Making Wind Turbine Stators: Vacuum Injection 

good day. can i use it vertically? thank you.

Да мужик, молодчик!!!

Thanks Andy!

Really tho.

Thanks Phil, you bet!

Yes, I've used both in the past. Using star with this build, it's typically the most effective for generating electricity via the wind. A switch that can automatically switch from star to delta depending on the wind speed would be ideal, we'll see what the future holds.

Yes, it produces electricity when spinning in either direction.

No problem. Hugh Piggot explains how to calculate # of coil turns for a given # of coils and magnet sizes/strength in his 'Wind Turbine Recipe' book. Theoretically, more turns of copper per coil = more voltage, and more magnetic flux = more power. But with an axial flux generator, space is an issue. Making the coils thicker will actually decrease power output because a thicker stator increases the distance between the two magnet rotor plates, which decreases the magnetic flux strength between them. The closer the magnet rotors are to each other, the stronger the magnetic field will be. Coils with more turns should be made wider instead, so that the magnet rotors can be placed as close together as possible. For a good working machine, the stator shouldn't be thicker than 5/8" (16mm). A bigger magnet doesn't necessarily mean more magnetic flux either. Neodymium magnets are graded for strength (measured is gauss). A 2"x1"x1/2" magnet that's N42 grade will have ~13,000 gauss for strength, while the same size magnet that's N52 grade will have over 14,000 gauss. So you have to pay attention to the magnetic flux strength in gauss when choosing magnets for your generator (do not choose based on pulling power, ie: how much weight the magnet can lift in lbs - this rating is for different applications). The size of the magnets only matter in regard to whether they'll fit in the allotted space on the magnet rotors or not.

Magnetic flux is not affected by resin. Air gap is what matters.

Thanks!

Read the video description. It exists for informative reasons, my friend. Few utilize it for their benefit for some unknown reason, though.

@@JamesBiggar dear sir please send me how quality use of magnet 5 kw turbine and how use winding wair I make 5 kw turning so kindly hilp me make 5 kw turbine I hope you hilp me thanks

Like I said, read the description. I already helped you.

ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-vldUqRRf_pc.html

Same as 12 coils, less two coils per phase (two coils per phase instead of 4 coils per phase as shown in the diagrams in the video).

thanks sr

Never mind . 2 and 4 magnet rotors

Theoretically up to ~4000W @ 30mph with my pmg arrangement.

@@JamesBiggar I can't wait to see the results.

I use both lol. Either work fine in an encapsulation, no need to worry about any sort of leaks, electrical or otherwise ;)

I thought the same thing until I realized its going to be sealed into the epoxy. If the adhesive on the tape breaks down it won't matter.

Encapsulation eh? OK... but I like heat shrink best.

Yep. Note the end of the video where the stator is cast in epoxy. I like heat shrink best as well, however, it has it's limits - like when connecting the large flat lugs to the thin 14 awg wire. Gotta use a large shrink tube, but it will only shrink so much, nowhere near enough to cover the wire sufficiently. So I used tape in that case. Everything else has shrink tubing, as demonstrated.

Thanks for the reminder... agreed.

The center of the coil should match the mag in both dimension and shape, or as close as possible. The flux lines extend from the surface of the magnet out, so the coil should be shaped accordingly. They can be wedge shaped like mine to minimize space requirements, but without matching with wedge magnets there is a slight compromise in efficiency (not enough for me to pay 3 times more for magnets though - CBA is the bottom line). The mag does not need to be as big as or bigger than the coil - this would be a waste since some of the flux lines would extend well beyond the steel plates and would be lost (google dual rotor axial flux animations for a visual of how the flux travels) - the plates would also need to be ridiculously large/heavy. You can certainly put a ferrous material in the coils, but that would just be dead weight that would cause cogging and increase the required startup wind speed to get things spinning. The air core axial flux pmg is designed with an air core and dual steel mag rotor plates for that reason. The steel rotor plates capture the flux from the mags and keeps it from escaping beyond the perimeter of the generator, combined with the alternating poles on opposing plates and the pancake design forming a very small air gap between them, this does the job of directing the flux back and forth through the coils from pole to pole on each plate. People have built single rotor axial flux pmg's too, but they're not near as efficient. Steel laminations are used in conventional generators because the configuration is different and subsequently the flux has different distances to travel. The steel cores help to carry flux through deep coils/air gaps particularly in single rotor generators because there is no second rotor with a second set of mags on the opposite side of the stator to help. Adding steel cores comes at a small cost due to the cogging effect but is required for certain designs. It's not required for this design, so adding them would hinder performance more than help.

...other good sources of information are Hugh Piggot, Chris Oslen, and thebackshed.com

@@JamesBiggar Thx for the detailed answer, I do want to build a dual flux generator. It makes sense that I don't need additional material in the coils if the flux is directed. That helped a lot for my design.