Stator construction

Permanent Magnet Generator Constructione

This section tells how to make a stator, using the jigs and moulds from section 3. It is a good idea to wind a coil before making the stator moulds, so that the mould can be checked for correct fit. Mount the reel of winding wire on an axle behind you, in line with the coil former. The wire should form an 'S' bend as it winds onto the coil diagram 26 . Bend the tail of the wire 90 degrees, at a point 100mm from the end. Do not handle the bend any other part of the wire leave it straight. Bent...

Introduction

Volt Magnet Generator Diagrams

This manual describes how to build a 'permanent magnet generator' PMG . We can also call it an 'alternator', because it generates alternating current AC . It will not generate 'mains voltage' or 'utility power' AC. It generates low voltage, 'three phase' AC, and then changes it into 'direct current' DC for charging a 12 volt battery. The PMG see diagram 1 consists of - A stator containing coils of wire The stator contains six coils of copper wire, cast in fibreglass resin. This stator casting...

Jigs and Moulds

This section describes how to make the jigs and moulds for building a PMG. Once you have made them, they can be used again, to build more PMGs. The PMG stator contains six coils of copper wire see diagram 4 . The coils will be wound on a plywood coil-former. The former is mounted on the end of a crankshaft, between cheek pieces. Make a crankshaft, turned by a handle see diagram 5 . Cut a small flat steel plate 60 x 30 x 6 mm suggested sizes and fix it securely or weld it to the end of the...

Rotor construction

Permanent Magnetic Disk Diagram

There is also a procedure later for assembling the parts. First collect together the magnet plates, magnet blocks, stainless wire rope, etc. as described next. Each magnet rotor is built on a steel disk, 6mm thick. See diagram 32. Do not use aluminium or stainless steel for this disk The disks have to be made of magnetic material. The disk has holes to mount it to the hub - in this manual the hub has four holes, each 10mm diameter, on a circle at 4 inches...

Testing and connecting

Pmg Coils Connection Diagram Windgenkits

Check that the PMG has no faults before it is put into use. It will be much easier to correct the faults now, than to return the unit to the workshop later. Mount the spine vertically in a vice. The magnet rotors are free to move. The shaft is horizontal, as it will be in a wind generator. Check that the wires are not touching each other, creating a short circuit which makes the PMG harder to turn. Check that the rotor will spin freely. Spin the rotor and listen for sounds. There should not be...