All three phases are individually wired. All that is left is to cut the loose starts to length, remove the insulation & connect them all together in star configuration…

Three Phases ready to connect in star

So let’s do it:

Soldering the Star connection

The three phases are wired together:

Three Phases Wired

I could’ve cut and attached the outer diameter to the plywood base of the Continue Reading »

Larger versions of the images in this post (and more) are viewable in The PMG Gallery. Click on each thumbnail image in that gallery for a more detailed descripiton of each.

The wire arived last week and by dinner-time this evening we had the 1st phase of coils in their proper layout and connected together on what is to be the beginning of the mold for the stator. The plywood is for layout purposes and will eventually be used to cast the fiberglass epoxy around the coils. It will not be part of the machine. You can also just make out the other 6 completed coils in the shadow of the shelf.

Fig 1. The stator began by figuring the arc of travel the magnets will eventually make as part of the rotor and laying that out inside the outer diameter of the stator. This will allow me to place the center of each coil in the path of optimum magnetic flux.

Fig 1: 18" square plywood with 8", 12" and 15.5" Concentric Circles

 
Fig 2. Using a Table of Sides, Angles and Sides I was able to determine that Continue Reading »

The Coil Winder is made from:

•  2 – 6″ dia plywood discs (one 1/2″ & one 1/4″ thick)
• 1 – 4″ dia 1/4″ plywood disc
• 1 – 5/16″ x 3″ bolt (with a hole drilled in it for the nail
• 1 – 5/16″ x 2″ bolt (holds the wood dowel handle on)
• 1 – 1″ x 1/2″ x 3/8″ plywood block
• a couple of pieces of 1″ x 1/4″ flat stock (base & crank)

6" Dia Plywood Disc with 3/8" Thick Block Glued in Place. The Block determines coil thickness.

  Continue Reading »