1801 Winding Star (Faulhaber) Coils And Making Litz Wire 

in power tool motors the magnets are set at angles to coincide with the angle of the copper.

If more classroom teachers taught with the same joyous enthusiasm as you, students would learn much better than they do, Because you teach love OF the subject, not just the subject - and you do that with your sheer unbridled exuberance, demonstrating your love for what you're doing. Once someone is hooked by love for a subject, there's nothing they cannot learn About it. That is your gift.

I'm seriously jealous of your huge roll of copper wire! 😮😆

Love the extra detail and information about how stuff works and showing it almost all the way through. ❤ keep it up!

I am extremely glad I fell upon your channel. The subjects you talk about are always interesting, and informative. Keep up the great content creation.

I LOVE this stuff, I became fascinated with axial-flux motors and litz-wire when designing one of the many thousands of abandoned robot-wars entries that litter the world lol.

Fascinating! Looking forward to seeing how it all works out!

I'm really excited 😁 too see you covering this topic. I hope you do some on liner generator also. Thank you Robert for being such an Inspiration and explaining electric generation.. A+

Looking forward to seeing the results. Very cool Rob!

Appreciate taking your time to show this process Thank you

You've always been a great whistler

Wow! Cool artistic whistling!

This brings me back to my school years. My physics teacher made me wind all kinds of coils for loosing a bet or discussion and sometimes as an alternative punishment for being a bit of a prick. Good times. He’s still my favourite teacher.

I have been trying to figure out how to make my farm more self-sufficient and this channel has basically all the ideas I've thought of with actual testing them. I absolutely need to get a 3D printer and get started. I have plenty of room to do both wind and solar I was previously convinced wind was outside my grasp, but not anymore ❤

This channel is strangely addictive I love it. This one reminds me of making xmas wreaths. If only we knew the physics country women would (and do) power the world!!

I wondered why the little drone motors had that kind of coil/wrapping pattern. But never looked into it. Thanks, Rob! :)

Nice! Thank you Robert.

I really think I'd like to try and make one of these. I totally agree with what you said about the benefits being dependent on what it is you are trying to achieve rather than seeking an absolute superior design!

Fascinating Mr. Smith! It looks cool, too!

Very good, indeed! Thanks Rob. Waiting for the next fascinating videos.

Correct and good explanation of where and why to wind the coil in this spacing and angle based on the magnet size and not just any angle or location of without a logical spacing.

Thanks again for the teachings, very enlightening. Cheers mate!

thats great, this is how ive been doing my litz wire for years. makes great matched load windings too, within limits.

Awesome build if you put 1 on each side of the magnets disk and spin the magnets turn 1 of the coils 11 degrees out of sink with the other you should have a very clean output. might be worth giving it a try . Another great video Robert cheers mate.

Educational as always, thx for sharing this, thx for uploading, Also don't forget not to get burnout and pace yourself if truly needed!

wow .. this man is legend .. i love his videos .. so much info ,,. and trhe enthusiasm hahaha i love it. Thank you for all your work and sharing wid us sir.

Beautiful winding

Thank you very mush.. that was wonderful explanation

Wow. Seems to be a great channel. There is insufficient time to satisfy all my curiosity. 3 minutes in, I'm seeing an exemplary presentation by a skilled teacher. I don't expect to be back, but I wish the best to the channel!

Great info as usual. I appreciate the education kind sir.

Delightful Sir!

I'm finding this series fascinating. I've been toying with the idea of building and winding my own generator for a long time and I think this has finally incentivised me to do so. One project I have wanted to do for a while is to build a generator with some VERY strong HDD magnets I salvaged from very old SCSI drives many years ago. The problem (as I understand it) is that the poles are not oriented correctly. The poles are at the edges instead of at the top and bottom so they would essentially cancel each other out as they pass by the coils. I've been thinking that there must be a way to wind the coils to not only eliminate this issue but actually take advantage of it but I'll be damned if I can figure it out. Not my area of expertise.

This is the first time I've seen your program, I've been looking at many that are producing 220 vAC power. Bur the star winging gave me an idea, the suggestion I have is if the Magnets were made in the shape of the star windings, then they would have the star windings at the correct orientation to the magnetic force 100%of the time. Then I there was another star winding on the same shaft using the other pole of the magnet there would be in opposite phase. Use one of the phases to drive the electric motor to turn the generator and the other phase to use to operate other machines and lighting. I haven't looked at how magnets are produced but they come in various shapes so how much a star winding would cost an of course demand.

Good stuff 👍

Patience is a virtue😄

Very cool...Thank You !!!

This is so cool to me. I am curious how this would compare to a geared "stepper" wind generator. Maybe after you turn this into a generator, you could: A) grab one of the generators you made with a stepper motor. B) gear it, so that it takes an equal amount of force to spin as the Faulhaber coil generator (so both work in low wind speed). C) see how they perform under equal conditions. I feel you would have to create a 2-phase Faulhaber coil (or only hook up half the stepper motor) to get accurate comparisons.. But I consider you the professional here. Thanks again for the great content! And even more teaching us how to make Litz wire. I have been spending WAAAY too much time on my toroidal transformers..

Ty!

Hi Rob Sir this came much in time I am working with a windmill project these days, will share images soon 🙏🏻🙏🏻

Im fascinated with coils and antennas and I am amazed by the sounds of my handmade AM radios as I tune the channel

Amazing! Thank you!

I love your channel

"headphone lead" is a great soure of HF-Litz wire for small projects

Awesome!

master of excellence.

Thank you. 👍👍🐝🌞

Awesome 👏

That makes a rather pretty winding. It will be interesting to see how it performs.

DYI Litz caution: Damaging the insulation while twisting..

This man developed the process of whacking a gallium arsenide semiconductor with a block of wood to create the first UAP de-cloaking sensors.

You're a STAR. Too late for Christmas, but they would have made great halos (don't fret, just winding you up 😁)

Keep up the good work mate ;)

1) what about angling the magnets also, either with it opposite the copper? 2) what about making a longer axel on it and putting two coil types one to pick up the low wind and one to pick up the higher wind? 3) advantage/disadvantage of one phase vs three? Why not more than three if three is better than one?

As some others have alluded, changing the geometry of the permanent magnets can provide an excellent trade off for additional torque, both with angles and overall sizes (reduced distance between poles, more poles per cycle, lower kV [for simplicity], higher relative torque vs the opposite). One should also consider, assuming this is an academic conversation, that changes in the current geometry must also change the thrust geometry, so in instances like this demonstration (and as another user has pointed out about power tool stator geometry that use FB coils), one may potentially lose more than they gain to friction without a carefully tuned alignment. Again, this is almost purely academic, food for thought, makes hardly any (if any at all) difference in concept demonstration and learning, but it can make a fair difference in industrial or infrastructural scales. I suppose the real question... Really is whether or not a given design in the real world can maintain electrical, mechanical, and thermodynamic efficiency above the cost of copper saved. The amount of motors I've repaired, handled, I have definitely seen a fair bit of poor, low budget executions that still work, and that's sometimes frustrating because the real cost to do it right for a given application (better?) Is about the same. It just doesn't make sense to me as a reasonable corner to cut, circumstantially on a precision motor; RM-S's explanation enforces this, IMO. Thank you again, another great video. Cheers from across the pond.

Spinning like billy oh huh? 🤔😅 And thank you again for another wonderful english euphemistic expression to add to my vocabulary. Lol Thanks for the rundown.

Looks nice, super nice. Could it be made reversible i.e. spin the copper at some speeds and spin the magnets at other speeds?

As a master electrician for over 45 years I have been exposed to many different electrical projects. I majored in chemistry and received my master electricians license in the 90s . You have presented a new idea with motors and magnetism I salute you.And I will have many sleepless nights understanding what you have described. Post script: I am working on a DC /AC motor based on similar principles . LOL like for the last 45 years.! LOL

If you make the core from a water or alcohol soluble material you could remove the center . This will make the coil thinner and that allows for thinner magnets. I have a design like this that uses three windings one for each phase. Nice job explaining basic electrical phenomenon. Thank you.

Zigzags are the most efficient shape for UHF TV/radio antennas, too. I’ve built several designs, and I get the best gain with them.

Litz wire is used in the tone arm of record players. It's normally in higher end decks.

A lot of people don't realize flywheel mass in a wind turbine is less desirable. Spinning a coil under a load pose a challenge in keeping it secured to the rotor when experencing back torque, but the wind turbine will be operating more efficently in varying wind.

I am wondering how much increase in the electrical efficiency you will get with the Litz wire Robert. I am just amazed with all the amount of experimentation that is happening these days some has not found a super way of super efficiency. Look forward to see what you will come up next Sir. Good day too. vf

For the central piece I think I'd go with sandwiching the coil disk with two more acrylic or whatever disks. 1. protects the coils from accidental touches to the stator/rotor (and damaging the coating), 2. more stable central axis when it's threaded through 2 points further from each other, 3. easier access to the coils should they require maintenance (compared to glueing the central disk in), 4. completely rules out the need to know the inner diameter (or outer, for that matter), 5. keeps the coils compressed and in shape at all times, and prevents winding slips on the acrylic disk (which could damage the coating).

Coreless motors/generators would be an interetsing topic for me as it implies I could 3D print the housing/stator assembly and have it all be just PETG, the magnets and some copper

Mechanical engineer for an Aerospace company that makes generators. And designed PM and switch reluctance machines. That plastic disc significantly decreases fielded strength. Heat up the coil to melt the disc and then extrude the plastic through the coil to remove its thickness from the air gap.

A very long armature would also put more flux cutting conductors in the field, and at 90°. Putting such an armature inside of the wind spiral would also serve to multipurpose the volume.

Good, 100% agree! Thank you:o)) Try a "Star Coil" may be bifilar! Cheers, great video

After this Great Series maybe DIY coil tester like motor shops use and I don't mean an ohm meter or Megger.

With more phases you get less ripple , if you rotate the coils and your diode array the diodes can be arranged so that while spinning they get air cooling , such an arrangement can have output through sliprings with multiple brushes on each ring to minimize electrical noise that can be minimized with small capacitors and because of the low ripple smaller filters ( my favorite being a voltage follower set to a voltage below the ripple ( completely eliminating power ripple capacitor ) ) to no filters are necessary for direct utilization .

Now I know why Faulhaber moved their production to India. Winding coils like that must be quite costly! I can't imagine the machine that they would need to do that!

The problem with trying to harvest low wind speeds is that the power contained in the wind is a function of wind speed cubed. So if your local wind is 4m per sec, you only get 1/8 of the power compared to if it was 8m per sec. Doubling the wind speed gives you 8 times the power. So to harvest low wind speeds with any decent result means MASSIVE surface area to catch the wind. And the working surface area of the turbine is very expensive being (probably) the highest cost of the enture turbine. If you seriously want to get usable,power generated from 4m per sec winds, I think you should be focusing on building very large turbine area very cheaply, and the type of electric generator etc is almost irrelevant (provided you gear it at the optimum ratio). And there is a reason why commercial windpower operations dont try to harvest low wind speed areas... 🙂

Speaking of coils, any one else wonder why we still wind coils mono-fillar when it was discovered over 100 years ago, that winding the coils bi-fillar creates capacitance inside the coil itself and power-factor corrects the coil extremely efficientlly? I did, I read the patent and was like "Oh that make sense, just make this one simple change to the manufacturing process and we automatically make every machine on the planet more efficient." The other thing, about the coreless motors and generators makes sense because, with nothing for the magnets to be attracted to, there's nowhere where they want to "stick" so you don't have to fight that. After I'm done my current project I was actually thinking of making a bi-fillar panckake coreless generators/motor. Want to bifillar pancake set-up to make the most of the air/epoxy core before it atennuates too much, then the generator/motor will be automatically power factor correted and I should have a really efficient machine! It'll be a brushless PM-AC motor/generator and since it uses bifillar coils, if I tune the coil length right, I should be able to get the generator coils to resonate if I get the rotational speed right.

Dollar store earbuds are a great source for extremely fine litz wire. Just skin the cord. I was using individual strands for repairing pcb traces.

Excellent Robert Murry Smith, what great initials you have. RMS. I'll be very interested to see your Generator with the Faulhaber coil fixed and rotating magnets. And very interested in what Wire AGW and turns etc you use and what power of Magnets you use. You've given me loads of enthusiasm to DIY rather than anything bought of the shelf.

Wicked!

I have a bunch of the Maxon DC motors. They are insane for response n servo applications. With no iron in the winding, the start, stop, and position response is really quick with good torque and very little change in torque for the current in the rotation. It is as close to a rotary voice coil drive as possible to get in a motor. Older motors unfortunately get clogged up with carbon from the brushes as most are sealed for clean applications, so the dust is trapped inside leading to the eventual failure. Similar tech is now using AC permanent magnet motors for servo application in robotics.

That Liz wire was sold in comerce for radiotecnics named antena wire very useful for GALENA RADIOS in the pastime.

There were some other comments asking about how versatile this setup could be for places with varying wind speeds. I had an idea that I thought could make a really fun project, but I am not quite sure how it could be completed. The basic thought is this... Construct a Faulhaber generator with 3-6 phases, then dictate a way (without electronics) to open and close the circuit to each phase depending on wind speed (turbine RPM). In low wind speeds, only one phase would be online. As the wind got faster and the turbine sped up, it would hit an RPM threshold and close the circuit to phase 2; effectively increasing the load and slowing the turbine. Vice versa if it slowed down to a certain threshold it would open said circuit. In theory, you should be able to scale the number of phases up or down for any amount of wind correct? Running 10 phases in 150kph winds, I GOT YOU ;p

Fascinating! Never saw a Faulhaber winding before! How would it perform against a rewired F&P washer motor?

we haven't even begun to use Superfluids.

Seems like you got a cool coil design to show us every day. Are you doing research and experimentation with a specific goal in mind? You seem very fixated on axial-flux lately and that is great because I have the same need for a cheap / diy generator for VAWTs.

OMG Rob you made Star Gate...😃! Is Earth going to get attached by Aliens now 😂! Plz say yes.

This is nice Rob! Can you also show how to make a radial flux coreless stator? Im fascinated by slotless/coreless winding with the faulhaber pattern!

Cool

you need to make the spindle of ramsbreath attached to the ferroloc wound in such a way, introduce a lode stone at certain points around your spindle mounted on a shaft.

Cool, after you make this a generator it would be cool to see how you run it as a motor. Could you control it with off the shelf ebike components?

Very interesting RMS , I am looking forward to seeing how options in phases / pole count can affect horsepower / torque outcomes for EV use. There are many successful pancake style axial flux motors being developed recently . :) woohoo

great!

Patience and attention is required.

I'm very interested to see how this turns out. I may be getting hold of an old car engine soon, and I had the crazy idea to turn it into an inverter generator. I'm not sure how, but I think I'd need to come up with some sort of governor so the engine can idle low, but get some extra fuel when more power draw is placed on the generator. I'm also thinking of replacing the stock alternator with a more standard generator/motor since car alternators aren't very efficient. This would be a "just for fun" project. I wouldn't expect a machine that's as good as store-bought, but as the engine would be free, I suspect it may be slightly cheaper. Depending on the cost of the generator/motor and inverter. Anyway, I love all this DIY stuff. I wish I had enough wind to make wind generators worth while, but it's just too calm here, except for wind storms. Good for painting outdoors though. :)

THE SUPERETHERODINE RADIOS OR WIRELESS USED THAT TIPE OF COIL IN THE STAGES OF INTERMEDIARY FREQUENCIES in a range OF 275 Kc tô 475 Kc AND it was named "Honey Comb" coil in order tô dimmnish the counter motor electro force the Lenz Law in these frequencies.

If the copper is at an angle to he rotational direction, say at 45 deg, the usable length will be sqrt(2) times the length, so that 41% is wasted. This amount may as well be positioned in the overhang position( end windings) wit the wires straight. You cannot rally win. Thank you.

To think one of those roles of copper drums he has is thousands of dollars. And this star pattern designs which increase voltages is giving me some insights into Ancient Star Forts found around the world. Shape modulates voltage and energy flow and them Star Forts might actually have been built as some kind of giant Generator.

I understand that the different windings have advantages, but the common windings on the average motor are many times easier, and quicker to make, are cheaper, and the extra weight doesn't affect the power used or generated. I do find the last 2 videos interesting, and informative.

Spent a large part of my adult life working on electric motors, up to 6000 horsepower, they tend to dim the lights on the entire grid when starting . Have had many an adventure, survived enough to retire. I'll have to watch this over to determine a use for your motor concept. Look forward to learning new concepts . The motors I deal with now are mostly on little flying things, that are being slowly outlawed. Why they are worried about the threat of small flying things now but ignored a German saboteur, who worked just down the road, kinda confuses me. Heck as a young man I shipped many a large black airplane kit to embassies, American only, now 50 years latter they are dangerous ... and China makes all the parts , lol .

Can you rotate the magnet to get closer to perpendicular to the wire? Perhaps reshape the magnets more pie shaped parallelogram?

just had a thought to cock the magnets staggered the same degree to parallel the coils? but i see the problem there too would be the next coil would have less effect.or would it?

Forming the resin would be really super easy, put mold release in the bottom of a cake tin [if the diameters allow it] or some similar sized pan [of course it would be helpful to know in advance so you can find a pan the size that matches your coil] even a pizza pan might work, albeit you might need one made for deep crust, and some restaurants have round server's trays with lips on them that might also work. But if none of those are the right size, just put some waxed paper on the top of a smooth board and cut a hole in a matching sized piece of board, and line its edges with waxed paper, and maybe rub just a little bit of bee's wax or softened candle wax into the gap between the boards so the resin does not run out, and you should be ready to place the coil and pour. Of course be sure you have your slip ring arrangement already prepared and attached, as well as safely masked off so epoxy does not get on them and have to then be removed later. A couple of small lengths of copper pipe slipped over some PVC pipe, slipped over a metal axle would give both connectivity, insulation and strength. Then slip those into a pair of bearings, and on one end add a pulley, or chain sprocket or gear, or fan blade, or water turbine. Of course finding the best working speed might take some tinkering.

Can you go into how to align the magnets to the coils so that you make the best use of the magnets without working against yourself? (generation wise)

Have you tried the Rodin coil?