: November 28, 2017, 07:51:30 AM »
The coils pressed in the mold.
Now I want to connect them according to the scheme in reply #870 in the topic Active Pitchcontrol.
This time with 24 coils.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #13 on: November 30, 2017, 07:12:37 AM »
Taken the stator from the mold. Now going on with the other components.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #14 on: December 02, 2017, 05:36:26 AM »
The base ring for the statorbracket.
Composed of thin sheet material to save weight.
« Last Edit: December 02, 2017, 05:57:13 AM by mbouwer »

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #15 on: December 04, 2017, 08:37:16 AM »
Stator bracket.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #16 on: December 05, 2017, 11:14:14 AM »
Stator on the teststand. Next is the hub and the magnet backing rings

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #17 on: December 06, 2017, 05:50:26 AM »
Composite hub base.
« Last Edit: December 06, 2017, 12:36:34 PM by mbouwer »

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #18 on: December 09, 2017, 05:58:37 AM »
Hub completed.
Now I want to continue assembling the magnet backing rings.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #19 on: December 10, 2017, 05:35:13 AM »
Rear magnet backing ring.
With reinforcements at the fixing points I think I need to use less iron (= less weight )

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #20 on: December 11, 2017, 08:57:17 AM »
The composition mounted on a driven yaw bearing.
All this on the upper part of a polyester cladded lattice mast.
Now shaping the front magnet ring.
« Last Edit: December 11, 2017, 09:01:28 AM by mbouwer »

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #21 on: December 13, 2017, 10:16:35 AM »
Basis for the front magnet ring.
« Last Edit: December 13, 2017, 01:29:23 PM by mbouwer »

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #22 on: December 15, 2017, 05:25:55 AM »
After mounting the front magnet ring.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #23 on: December 16, 2017, 10:13:03 AM »
To be able to manage the forces during lowering the magnet backing rings,
I now made threaded holes with removable adjustment bolts.


mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #24 on: January 08, 2018, 07:32:16 AM »
Are there in this topic shown enough details
to start a discussion of how to proceed?

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #25 on: January 11, 2018, 07:56:56 AM »
New test rig. First I plan to tape 40 magnets 20 x 10 thickness 2 mm on both magnet rings.

SparWeb

  • Global Moderator
  • Super Hero Member Plus
  • *****
  • Posts: 5452
  • Country: ca
    • Wind Turbine Project Field Notes
Re: axial generator with lamination core
« Reply #26 on: January 12, 2018, 12:24:53 AM »
It's a very good looking machine, MBouwer.  I enjoy seeing your progress every day.
No one believes the theory except the one who developed it. Everyone believes the experiment except the one who ran it.
System spec: 135w BP multicrystalline panels, Xantrex C40, DIY 10ft (3m) diameter wind turbine, Tri-Star TS60, 800AH x 24V AGM Battery, Xantrex SW4024
www.sparweb.ca

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #27 on: January 12, 2018, 05:40:38 AM »
Thanks Sparweb,
Maybe I can about for a while make test stands like yours.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #28 on: January 13, 2018, 05:56:35 AM »
The test rig in reply #25 shows 1 volt at 60 r.p.m.
To scale up the stator I found transformer sheets from which I can cut 38 x 19 or 44 x 22 mm.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #29 on: January 27, 2018, 06:22:00 AM »
With these teeth out of stator sheet
I plan to shape a new stator of about 27.5 mm thickness.
« Last Edit: January 27, 2018, 06:37:19 AM by mbouwer »

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #30 on: January 29, 2018, 07:52:26 AM »
On a pitch circle of 280 mm. 54 packages can be installed.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #31 on: January 30, 2018, 05:25:56 AM »
with 54 packages I have space for a coil leg of 8.3 mm.
with 51       --       9.3 mm.
with 48       --       10.3 mm.

mbouwer

  • Hero Member
  • *****
  • Posts: 1023
  • Country: nl
Re: axial generator with lamination core
« Reply #32 on: June 24, 2018, 04:08:27 AM »
A new setup.