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Gizmo

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Posted: 06:50am 23 Jun 2011

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Today I made a coil winder. Printed out the cad drawing and glued to some 9mm MDF.

Cut out and holes drilled in the coil formers.

And this is my throw together coil winding jig with counter.

The counted was from a photo copier I junked years ago, its trigged by a microswitch as the coil former rotates around.

I intend to apply epoxy to the coils as I wind them, so ideally I should make 12 formers, one for each coil, so I can wind them all in one hit and then give them time to set.

Glenn

The best time to plant a tree was twenty years ago, the second best time is right now.
JAQ

Gizmo

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Posted: 06:52am 23 Jun 2011

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Hmm, looks like the automatic image resizing code is broken after transfering the web site. Better fix that.

Glenn

The best time to plant a tree was twenty years ago, the second best time is right now.
JAQ

Gizmo

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Posted: 06:55am 23 Jun 2011

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Thats better.

The best time to plant a tree was twenty years ago, the second best time is right now.
JAQ

shawn

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Joined: 30/03/2010
Location: New Zealand
Posts: 210

Posted: 09:52am 23 Jun 2011

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Glen even after lots of relese wax or grease whatever you use, the set coil is hard to take off the centre part of your winder what I found worked best was about 4 turns of electric tape the cheap stuff around it first, this gave me the movement after it was set and it came off easy without distorting or wreaking my winder centre.
I replaced the tape for each coil.

Hope this makes sence.

shawn

Gizmo

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Posted: 10:24am 23 Jun 2011

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Thats a good tip Shawn, I'll use that. Thanks.

Glenn

The best time to plant a tree was twenty years ago, the second best time is right now.
JAQ

Rastus

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Joined: 29/10/2010
Location: Australia
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Posted: 01:09pm 23 Jun 2011

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Hi Glen,
Everything is looking very professional from the start,don't feel the pressure,but we are exspecting great results!All the best Rastus

see Rastus graduate advise generously

Gizmo

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Posted: 06:27am 28 Jun 2011

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Today I picked up the lasercut steel bits. Pretty happy with the quality and price.

Using the magnet template I made earlier, I fitted the magnets to the steel plates.

I think the magnet template is a good idea. It was just like putting round pegs into round holes. Add a drop of superglue and drop the magnet in, I didn't have to worry about positioning the magnets, the only thing I had to think about was which pole, N or S. The template was about 8mm above the steel plates, so I could blow down each hole to clear out any dist or wood fibres before dropping in the magnet.

Next up I need to make the bearing.

Glenn

The best time to plant a tree was twenty years ago, the second best time is right now.
JAQ

shawn

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Posted: 10:38am 28 Jun 2011

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That looks like it will cool very well almost a fan going around the stattor it will be interesting how hard you could run it before it heats up,got a tractor pto handy or ???

Gizmo

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Posted: 07:52am 29 Jun 2011

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More progress today. Bought a couple of 6205 bearings to make up the bearing hub. Machined the center tube, fitted and welded the flanges, and put back in the lathe to bore out the bearing holes and true up the face where the magnet plates bolts on. It was a struggle for the little lathe, but it got there in the end.

Finished and painted. Paint is good for hiding bad welding

Then a mock assembly. It drew blood, the magnets might be ceramic but they can still pinch

Tomorrow I'll wind up a test coil and see if I can get some figures.

Glenn

The best time to plant a tree was twenty years ago, the second best time is right now.
JAQ

Tinker

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Joined: 07/11/2007
Location: Australia
Posts: 1904

Posted: 01:26pm 29 Jun 2011

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Nice work Glenn, interesting to see your 'adaption' of a drill chuck to serve as a live center

Klaus

Rastus

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Posted: 01:37pm 29 Jun 2011

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Hi Glenn,
Just noticed I've been mis-spelling your name,my mistake

Your mill is progressing very nicely and like Murphy Law no job is complete without a little "Blood sweat and Tears".You're right I can't see the welding at all,but my guess is that the paint isn't the only thing holding it together!Cheers Rastus

see Rastus graduate advise generously

niall1

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Joined: 20/11/2008
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Posted: 10:12pm 29 Jun 2011

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hi Glenn

"it drew blood"...potential there ...

very few axial builds with ferrites out there ...sounds interesting

the mags look much bigger when installed "in the flesh" Edited by niall1 2011-07-01

niall

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Posted: 10:53pm 29 Jun 2011

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Hi Glenn

Looking good nice job, should be plenty of cooling with the open design.

If you need a bigger lathe to do anything I am just a coffee stop away, you are welcome any time.

All the best

Bob

Foolin Around

mac46

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Posted: 02:37am 30 Jun 2011

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Hi Glenn

Just wanted to let you know...Looks very profesional, perfect fit on the flanges to the bearings, was that bore already cut for you or did you have to use you'r lathe for the final bore size?

I am very interested with this project. Thanks for shareing this.

...Mac46

I'm just a farmer

Gizmo

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Posted: 04:07am 01 Jul 2011

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Made a test coil yesterday.

The best time to plant a tree was twenty years ago, the second best time is right now.
JAQ

Gizmo

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Posted: 04:14am 01 Jul 2011

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Dont you hate it when you click Post instead of Preview

Anyway, made a test coil. 25 turns on a former. Fitted a waterpump pulley to the front of the alternator, then rigged up my little lathe and a loop of rubber cut from a old bike inner tube to drive the alternator.

Took a heap of measurements at different magnet gaps, from 9mm to 27mm. Interesting results, will post once I do all the maths, and get a little help from the guru.

One thing I noticed was the test coil position is important, I get very different readings when the coil is closer to one side, or in the middle. The photo below shows the coil close to the front magnet plate, 18mm magnet spacing. In this postion I was reading 1.54Vp-p, and when it was mounted in the middle, I read 1.39Vp-p

GlennEdited by Gizmo 2011-07-02

The best time to plant a tree was twenty years ago, the second best time is right now.
JAQ

Greenbelt

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Joined: 11/01/2009
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Posted: 06:45pm 01 Jul 2011

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Hi Glenn,,

just Curious whether this would effect Inductance? (from page 2).

Try it with a single Mag, would be interesting to see how much effect the 2 mags have on the field pattern.
Good looking work Glenn. -----Cheers, Roe
Edit; If the're not glued permanently Edited by Greenbelt 2011-07-03

Time has proven that I am blind to the Obvious, some of the above may be True?

mac46

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Posted: 02:25am 02 Jul 2011

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Hi Glen,

I was looking through you'r posts and I see that you bored the inner pipe, sorry for bothering you with a repeat. Why does it have unequaled output when you tighten the clearance to one side? and how much does this effect the sine wave pattern?

Most exellant work Glen,
...Mac46

I'm just a farmer

Jarbar
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Joined: 03/02/2008
Location: Australia
Posts: 224

Posted: 02:52am 02 Jul 2011

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Hi Glen,
or maybe place a second coil next to the existing one.The same positive effect might occur in it also and if so pot two separate coils side by side all the way around and configure connections for best output.

Anthony

"Creativity is detirmined by the way you hold your tounge".My Father
"Your generation will have to correct the problems made by mine".My Grandfather.

Greenbelt

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Joined: 11/01/2009
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Posted: 04:01am 02 Jul 2011

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Jarbar.

Sounds like an Idea ! Maybe a longer coil with fewer layers to take up the space.

Glenn
After reviewing your photos it may have more to do with flux path than distortion
It is possible that the forward magnet plate having more steel ,(Hub etc.) is a better
magnetic path.----- Cheers, Roe

Time has proven that I am blind to the Obvious, some of the above may be True?

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