3-Phase Complete PMA Generator by relic

Last crawled date: 3 years, 1 month ago

7/28/2018 - Home from hospital : ) ... Stator windings done and inserted into one half of housing. Hope to assemble today and start some bench testing. New o-scope arriving Monday to do some in depth testing. Housing is VERY tight fit. I got 3 sides inserted, then used a screwdriver in one of the housing's 4 mounting holes to give me leverage to gently pry away. The 4 mounting bolts for the housing may not even be needed.
Once inserted, consider a double coat of clear lacquer on the inside.
ADDED 2 ALTERNATE ROTORS FOR LARGER N52 MAGNETS TO INCLUDE: 60 x 10 x 5mm and 2" x 1" x 0.5" (50.8 x 25.4 x 12.7mm)
Also added wire retainer strips that tightly fit each stator slot, preventing coil wires from coming loose.
I chose to go with a 3-phase winding configuration. But the stator has 36 slots so I leave it up to you to wind any way you wish depending on your application. I've provided a great video showing how to wind for 3-phase.
Cooling: It's recommended to place a fan blade on both sides of the housing ... one pushing air in and the other pulling air out. Increased housing height to allow plenty of room for windings and added more cooling vents.
GREAT video on 3-Phase stator coil winding technique - https://www.youtube.com/watch?v=TwYUVbg5Jmc
7/11/2018: PMA Frame.stl added. Use two 6mm shafts/rods (each 200mm long) on the 2 bottom holes of the frame. It also provides support for the housing.
7/6/2018: Updated rotor & housing STL's as 10mm shaft / bearings needed larger holes. Received all needed hardware from amazon & in process of building now. Magnets fit rotor perfectly! If you wish to use larger magnets (6 large N52's would be nice) just import the rotor into TinkerCAD and modify. For 6 magnets, rotate them 60 degrees apart.
7/4/2018: Added a new version of thr stator core to accept more wingings & larger gauge wire. A free-standing frame is ready that uses two 6mm rods.
Assembly break-down video - https://www.youtube.com/watch?v=cgKV0p0UAHs&feature=youtu.be
Proto-pasta makes 'rustable' filament containing iron. A while after printing with it, the iron begins to oxidize. This type of filament could be used to increase the permeability of the stator core.
Rustable Filament: https://www.amazon.com/Proto-pasta-FEP11705-Rustable-Magnetic-Spool/dp/B00X8BQYPS
Includes PMA housing, rotor, stator core, Side-mounting stand brackets, pulley and fan blade. Magnets are 60x10x3mm commonly found on amazon. 12 magnets arranged in a north-south-north-south manner. Using 20AWG wire I was able to wind 11 turns per slot. Wire all sets in star configuration for more voltage @ lower RPM. Smaller wire allows more turns hence more voltage but less current.
Tip: Wood skewers help keep wires in place :)
Wire: https://www.amazon.com/Remington-Industries-20H200P-25-Enameled-Diameter/dp/B00L5IVNWK/ref=sr_1_1?ie=UTF8&qid=1530519204&sr=8-1&keywords=magnet+wire+20+awg&dpID=51V7e67fUHL&preST=_SX342_QL70_&dpSrc=srch
Rods: https://www.amazon.com/uxcell-Diameter-200mm-Length-Metal/dp/B01DBZSZA2/ref=sr_1_6?ie=UTF8&qid=1530520597&sr=8-6&keywords=10mm+rod
Magnets: https://www.amazon.com/DIYMAG-Neodymium-Magnets-Double-Sided-Adhesive/dp/B07B6NX5NP/ref=sr_1_3?s=industrial&ie=UTF8&qid=1530519512&sr=1-3&keywords=magnets+60x10x3&dpID=51XtKDhcpeL&preST=_SX342_QL70_&dpSrc=srch
LARGER N52 Bar Magnets for wind turbine applications - https://www.amazon.com/CMS-Magnetics-Neodymium-Countersunk-Projects/dp/B01N8RTOJP/ref=sr_1_29?ie=UTF8&qid=1531589164&sr=8-29&keywords=n52+bar+magnet
Bearings: https://www.amazon.com/uxcell-Sealed-Groove-Roller-Bearing/dp/B00VG3PVLS/ref=sr_1_4?s=industrial&ie=UTF8&qid=1530521285&sr=1-4&keywords=10mm+bearing
Bridge Rectifier for 3 Phase: https://www.amazon.com/gp/product/B07BGR2JFV/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1