Dynamo build by castings

[Don1966]

From what I see in the photos are you going to make one with an iron rotor and one with polyurethane? The motors are looking good in your photos.

Don

 

[manfred albert]

I have forgotten to explain, the withe rotor is a tool for aliening the parts on the base plate. It is importend to have a small air gap between the magnets and the coil. This is the only critical adjustment.
This tool have three function:
1. for aliment
2. to fill up the coil with resin
3. to make the wirer connection of the coils befor final installing

Best Regards
Manfred

 

[Don1966]

Thanks for pointing that out Manfred. I would like to know what material the rotor will be made of? I know the rotor in your demo was polyurethane.

Don

 

[mu38&Bg#]

Fabulous work!

I think you'll be running into eddy current losses with the cast stator housing. I had a part I designed recently with a motor in an aluminum housing. The housing was aluminum and the airgap was 12mm or more. I test assembled it without the iron stator, and the eddy losses were extremely large, far more than I expected. This motor is 61mm long and the magnets only ~2.5mm thick. This is going to be a problem with air core coils. It may be less of a problem with the plastic rotor.

Greg

 

[manfred albert]

Don the rotor is made from iron casting, that is planed for to day, now it is 7:30 AM.
Greg, if I run into the eddy current problem, I`m going to change the housing to polyurethane.

Best Regards
Manfred

 

[manfred albert]

the day is gone and the 3 rotors are not finished. The 36 grooves 1mm deep are left. Each rotor is made out of tow pieces and fixed on a center wheel.
The groove at the center is made with a keyway broaches under a press. The lathe operation are simple, nothing special.
To make all this parts from bar stock, that is only for highly trained experts.

Best Regards
Manfred

 

[smfr]

That's a neat stepped collet fixture you have there. Looks like it would hold various large sizes of flywheels and such? Did you make that?

Simon

 

[steamer]

That would be a bell collet. Nice if you can find them...very popular in Europe.
They come in sets
Dave

 

[manfred albert]

Hello Simon,

each collet set are 6 pieces ( 6 inside and 6 outside ), the max. diameter are 70mm in steps of one mm. This tools belong to the weiler lathe.

Best Regards
Manfred

 

[manfred albert]

Hello,

from the drafting board to the pattern, from the patter to the casting parts without trouble. With a new construction a failure can be done easily.
The magnet on the rotor are glued with JBWELD. The space between the magnets become filled up with resin.

Best Regards
Manfred

 

[Don1966]

Hi Manfred glad to see you are still making progress. The rotor look good and are there two magnets stacked together per position? I seem to see this on you last photo.

Don

 

[manfred albert]

Modification of the rotor layout. To find the best magnet configuration I have made several test. Test 5. give the best result. One layer of 36 magnet, tow magnet north and than tow magnet south and so on.

Best Regards
Manfred

 

[manfred albert]

a pic with the grinder in motion. Don`t grinde to hard, the magnets are start burning. oooooooh the spell checker is gone ? The most importend tool.






Best Regards
Manfred

 

[Henry]

That tool is gone!!! :-D I miss it too, If you use Mozilla there is a way to set it for check spelling in everything that you write in Internet.

 

[rhitee93]

It is good to see an update Manfred. Keep up the great work

 

[Don1966]

Manfred first Happy Birthhday. Glad to see you back on track I am waiting to see the completed dynamo. How is the project coming along?

Regards Don

 

[manfred albert]

Hello Don,

the project is going on. I`m closed to the painting job on this geni. I get 2 times 20V AC at 1000 rpm. So with low speed at the steam engine I can get 12V DC.

Best Regards
Manfred

 

[Don1966]

That is a good looking generator and represents the old generators of the times. I love it . Great work Manfred. Are you still going to product casting set?

Don

 

[manfred albert]

Hey Don,
I`m going to make one more rotor experiment. Than I have to finish and up to date the drawing work. I don`t like this shipping and packing work. I have in minde to place the pattern in the foundry and any one can make his one order.
A other way is to set up a Team Project and make a bulk order to the foundry to get a better price.

Best Regards
Manfred

 

[manfred albert]

Hello,

the painting is done and my hands have the same color. I have no fun with that.

Best Regards
Manfred