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Author Topic: Dia. Mag. Alternator  (Read 190183 times)

z.monkey

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Re: Dia. Mag. Alternator
« Reply #195 on: May 31, 2011, 10:12:18 PM »
This one is the NeoMag8.  It is one phase, and eight poles.  The magnets and the coils are synchronized such that the polarity is the same for all of the coils.  They can be wired parallel for current, or wired in series for voltage, and do not need to be phase corrected.  The stator has inside windings so it can be wired all the way around the stator, and I do not need to leave space for the mounting tabs.  The mounting tabs are further away from the windings, and the slots are situated so the wire goes away from the mounting tabs.  This one will need bearing plates above and below the stator to mount the rotor.  NeoMag8 has eight more winding slots than DiaMag7-2, and I can make the slots wider if I need to...
« Last Edit: June 01, 2011, 03:38:03 AM by z.monkey »

z.monkey

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Re: Dia. Mag. Alternator
« Reply #196 on: June 01, 2011, 02:36:08 AM »
Loose Cannon...  Hahahahahaha!!!3  Holy Fork!!!3

I put my safety glasses on for this one...

Got an 1/8 inch ID shaft spyder, fits the DiaMag spider...

Found an 1/8 inch piece of music wire shaft, fits the spider perfect...

1/8 inch collet in teh Dremmel...

Driver...

Check, ready for service...

No rheostat...

Oh well, lets go...

Bam!  Runs flawless at 30,000 RPM...

The Voltage jumps up to almost 13 Volts...

Teh lights are blindingly hot...

5 Volt bulbs at 13 VDC...

Holy Fork!!!3

I did make this thing industrial quality...

I have seen The Light!!!5
« Last Edit: June 01, 2011, 04:19:07 AM by z.monkey »

z.monkey

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Re: Dia. Mag. Alternator
« Reply #197 on: June 01, 2011, 02:52:04 AM »
Just measured teh Amperage...
600 milliAmps @ 12.8 Volts...
7.68 Watts...

Fork Yeah!!!5

Video up in a moment...
« Last Edit: June 01, 2011, 04:18:22 AM by z.monkey »

z.monkey

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Re: Dia. Mag. Alternator
« Reply #198 on: June 01, 2011, 02:54:53 AM »

z.monkey

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Re: Dia. Mag. Alternator
« Reply #199 on: June 01, 2011, 03:01:15 AM »
The fourth time I ran it I burned out all four bulbs...

Hahahahaha!!!

Open Circuit DC Voltage is around 14 VDC...

Fork Yeah !!!3
« Last Edit: June 01, 2011, 04:17:53 AM by z.monkey »

z.monkey

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Re: Dia. Mag. Alternator
« Reply #200 on: June 02, 2011, 01:05:55 AM »
Got better bulbs rated at 14 Volts, and 330 milliAmps.
Now I'm getting 11.2 Volts and 1.2 Amps on the load,
13.86 Watts.  So, getting close to the theoretical
potential...

I guess I can call it a success now...

nievesoliveras

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Re: Dia. Mag. Alternator
« Reply #201 on: June 02, 2011, 02:06:13 AM »
Congratulations for your success @zmonkey!!!!

Jesus

z.monkey

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Re: Dia. Mag. Alternator
« Reply #202 on: June 02, 2011, 02:10:26 AM »
Congratulations for your success @zmonkey!!!!

Jesus
Thanks Jesus!

loosecannon

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Re: Dia. Mag. Alternator
« Reply #203 on: June 02, 2011, 05:56:09 AM »
Zmonkey, that mustve been a bit nerve racking the first time you hit that switch eh? LOL

very cool!!!

i dont have access to the tools or space to build anything right now, but when i do; this will be the first project i do.
very exciting to say the least.

kinda scary to think about your mag motor turning that fast! ;)

you have my attention sir.
LC

z.monkey

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Re: Dia. Mag. Alternator
« Reply #204 on: June 02, 2011, 11:05:36 AM »
kinda scary to think about your mag motor turning that fast! ;)
I would be delighted if it goes that fast...

z.monkey

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Re: Dia. Mag. Alternator
« Reply #205 on: June 03, 2011, 04:34:01 PM »
OK, now I am starting the fabrication of DiaMag7-2.  This plate is literally a piece of scrap I pulled off some discarded computer equipment.  It is 3/32 (0.09375) inch thick, about 3.2 inches tall and 10.3 inches wide.  What I need for DiaMag7-2 are two, three inch square end plates.  You can see in the pic below I have the outlines defined for both plates, but only one is marked with the remaining cuts.  I only mark one plate because they will be stacked in process.  Also the slots are just lines, and not detailed.  This is because the end mill will define the sides of the slot, and we only need to follow the center line with the end mill...

The process goes in a structured order so that in the end all the holes will be precisely aligned.  First thing is spotting the two center holes.  Everything else literally revolves around the center holes.  Then we will cutout the outlines.  Once the plates are freed then we can finish cut the center holes to 3/8", the size of my center clamp bolt.  We will also need a sacrificial block, with a 3/8 inch center hole.  Then we will stack the plates up, setup the center clamp, align the plates, and lock the table clamps.  Spotting the four corner mounting holes is next.  Then we will take the stack apart and prepare the stack for the actual cutting process.

I'm cutting on the Palmgren Table this time and not the Rotary Table.  I get much better results on the Palmgren Table.  This time I am using the four corner mounting holes to hold the stack together.  I'll drill the four corner mounting holes to 1/4 inch, and countersink the back of the sacrificial block.  The short, maybe 1/2 inch long, stack bolts will sit inside the sacrificial block so that the stack is free to rotate about the center clamp.  Then I'll use the table clamps on both sides of the stack.  I am hoping that I can actually finish mill the slots this time and not have to file down each slot.

Finish milling the slots takes more time, but with the Palmgren Table I think I can do it.  It was just not possible on the Bitmoore Vise with the Rotary Table.  So this process starts like the other milling I have done, a set of overlapping vertical mill cuts.  Then I'll run the mill down in entire slot as though I were side milling.  I am hoping that this will take off all the scallops, and leave a nice finish.  I may increase the spindle speed of the drill press to improve the end finish of the slots.  Now that I have the slot liners I want improve this process to make it more efficient.  It took a whole Saturday to mill the DiaMag7 plates.  I want to make this next set faster...

z.monkey

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Re: Dia. Mag. Alternator
« Reply #206 on: June 03, 2011, 05:48:58 PM »
Well, made a little change.  Decided to do the outline first, and then spot the center hole.  This lets me punch the center hole through all three pieces simultaneously.  When I get back to my Mini-Mill all I have to do is set the stack one the table, align the stack, lock the clamps, and start spotting.  Is it the weekend yet?

z.monkey

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Re: Dia. Mag. Alternator
« Reply #207 on: June 08, 2011, 03:28:04 AM »
Got the DiaMag7-2 Plate spotted and ready to cut...

z.monkey

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Re: Dia. Mag. Alternator
« Reply #208 on: June 08, 2011, 04:43:26 PM »
A note about efficiency...

Lets look at the power required to run the Dremmel.  Rated at 120 Volts, and it boasts 1.15 Amps on the label.  That is 138 Watts.  In the last test, with the new load, the DiaMag7 put out 13.86 Watts.  A little better than 10 percent.  Is this right?  Yeah, its the rotor physics.  The monolithic magnet has a natural flux field, and as it turns out a natural flux field is not very efficient.  We need to increase the pole surface area, and add more poles to kick the efficiency up.  The NeoMag8, with 8 poles and maximum pole surface area will do this.  I do still want to build DiaMag7-2 anyway, with a different coil configuration, just to have a little more empirical proof that this is the rotor physics.  The rotor is key to the whole device.  Mo betta rotor, mo betta efficiency.  Looks at it the way Spicoli would...

If you want bodacious output, like, you gotta have a schweet rotor, man...

The poles of the monolithic magnet in the DiaMag7 are only an estimated 16 percent of the surface area of the magnet.  The NeoMag8 magnets have 100 percent of the surface area covered with poles.  Do you see a bit more efficiency there?  I am chomping at the bit to get NeoMag8 into fabrication, but I really need to spend some more time gathering data first...  I know, boring, but its the scientific process, and I want a lot of data to support my endeavor...

Also, now that I am starting to measure efficiency, I am starting to build an efficiency testing jig.  I scrounged up a 10 Ohm Rheostat.  Also I have a 12 Volt motor, was the driver for the Bicycle Wheel Alternator.  Then got a 12 Volt, 7 Amp hour SLAB (Sealed Lead Acid Battery) to drive the motor.  I'll add test points for measuring Voltage and Current.  Then I can measure efficiency over a range of power levels and speeds.  I may wind up getting a bench power supply, just so I can play with the Voltage and the Current.  Then I feel that I should be able to get more accurate efficiency numbers.

If we look at the efficiency from the Dremmel test and apply it to the hand drill test (1400 RPM) then the hand drill is putting out about 5 Watts, the DiaMag7 output numbers were around half a Watt...
« Last Edit: June 09, 2011, 02:48:44 AM by z.monkey »

z.monkey

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Re: Dia. Mag. Alternator
« Reply #209 on: June 10, 2011, 03:23:34 AM »
Shredding...

The most fun that I can have is shredding metal...

I am experimenting with finer cuts, smaller increments.  Before I was cutting the next cut more than half diameter of the mill.  Now I am only moving the cut over one quarter of the way over.  This puts the circles closer together, and reduces the scallops.  this is how I have to do the round parts now.  There are still scallops, but smaller, easier to smooth...

On the slots I am using the same method, but afterward I run the mill down the slot like a side cut.  This smooths out the scallops and leaves a nice finish.  Starting to feel Zen with the Mini-Mill...

I'm scoping out a Rotary Cross Slide Table.  It will make the round cuts pretty, like the slots...