Building P.M.G. Generators - Brian Energy Creator

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Building P.M.G. Generators.

1e edition 2015

Written by Brian Energy Creator

This document is for private use only.Information from this document may not be distributed, copied or published in any manner

whatsoever without written permission of the author.

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Page

1- Why this book…………………………………………………………………… 32- Something about Generators to day………………………………………..... 43- What people use as a generator…………………………………………….... 7

- 1 - The washing-machine-motor-generator………………………………………. 7- 2 - The rebuild sealing fan generator……………………………………………... 8- 3 - The rebuild car alternator……………………………………….…………...… 9- 4 - Most of the P.M.G. generators made in China………………………..………. 9- 5 - P.M.G. generators whit have aluminum housings………………..………….. 10- 6 - The alternated axial flux generator. ………………………………..……..…. 10

4- Explanation about the coil of the generator…………………………….…. 125- Why we build generators in a divergent way………………………….….. 136- Single face coil explained……………………………………................….…. 147- Three face coil explained………………………………………………..……. 168- Double three face coil explained……………………………………...…..… 189- How to build the generator………………………………………….….…..… 20

10- Working with polyester compounds………………………………...……… 2111- Making the rotor for the generator……………………………..............…… 2212- Making the stator coil for the generator………………………............…… 3813- The wire guider……………………………………………….……………...… 4114- Determine the usable magnetic field distance…………….….…………… 4515- Begin wiring the stator coil……………………………………….………..… 4716- Making the generator shell……………………………………….……...…… 5417- Electronics………………………………………………………….…………… 6018- Linear generator…………………………………………………….…...…...… 6519- Building generators with a 3D printer……………………….….....……..… 67

- 1 - 3D printed outside parts………………………………………………....…… 68- 2 - 3D printed rotor……………………………………………………….…....… 69- 3 - 3D printed coil tube…………………………………………………..….…… 70- 4 - 3D printed tools to make the coil of the generator……………………....…… 71- 5 - 3D printed wire tool……………………………….………………….……… 73

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1 - Why this book.

Hello I am Brian of Energy-Creator.comI make generators for wind and water turbines for several years.I make the generators in my own way, that’s why I wrote this book.To put my knowledge about building generators on paper to help people in therequest of building there own generator.There are a lot of books on the market about this subject and I did reed a lot ofthem.Most of these books are a disappointment, be course the tell you a lot of how tobuild a windmill or watermill, but not how to build the generator for it.When you com to the part were you need to install the generator for you homebuild windmill or watermill they leave you with a very small choice ofgenerators, or even with a very bad choice for a generator.I have a lot of question marks about these generators they want you to use.Most of them produce just a small amount of energy and most of them need alsoa lot of wind or water power to get that small amount of energy.Or the generators need a rotation speed what is much to high to use for awindmill or watermill.This is the case for the self build generators and also for the factory buildgenerators.If you take al the time and trouble to make a windmill or watermill you want atleast a decant generator who can supply a decant amount of energy to chargebattery banks to power your home.If you buy a generator out of the factory there is a lot wrong with most of them.That is why I wrote this book.I wrote this book so you can make decant generators for your windmill orwatermill project.You can build the generators your self without all kind of complicated buildingmethods and complicated calculations of magnetic flux fields.Yes we have to calculate some things but we do this in a simple way.I make Generators to harvest the energy out of wind and water power for years.The generators also run for years, not one had broken down and we make thegenerators with simple tools who most people have in there home.We can make the generators in any size with a good power output, enough topower your home.We make the generators in our own way and that is in a divergent way howgenerators are build normally today.

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2 - Something about Generators to day.

Firs I like to say that there are two kind of generators.There are the Generators in the big windmills who produce mega watts, thosewindmills haze automatic gearboxes and are self regulating.The generators in big windmills can regulate the magnetic field (pulling power)of the magnets by having electric magnets.The second type of generator haze permanent magnets, these magnets can notchange the strange of the magnetic field (puling power).The second type of generators are permanent magnet generators ( P.M.G.).

Large windmills small windmill

Permanent magnets are mostly made of niobium, these are very strong magnets.The permanent magnet generators (P.M.G.) are mostly used for smallerwindmills.The smaller windmills don’t have gearboxes and most of them have a directdrive system.But there coils are in the same way constructed as the large windmills and herelies a problem.There is not much changed in the constructing principles for generators in thelast decades.There performance haze gone up by new and better materials and blade designs,but not much else haze changed.The big windmills who produce mega watts are reel good windmills nothingwrong with them.But the small windmills for powering your home haze a lot wrong with them.If you build a small windmill in the same way as a large windmill you will havea lot of complications.The complications lies in the way of construction of the coils of the generator.The coils are made by winding a lot of copper wires around a iron core, just likeby the large windmill generators.A generator of a large windmill can regulate there magnetic pulling power and asmaller permanent magnet generator (P.M.G.) can not.Here lies a problem and this is why.

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The problem lies whit the iron core in the coils of the generator.There are iron cores in the coils because it will boost the eclectic output a lot soles copper wire haze to be used.When the generator turns the magnets are pulled to the iron core and need a lotof force to turn a way from the iron core, this gives a gouging effect.The gouging effect will make your generator want to turn in steps.Just like turning a stepper motor, it needs a lot of force to overcome those stepsand it is something you don’t want for a small windmill.

Generator coils (stators) wit iron cores

There is a lot of wind power needed to over come this gouging effect andsmaller windmills are closer to the ground then large windmills and wind speedsare much lower close by the ground than high above the ground.That is why you can not create a generator for small windmills by the sameprinciples as a generator for large windmills.If you like to generate a decant amount of electricity by low wind speeds that is.To overcome this problem, the first thing we have to do is remove the iron corein the coils.Than we have immediately the problem that the generator gives a lot less energyoutput and we don’t want that either.

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So we have to construct the coils in a totally divergent way like here below.This is a very dens wired coil what not waist any magnetic force of the magnets.The niobium magnets are the most expensive components of the generator.There for we like to use the magnetic forge of these magnets as much as we canand don’t waist any of this magnetic power.

These are the kind of stator coils we are going to make for our generators.This stator coil is a double winded three faze stator coil.It’s actually a six faze stator coil brought back to 3 faze again.There is no iron cores used and the copper wires completely covering themagnetic field of the magnets.In this book we explain how to make these coil your self.First let take a look what people use as generator for there home build windmilltoday.

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3 - What people use as a generator.

First I give you a overview of what people use as generator and point out what iswrong with these generators.If you want to spear yourself a lot of trouble, money and disappointment thanyou better do not use, make or buy these kind of generators

1-The washing-machine-motor-generator.

The washing machine motor generator haze a lot of coils with iron cores.This will give a gouging effect when turning and besides that it is just availablein one size.If the blades of your windmill are to small it will never turn only in storms and ifyour windmill blades are to large, the blades will spin to slow because of themaximum rotation speed of the blades.Small windmill blades haze a much higher rotation speed than larger windmillblades, the Mph on the tips of the blades are mostly the same.Also a rebuild washing machine motor is not intended for use outdoors in allkind of weathers conditions

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2- The rebuild sealing fan generator.

The rebuild sealing fan generator gives the same troubles as the rebuild washingmachine motor generatorIt is even more difficult to make and often the cores of the coils are fromaluminum.By rotating of the generator the magnets are moving over the aluminum cores ofthe generator.Moving magnets over aluminum will act as a break, besides of the gougingeffect of the generator the generator will never go very fast because it wants tostop by itself.If you like to test this, take a niobium magnet and rub it over a thick peace ofaluminum plate.How harder you want to move the magnet over the aluminum the harder themagnet wants to stop moving.You don’t want this as a generator.

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3- The rebuild car alternator.

The rebuild car alternator also haze iron cores what gives a gouging effect.They need a lot of wind power to turn.There available in a few sizes but haze to turn very fast to produce a decantpower output what it almost never will only in storms.

4- Most of the P.M.G. generators made in China.

Most of the P.M.G. generators made in China are rebuild traction motors for beltdrive systems fitted with niobium magnets.They have iron cores and give a gouging effect and need a lot of power to turn.

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5- P.M.G. generators whit have aluminum housings.

Why generator with a aluminum housing are not good.Again, it haze to do with the magnetic field of the magnets and aluminum.If you take a magnetic field and move it over aluminum, the aluminum will actas a break.How harder you want to move the magnet over the aluminum the harder themagnet wants to stop moving.How faster the generator wants to rotate in the aluminum housing how harderthe generator wants to stop because of the magnetic field of the magnets areinteracting with the aluminum housing of the generator.

6- The alternated axial flux generator.

The alternated axial flux generator is a generator what a lot of people try to buildon the internet and YouTube.This generator will give you a lot of building complications and will not giveyou a lot of energy.Lets look closer to this generator and I will tell you why.Often people choose to make this generator because the coils are simple tomake, but that’s the only thing what is simple about this generator.

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If you come further down in construction of this generator you will get a lot ofcomplications.

As you can see in this picture the metal blocks should be the magnets, there notreally magnets in this picture because there laying in each others magnetic fieldand will snap to getter in a instant if they were real magnets.But lets assume these blocks are the magnets.The magnet of this generator only magnetize the sides of the coils, the top andbottom are not magnetized.The electrons in the coil who are pushed away by the magnets are coming atease in the part of the coil what is not magnetized.Also there are a lot of empty spaces in the coils what is a waist of magneticenergy.If you come further in construction you have two large disks who turn very closeto each other, if there is any friction of any kind by a wind gush for example theturning disks can tough each other and will destroy the generator.Besides all this it is a big disk that blocks a lot of wind and need large blades.Large blades gives you a slower rotation speed again.You have to turn this generator very fast to get any usable energy out of itbecause of all the empty spaces in the coil and just partly magnetizing of thecoils.I would not recommend this type of generator for your windmill.

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4- Explanation about the coil of the generator.

Here below we can see a 3 faze coil configuration, the colored fields representthe copper wires of the coil.The brown field is empty middle space from the coil, when the magnets arepassing by these empty spaces the magnetic energy of the magnets is wasted.

In the picture below the coils are on top of eats other to fill up this empty space,This creates the problem that the coil closest to the magnets gets the mostmagnetic energy and the coil further away gets less magnetic energy.This results that the fazes of the generator gives each a divergent power output.

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5 - Why we build generators in a divergent way.

In the picture below we have a much better 3 faze coil configuration.This is the wire configuration for the coil of the generators we are going make.Here we can se that all the copper wires of the 3 faze coil are all woven in to onegenerator coil.This means that there are almost no empty spaces between the wires, there isalmost no magnetic energy loss.It also results that the fazes of the 3 faze coil have all the same power output.This results that the efficiency of the generator gets higher and the dimensionsof the generator gets smaller, smaller and stronger generators.

We are showing the coil with this wire configuration in the picture below.

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6 - Single faze coil explained.

Lets start by explaining a single faze coil.Here below we have a drawing of a rotor of a generator.the colored lines are rows of magnets.The red lines are a row of magnets pointing there south poles up and the bluerows are a row of magnet pointing there north poles up.

If we unfold the rotor like a sheet of paper it looks like the picture below.

Now we have a simple overview of the magnetic lines of the rotor.

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Now we make a point on every colored line.On the blue lines we mark a point in the middle of the line on the left side.And on the red lines we mark a point in the middle of the line on the right side.And draw lines between them like in the picture here below on the left side.

With out the magnetic configuration on the back ground the wiring looks likethe picture on the right.The vertical lines on the sides of the picture are the sides of the rotor, they arenot wires, only the zigzag lines in the middle are the wiring configuration.If we wire a single faze stator coil for a generator like in the drawing it lookslike in the picture below.

This is a single faze stator coil with a lot of empty spaces between the wires.The empty spaces are a waist of magnetic energy and it’s something we don’twant for our generator.

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7 - Three face coil explained.

Now lets look how a three faze stator coil is wired.We have fitted two more fazes to the generator, there al with the same distanceaway from eats other.We have made each faze a other color to make it more simple to see.Faze one is black, faze two is green and faze three is yellow.

On the left side again the wire configuration whit the rotor on the back groundand on the right site only the wire configuration with out the rotor.

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When we wire a three faze coil like the configuration in the drawing it looks likein the picture below.

As you can se the empty spaces between the wires are a lot less but there are stilla lot of empty spaces between the wires.If you put all the empty spaces in the coil together it covers almost a third of thecoil.So these empty spaces are still a waist of magnetic energy.The permanent magnets are the most expensive part of the generator.With that conclusion we like to use the magnetic energy of the magnets as muchas we can.So again the empty spaces between the wires are a waist of magnetic energy andis something we don’t want for our generators.We like to do this better, and we can as we explain in our next chapter.

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8 - Double three face coil explained.

Now lets look how a double three faze coil is wired.It is like how a three faze coil is wired and over the three faze configuration amirror image of a three faze configuration again.When we do this in this way we get a double three faze configuration as shownin the drawing below.

On the left side a double three faze wire configuration with the magnetic lines ofthe rotor in the back ground and on the right side the double three fazeconfiguration with out the rotor configuration.As you can see it is a three faze wire configuration with a mirror image of athree faze wire configuration over it.In this way we get writ of all the empty spaces between the wires as much as wecan.

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When we wire a stator coil whit the double three faze configuration the coillooks like in the picture below.This is actually a coil of a small generator, there are still a few little spots ofempty space.

In the picture below we made a double three faze winded coil of a big generatorand as you can see the empty spaces are all gone.

Now we have wired a generator stator coil in a way that the magnetic energy ofthe magnets in the rotor of the generator are continuously in action whit thewires of the coil of the generator.Now there is almost no waist of magnetic energy of the magnets by thisconfiguration.With this wire configuration are we going to build our generators.It sounds all complicated to build these kind of generator coils when I tell youthat we are going to wire these kind of coils with six wires at ones.But don’t worry, it is actually very simple, we have to make some simple toolsto make the generator as we will explain further down this book.

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9 - How to build the generator.

In this chapter we will explain how to build a double three faze generator.Were not going to build the single faze generator or the three faze generator.I like you to build the best possible generator for your windmill project.If it is all a little bit hard to comprehend, there is also a detailed step by stepinstruction movie available on my website: www.energy-creator.com.All the pictures I use in this book are coming from this two and half hour duringinstruction movie I made in the year 2012, called: Energy Creator the movie,D.I.Y. Generators, The instruction DVD is shown in the picture below.

In the movie on this DVD as in this book we make the generators by hand andfrom PVC pipes together with polyester compounds.These days I make the generators whit a 3D printer, it’s a big dividends betweenthe two building methods, its much easier whit a 3D printer.With a 3D printer you just print all the parts of the generator and glue themtogether, you don’t have to make any generator parts by hand any more.Its also a big must if you like to build more than one generator.You don’t need a expensive 3D printer for it, personally I use a cheep Chineseremake of a Makerbot 3D printer and it works just fine.I will explain the building dividends of building generators by hand and buildinggenerators with a 3Dprinter as well in this book.Not everybody haze a 3D printer jet so I explain how to build our generator byhand.First a few important facts about working with polyester compounds.

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10 - working with polyester compounds.

Polyester is a chemical compound that comes with a harder compound.The harder for polyester is a peroxide, with out this peroxide the polyester willnot harden.Mostly you have to use 2% or 3% of this peroxide to mix together with thepolyester to harden.Polyester can shrink up to 5% when its harden, remember this.Polyester haze a very intense odor, its at least ten time worse than regular paint.If you are not used to work with polyester you will probably get a headachefrom the smell.Polyester is also bad for your health and is iterating on your skin.You have to protect your self when you work with polyester, were at leastrubber gloves and safety goggles.Don’t work with polyester in the weekend on your kitchen table.If you have a separate hobby room in your home, you don’t want to work withpolyester in there as well, your entire home will smell like polyester for days.Use polyester outside if you can.We also use glass bubbles to thicken the polyester and chopped strands to makethe polyester stronger when we build our generator.These chopped strands and glass bubbles are products made from glass, the arealso iterating on your skin and certainly you don’t want them coming in to youreyes.If you get any of these products in your eyes you have to wash them out wit lotsand lots of water and probably go se a doctor.So if you never have worked whit polyester and you can not work outside?The only thing is what I can advise you is don’t!Better buy a 3D printer, its easier to build generators with a 3D printer any way.Also with a 3D printer we can make the generators much more precise so youget better generators.You don’t have to design the generators your self, files to print out generatorsright away are also available on my website www.energy-creator.com.

For those who like building generators by hand, lets start building a generator.

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11 - Making the rotor for the generator.

To build a generator, first we have to do is make a rotor for the generator.In the picture below we show the materials you need to make a rotor for agenerator, a peace of PVC pipe, two end caps, two ball bearings, a threaded rodwith two nuts, some wooden blocks for filling and some paper and tape.

First you take some paper sheets as wide as the length of the PVC pipe.Tape the surface of paper sheets entirely.

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Now role up the paper in a way that we get a paper wall of several layers.Depending of the thickness of the paper you need mostly 4 or 5 layers of paperto get a decant paper wall.Make sure the taped surface points to the inside.Than tape the inside that the paper stays in place.

Now take the end caps and drill holes exactly in the middle with the samediameter as the threaded rod.

Take the threaded rod and put a nut on.

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Then take a end cap and slide it over the threaded rod.

Now fasten the end cap with the second nut.

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Drill a hole in the table so the end cap stands upright.

Now take the peace of pipe with the paper and end caps and grease it up a littlebit with Vaseline spray.Make sure you don’t grease up he threaded rod and the wooden blocks.Now slide the peace of pipe with the paper in the end cap.Take the wooden blocks and second end cap for later.

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Now make a mixture of polyether with harder and glass bubbles.Make the mixture as thick as yogurt.Pour some of the mixture in the pipe with paper and put wooden block in.Than pour some mixture again and than a wooden block again.

Repeat the process until the peace of pipe is filled.

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Now place the second end cap.

Wait until the polyether mixture is a little bit hardened and remove the excessmaterial from the end cap.

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Wait until the polyether mixture is hardened and cooled down and remove theend caps and the peace of pipe.

Now remove the paper and sand away ruff edges and remove the grease.You can wash the polyether rotor with some warm water and some soap.

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Print out a file like this for magnet configuration, make sure you always have aeven number of lines.On every line comes a magnet, make sure the lines are not to close to each other,otherwise the magnets don’t fit.

Place the rotor on the stencil and make markings on the rotor where the lines ofthe stencil are.

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Lay the rotor flat, like in a vice and draw lines were the markers are.

The red lines become the positive sides of the magnets and the blue linesbecome the negative sides of the magnets.

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Make markings where the magnets are coming.

Take a drill and tape the drill in such a way that you can only drill the depth ofthe magnet.

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Drill holes on the markings

Like this.

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Now drill the holes again with a drill who haze the same diameter of themagnets.

Now sand the rotor again and we are ready to place the magnets.You can sand quite a bit off the rotor be course the rotor haze to rotate freely inthe PVC pipe we used to make the rotor.

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Now we have placed the magnets in the configuration of the blue and red lineswe made earlier, the magnets don’t fall out be course of the magneticconfiguration of the magnets, even when the magnets are a little bit lose in thedrilled holes the magnetic field attract the magnets, there all pulled to the centerof the rotor.

Now we need some fiber glass cloth and a mixture of polyester with harder.

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Take a cardboard box against leaking and fixate the magnets with the glass fibercloth and polyester.Make sure the ends of glass fiber touch each other and don’t overlap each other,the thickness of the polyether should be every ware the same.

Wait until the polyester is hardened and cut away the excess glass fiber cloth,sand away hardened polyester drops and bumps.And we have a rotor with the magnets in it.

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Take the PVC pipe and the end caps and put it together again and look of therotor will rotate freely in the PVC pipe.When the rotor rotates freely in the PVC pipe the rotor is finished.

When you make large rotors this way you have to ad a little bit of glass fibberchopped strands to prevent cracks in the polyether of the rotor.Just use a little bit of these glass fibber chopped strands be course they swell inthe polyether mixture, the mixture can get to thick and will create air pockets inthe rotor and you don’t wand that to happen.

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This is a larger rotor without the glass fiber chopped strands in the polyestermixture.There are big cracks in the rotor, the rotor is ruined and we can not use this rotorany more.

Now that we have made a rotor for our generator we have to make the stator forour generator.In the next chapter we will explain how to make a stator for our generator.

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12 - Making the stator coil for the generator.

In this chapter I will explain how to build the stator coil for the generator.I will skip the single faze stator coil and also skip the three faze stator coil.I will restrict it to the double three faze stator coil be course this is the mostefficient stator coil, and if you know how to build the double three faze statorcoil you know how to build the single faze and three faze stator coil as well.

For the stator coil of the generator we need a peace of PVC pipe with the samediameter as the PVC pipe we used to make the rotor.The PVC pipe for the stator coil haze to be longer than the PVC pipe we used tomake the rotor.When we wire the coil, the wires will make a turn where the magnets in therotor ends and in the end we need to put end caps on the PVC pipe of the stator,so we need some extra length for the PVC pipe for the stator.

First we need to make a simple tool to put the PVC pipe for the stator on.This will work a lot easier.Its nothing more than a stand with a wooden block what can turn as in thepicture below.

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The wooden block haze to be the size of the inside of the PVC pipe we use tomake the stator coil.It haze not to be perfectly round, it just hold the nails in place what we use later.

Now we put the PVC pipe on the wooden block and draw lines with the samedistance from each other.We always need to draw tree times more lines than there are rows of magnets inthe rotor.For example, if you use 12 rows of magnets in the rotor we have to draw 3 times12 lines, so that will be in this example 36 lines on the PVC Pipe for the stator.

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Now we have to make the markings on the lines where the nails will come.If you put the rotor inside the PVC pipe the markings for the nails are there warethe row of magnets of the rotor ends.

Now we have to drill holes on the markings true the PVC pipe into the woodenblock and slightly under a angle and put the nails in.The nail heads should be al on the same height.The nails don’t have to be very tight, if the don’t fall out its enough, you have toremove them again later.

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13 - The wire guider.

Now we have to make a other simple tool, the wire guider.The wire guider is a little wooden block whit hollow tubes were the copper wirecomes true for wiring the stator coil of the generator.

First we need some hollow tubes, often find on candy sticks.

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Than we have to make markings on the wooden block between the nails of thestator were the hollow tubes haze to come.

In the picture below you see the hollow tubes in the wooden block.The hollow tubes are under a angle like the nails.

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The hollow tubes are under a angle like the nails so that the are easily slidingpast the nails when we wire the stator coil of the generator.

Now we need six roles of copper wire with wire of the same diameter and haveto hung them up above the PVC pipe whit he nails.The best way is to hung them up in pairs, like two rows with three roles copperwire.

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Like in the picture below we see two rows with three roles of copper wire.And now put the wire true the hollow tubes from the wooden block, like in thepicture below.

A important rule for choosing the right wire.

We have a rule for choosing the right diameter of wire.The rule is how longer the wire how higher the voltage the generator gives by acertain rotation and how thicker the wire how higher the amperage the generatorgives by that certain rotation.

- How longer the wire how higher the voltage.

- How thicker the wire how higher the amperage.

A important rule for choosing the right layer thickness of wires.

How many turns of wire we have to give to make the stator?If we give the stator not enough turns of wire we get not enough energy out ofthe generator.If we give the stator to much turns of wire than the top wires lay outside themagnetic field of the magnets and the generator will give less energy.So we have to surge for the ideal layer thickness of wire.

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14 – Determine the usable magnetic field distance.

If we take a plastic ruler and a magnet we going to use for our generator and airon drill we can calculate more or less the usable distance of the magnetic fieldof the magnet.Lay the magnet by the zero number of the ruler and slowly push the drilltowards the magnet until the magnet attracts it self to the drill.

When the magnet haze attracts it self to the drill we can calculate the usablemagnetic field distance.On the ruler in the picture below is shows 2,6 centimeters, split this number intwo and two fourth.This is the usable magnetic field distance, in this case the usable magnetic fielddistance will be between 1,3 centimeter and 1,7 centimeter.So the distance from the top of the magnet in the rotor until the top of the layerof wires of the stator is in this case some ware between 1,3 and 1,7 centimeters.

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Now we are almost ready to begin wiring the stator coil of the generator.

First we have to make some markings on the nails so we know how to wire thestator coil of the generator.Take two divergent colors of markers, we used a red and a black marker.Make a nail red on the right side of the PVC pipe whit nails (stator tube) with amarker.If you follow the line were the red nail is placed to the left side, the nail on thatline of the left side becomes black.Now go to the right side to the red nail again and than begin counting from thered nail, skip two nail and make the third nail black, skip two nails again fromthe black nail and make the third nail red, skip two nails from the red nail againand make the third nail black again and so one.When there is on the right side of the stator tube is a red nail on that line is onthe left side a black nail.When there is on the right side is a black nail on the line there is on the left sidea red nail on that line.Now mark all the nails in that way until you are by the beginning again.If that is done you can begin with wiring the stator coil.

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15 - Begin wiring the stator coil.

Now take wire four, five and six of the wire guider (wooden block with hollowtubes) and place them next to the nails.Wire four of the wire guider comes in front of the red nail, wire five becomes infront of the first blank nail and wire six becomes in front of the second blanknail.Fixate the wires on there place whit tape on the end of the stator tube and makesure the wires have some extra length so you can connect them later when wefinish the stator coil.

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Now follow the line of the red nail of the right side to the black nail of the leftside and place the first wire of the wire guider in front of the black nail.Place the second wire of the wire guider in front of the first blank nail and placethe third wire of the wire guider in front of the second blank nail.Now fixate the wires with tape on there place on the end of the stator tube againand make sure the wires have some extra length to connect the wires when thestator is finished.The fourth wire makes a turn around the red nail and the fifth wire makes a turnaround the first blank nail from the red nail and the sixth wire makes a turnaround the second blank nail from the red nail.Now we are ready to wire the stator.

Wiring the stator coil is like a zigzag route like in the picture below.

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If its not clear to see in the picture, the drawing below shows where the wiresbegin and how we wire the stator coil further in a zigzag route.

We end with wiring by the same nails as were we begun with wiring as shown inthe drawing below.

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Now we have wired the stator coil like in the picture below and have to decide ifwe have enough layers of wire on the stator coil.

First we have to push down the wires by hand and decide if we have enoughlayers of wire on the stator coil.Than we take some rope and fixate this on a nail and wind as tide as possible therope around the stator coil to push the wires as close to the stator coil tube as wecan.

When we do this we can give the stator coil a lot more wire before we get outoff reach of the magnetic field of the magnets.

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Now make a mixture of two compound polyurethane or polyether with harderand impregnate the wires (stay clear from the nails) so the wires will stay inplace when you pull out the nails.

When you have done this you can pull out the nails and connect the wires.Firs we have to do is take a peace of PVC tube and place six solder pins on it sowe can connect the wires in a easy way.Make this component two times.

Now take this peaces of PVC tube with solder pins and glue them on both sidesof the stator coil tube were the wires begin and place some solder pins toconnect the wires.

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We connect the first bottom wire (the second wire from the left) to the secondpin, the second bottom wire we connect to the forth pin and the third bottomwire we connect to the sixth pin.Than we connect the first top (first wire from the left) wire to the first pin andthe second top wire to the third pin and the third top wire to the fifth pin.

Than we connect with isolated wire the first bottom wire from the left with thefirst bottom wire from the right, and the second bottom wire from the left withthe second bottom wire from the right, and the third bottom wire from the leftwith the third bottom wire from the right.

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In the drawing below you can se how we have connected the bottom wires.

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16 - Making the generator shell.

When the wires are connected we are ready for our next step, making the outershell of the generator.First we have to make some peaces for the shell from PVC pipe like the picturebelow.

With the peaces of PVC and PVC glue we make a wall on both sides of the coilof the stator.

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We make this wall just a little bit higher than the wires of the stator coil.We have to make this wall on both sides.

When we made the walls the stator coil tube looks like in the picture below.

If you make a big generator you can also make a water cooled system to harvestwarm water from the heat of the generator for your swimming pool.In the next step we explain how, but its not necessarily if you don’t want to dothis.

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In the picture below we mounted a peace of PVC and clamp a hose for the watercooled system in place.

The stator coil with the beginning of the hose for the water cooled systemclamped in place.

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Make sure that you got enough length of hose to wind it all along to the otherside of the stator coil.

The hose for the water cooled system is mounted and clamped on both sides ofthe stator coil.

Now we take some glass fiber cloth and polyester or epoxy with harder andfinish the outer shell of the generator stator coil, make sure you make the outershell water tide.

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Make a mixture of polyester or epoxy with harder and some glass bubbles tomake a thick paste and fill up all the gabs on the sides of the generator statorcoil.

When the polyester or epoxy haze hardened and all the gabs are filed the statorcoil of the generator looks like in the picture below.

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Now we can make a housing for the wires, we do this in the same way as thesides.With peaces of PVC we filled up all the big gabs first, than we used polyester orepoxy with harder and glass bubbles to fill up all the smaller gabs.

Now we fitted a power cable to connect the generator.

From PVC we made a cap for the wire housing of the stator coil, we painted itwhit and places three rectifiers on it to change the AC generator in to a DCgenerator for charging battery banks.

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17 - Electronics.

Make sure all the rectifiers are placed in the same way, with the positive side toone side and glue them in place.

Now turn the cap with the rectifiers around and make a bridge with some peacesof wire.Solder the negative pools together and solder the positive pools to gather.

Now we can connect all the wires who coming out of the stator coil.Make sure that the wires who belong to gather are soldered to the same rectifier.For example the first top wire from the left side and the first top wire from theright side belongs to gather.

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Also the second top wire from the left side and the second top wire from theright side belongs to gather.And the third top wire from the left side and the third top wire from the rightside belongs to gather.You can check with a multi meter if the wires belong to gather.

Now connect the power cable on the bridge and make sure to connect thepositive to the positive and the negative to the negative.Now you can place the cap on the wire housing and fixate it with some screws.Use some glue or silicone to make the cap water tide.Now the stator coil tube of the generator is ready, now we going to make thesides of the generator.

Glue the ball bearings exactly in the middle of the end caps and put some tapeon them to protect them and make some wooden rings like in the picture below.

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Now glue the wooden rings with a mixture from polyester or epoxy with harderon the end cap and fill up the space between the ball bearing and the woodenring with the same mixture to fixate the ball bearings further.

Now we have all the parts of the generator ready, put the generator together.

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Now the generator is finished and ready for use for your windmill project.

You can make generators by this principle in any size.Normal generators, micro generators and big ring generators.Its also possible to make linear generators with this coil principle.

All these generators are made from copper wire, magnets, PVC, wood andpolyether.And these generators are made with simple tools from the hardware store.

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When you have a lathe or milling station you can make the generators a lotbetter, but these machines need a lot of space and cost a lot of money and youmust have a lot of skills to work whit these machines.Besides that making a generator cost a lot of time and expensive materials.You can also make generators with a 3D printer.Making the generators with a 3D printer you don’t need the skills to work withal kind of machines, you don’t need a lot of space for machines, you don’t needa lot of time because the 3D printer is doing the work for you and you don’tneed expensive materials.If you use a 3D printer (the kind who uses plastic wire from a spindle) you canmake the generator a lot cheaper and make the parts a lot more precise.When you use a 3D printer the only real cost for the generator are the magnets,the copper wire and the ball bearings.

Further down the book we will compare handmade generators and generatorparts and tools with 3D printed generators and generator parts and tools.

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18 - Linear generator.

Making a coil for a linear generator is almost the same way as the we build thecoil for the normal generators.Only when we lay the wires for the coil we go at a specific point the same wayback whit the wires.

Here in the picture below we see a setup for making a linear generator coil

We begin with laying the wires like by winding a normal generator.Here we start with al the wires from the same side and we stop at a specificpoint.

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At this specific point we go with the wires the same route back.

When you have the desired number of layers of wire for the linear coil you endthe wirer were you started the wire.

In this way we can make coils for linear generators or coils out of parts.

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19 - Building generators with a 3D printer.

Making the generators with a 3D printer has a lot of benefits.Not only is it a lot easier and much cheaper to make al the parts of the generator,also the parts are much more precise that has the result that the 3D printedgenerators are more compact and gives the generator a much better efficiency.

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1 - 3D printed outside parts.

Here we printed the parts for the outside with ABS material.We se the outside shell of the generator with two times the sides were the rotorfits true for later.Two closing cabs with the bearings on the inside of the generator design toprotect them from the weather.The base of the generators with mounting holes for easy mounting later, and aarea for the rectifiers and electronic connection.The benefits of printing the parts with a 3D printer is that we have a building kitwhat we have to glue together.We don’t have to make al the parts by hand and we don’t need the skills to makethe parts by hand, also we can print the parts over and over again to make moregenerators.We reduce the costs of the generator by printing the parts from ABS what comesin wire form from a spindle to feed the 3D printer, this is a low cost material thatreplaces al the costly materials what we needed to make the generators by hand.The 3D printer takes over almost all the building time of the generator.The 3D printer doing almost all the work for you.These benefits are important for choosing to make generators with a 3D printer.

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2 - 3D printed rotor.

Here we see a 3D printed rotor of the generator.Left - the part were we place the magnets in.In the middle – the part with the magnets in place and a tube what slides overthe magnets and the inside parts were we place the axel in what comes in thepart with the magnets.And with glue we secure all the parts in place.On the right the competed rotor.

A 3D printer makes the parts very precise what makes building a generatormuch easier and also makes the generator more efficient.We can make the generator more compact what is difficult to do with building agenerator by hand and the materials from the hardware store.

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3 - 3D printed coil tube.

Here we printed the tube to make the coil of the generator.The parts we printed in two peaces to fit the design in the 3D printer.Most 3D printers print just small parts and making some parts in divergentpeaces we can build bigger generators with a small 3D printer.

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4 - 3D printed tools to make the coil of the generator.

Here a very handy tool we also printed with a 3D printer.The rotation or the stepper counter is a important tool in the building process ofthe generator.With this tool we make the coil of the generator a lot easier, we can count therotations when we wire the coil.

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Here we see the set up of the rotation counter for making the coil

In this setup of the rotation counter we see the coil tube and nails in place, readyto make the coil of the generator.

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5 - 3D printed wire tool.

We also printed the wire tool for making the coil of the generator.

We don’t have to make the wire tool by hand anymore.

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When we place all the parts together we have a 3D printed generator.

The only problem of making generators with a 3D printer is that we have todesign al the parts of the generator first.It cost a lot of time and try and error to design the parts in a way everything fitsgood together.But if the design of the generator is right you can make the generator again andagain.If you don’t have the knowledge or time to make these generator design you canfind generator design for a 3D printer on the website www.Enery-Creator.comThe generator design files you can find on energy-creator.com are files you canput right away in your 3D printer or you can adjust them to your preference.Al the files comes with a building instruction movie what shows you how tobuild the generators in a detailed step by step way.

More information can be found on www.energy-creator.com

Brian Energy Creator.

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