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Forum Index : Windmills : Another couple of stupid questions

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Sonny

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Joined: 17/01/2010
Location: United States
Posts: 66

Posted: 03:34pm 06 Feb 2010

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I had asked about a DC motor I have and using it as a generator. well after I pulled it apart it turns out it had no magnets and would not make a good generator. so I am starting from scratch and using the DC motor as a base. I am in the process of tearing the armature down and am only be using the shaft for the generator. I am trying to save the magnet wire for another project I have in mind. The problem I am having is the coils are over lapping and I can't figure out where to start to take the wire off the armature. I have both ends of the coils loose so it's just a mater of a place to start. Here is a picture of the motor apart.

Second, the field or stator has 5 coils in it. I plan on taking these out and putting 9 coils in, in 3 phase, 3 coils each phase. I plan on putting as many of the 2x1x1/2 magnets on the armature I can get. The armature is a little over 4 inches long and 4 inches in diameter so my pan is to have as many rows of the magnets end to end making each row in effect 4x1x1/2. My question I guess is, can I put more coils in? say 4 or even 5 coils per phase? I am going to be using 13 gage wire and if I have the room would like to add as much wire as I can get in.
I have no idea if any of this will work but hey it's only money

So I can use all the help I can get.
Thanks
Sonny

a complete novice

oztules

Guru

Joined: 26/07/2007
Location: Australia
Posts: 1686

Posted: 12:18am 07 Feb 2010

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Oh dear.... put it away and use something else.

Firstly, the magnet coils are probably just coils around solid steel shoes. When you build your 9 new ones, they will act as an eddy brake. You need stator steel in the right orientation...... use an induction motor as your victim for this sort of thing.... so this one is a non starter.

The armature is probably wave windings, and is a dog to wind... and just as bad to unwind.
You need to slide the paper/plastic coil protectors out and then you have access to the wire. It will come out as short bits and pieces from the looks of your gauge.. better to keep this as a motor for something else.

DC motors are only useful in their native state as windmill generators. You can rebuild the magnets with stronger neo's and rewind the armature for your own voltage..... but a huge amount of work for a still unsatisfactory unit

DC motors are only good for getting your feet wet into windpower.

Not a good choice.

..........oztules

Village idiot...or... just another hack out of his depth

Sonny

Regular Member

Joined: 17/01/2010
Location: United States
Posts: 66

Posted: 01:53am 07 Feb 2010

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Oztules, thanks for the advice.
I am now going to freak you out. My plan for this thing right now is, when I get done and ready to start rebuilding the only thing I will have is the center shaft, the outer aluminum case and the two bearing caps on the ends. I know this sounds like alot of work and it is but it's something I enjoy doing.( machine work of any kind)
My plan for the armature is to do what one of the fellows on here did with a car alternator,( sorry can't remember his name right now) turn a piece of aluminum after pressing it on the shaft to the diameter I need. Then rap it in a piece of steel while allowing enough room for the magnets.
Next, my plan is to machine any steel that is in the outer case out after removing the coils. Now is where I start to run into a problem, not because of any machine work but on the information I have or I should say don't have. I don't know if I need steel behind the coils or not, if I do then I will try to leave enough of whats in there for that purpose. If I can't for some reason and I do need the steel behind the coils then I will make a ring to fit and then mount the coils in it and do a pour of the resin to hold everything together and mount that in the aluminum cases I have left. So I need to find if I need the steel in or not. I have no idea where to find that information other then here from you fellows.
Hope I haven't freaked you out to much

I need all the help I can get.
Sonny
Ps I did get the coils out without messing up the wire. Was easy once I figured out what I had to do.

a complete novice

Downwind

Guru

Joined: 09/09/2009
Location: Australia
Posts: 2333

Posted: 03:07am 07 Feb 2010

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Have you heard the expression ....Flogging a dead horse!

I feel you are trying to build a power house in a shoe box.
A lot of work with a poor out come.
Conside the same work (or less) with an induction motor and a good out come.
If its just the challenge of building something you are after than carry on.

You might find with just the coils stuffed in there and resined in, could have a heating problem and burnout.

Pete.

Sometimes it just works

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