Finally some progress!

[bradyaero]

Been a while, (4 years)!  but I have finally made some progress on my genny.  Put the coil winder togeather and cranked out 7 coils before my arm gave out   and I thought all that beer would have helped!  Finished the nine, and am now working on the stator structure.  I'm waiting till last to mount the magnets cause I am scared as hell of them.  A friend was over and was fooling around and exploded two of them together...  that was enough to convince me!

Glad to finally have something to contribute

[tecker]

By exploded I assume you mean they broke .I have a distinct memory of a piece of magnet flying past my ear in one of those episodes .Glad your project is of the deck . Looks good

[bradyaero]

They shattered when they hit with a shower of sparks! N42's in freefall

coils are a bit fugly but they'll do the job...

[bradyaero]

Like I said earlier, it ain't pretty, but it has air cooling.  Coils are semi-cast with air holes.  Everything is under 1/2" thick.  It just needs some lipstick

[bradyaero]

I got the rotors done today.  Great idea to mount the magnets on brass pins whoever came up with that one.  Next step is to paint some stuff and put it together for a test.  This sure is the fun part!



oh ya, I used bulldog grip to glue the magnets to the rotors and pins , the pins were tight fit to the rotors.

[fabricator]

What size prop is this gonna be? I hate to be a wet blanket but that shaft looks awful small.

[bradyaero]

Not at all , the genny is not part of the main hub, so there won't be the extra stress of the main rotor assembly to affect it, so the mounting hubs can be smaller.

What size prop is this gonna be? I hate to be a wet blanket but that shaft looks awful small.

[fabricator]

Ahhh, I see, carry on

[ChrisOlson]

What size prop is this gonna be? I hate to be a wet blanket but that shaft looks awful small.

I think I see a roller chain that must drive the generator at what appears to be a pretty severe overdrive ratio.  Doesn't look like whatever is driving it is going to be on the generator jackshaft.
--
Chris

[SparWeb]

It all adds up:

Axial flux + gear-up + posting on this site = VAWT

Cool, Brady.  Keep it up and good luck, and keep posting new stuff - you're starting at the right place.

[electrondady1]

brady,
like you , i've been using plywood to mount my coils.
just as a precautionary measure, when the stator is mounted horizontally,
incorporate some form of weather shield to keep the water off the stator.

for the last two vertical  mills I've done (direct drive) i used 3" thick Styrofoam
as an umbrella.
it's formed in such a way as to allow the alternator to sit up inside and stay completely dry.
 






 

[DragonFly III]

that actually looks pretty beefy to me.  I really to need to build up like that for some larger machines I've been thinking about lately.  I like the plywood form for the coils.  I don"t trust myself to cast stators and this seems like a good idea other than the expand/ contract tendencies of wood.  I guess if you sealed it really good it would be less prone to this.  Plus it really doesn't seem that it would effect the coils themselves just need to worry about air gap.

Nonethe less.  I think it looks aw some.
DFIII

[bradyaero]

>>  I like the plywood form for the coils.  I don"t trust myself to cast stators and this seems like a good idea other than the expand/ contract tendencies of wood.

Me too, as long as the plywood is well sealed and out of the weather to a certain extent.  I'll be building a shroud to cover the top half of the plates.  I like the idea of having some air cooling on the coils for sure!

>> It all adds up:  Axial flux + gear-up + posting on this site = VAWT

This one is actually a dhawt... drag type horizontal axis?  It's a great experiment before I build my variable pitch hawt.  It also gives me a nice test bed without a freakin tower to worry about.

[bradyaero]

My friend and retired Bell worker Hugh came over to give me some friendly support.

[bradyaero]

And he brought some Heavy Metal with him!!!  (good to 600 amps )

[bradyaero]

We were able to make some light together.  Turning the machine by hand (100 rpm) after the 1:2.25 gearing we were able to over-light a 50 watt 12v bulb almost to the point of blowing it.  Charging a battery I was able to get 2.4 amps at 17 volts at about the same 100 rpm.  My genny is running a 1 inch air gap at the moment.

[bradyaero]

So there you have it for now, a bit of tweaking and I'll be ready for the real world.  Looking forward to some accurate data recording to see how well this thing works, and how well my genny matches up with the turbine.