dChan - Q Origins Project Archive

Anonymous ID: dd8deb Oct. 15, 2021, 6:32 p.m. No.14794001 🗄️.is 🔗kun >>4013 >>4014 >>4026 >>4053 >>4065 >>4077 >>4094 >>4109 >>4120 >>4129 >>4141 >>4173 >>4183 >>4206 >>4218 >>4241 >>4254 >>4260 >>4270 >>4272 >>4291 >>4308 >>4326 >>4348 >>4364 >>4386 >>4401 >>4419 >>4435 >>4452 >>4470 >>4491 >>4530 >>4535 >>4547 >>4563 >>4578 >>4586 >>4592 >>4600 >>4611 >>4614 >>4643

What is a Magnet?

The general definition of a magnet is "An object made of certain materials which create a magnetic field."

However, the word “magnet” was first used by the Greeks as early as 600 B.C. for describing a mysterious stone that attracted iron and other pieces of the same material? According to one Greek legend, the name magnet was taken from the shepherd Magnets who discovered the magnetic stone by accident when his stuff was mysteriously attracted to the force of the stone. Another, and perhaps more believable, theory says that the word magnet came from a city in Asia Minor, called Magnesia, where many of these mysterious magnetic stones were found.

During the Middle Ages, this stone became known as lodestone, which is the magnetic form of magnetite. Today, magnets are available in all sorts of shapes including discs, rings, blocks, rectangles, arcs, rods, and bars. They are made out of materials such as ceramic (strontium ferrite), alnico (aluminium, nickel, and cobalt), rare earth (samarium cobalt and neodymium) and flexible, rubber-like material.

But what is a magnet?

A magnet is an object made of certain materials which create a magnetic field.

Magnets are objects that have a north and south pole at opposite ends. A magnet contains electrons that have both uneven orbits and uneven spins. Those magnetic atoms are aligned in nice straight rows inside each domain. And those domains are also lined up all in the same direction. And only with ALL of these conditions satisfied does this piece of metal become a magnet. Don't worry if this doesn't make sense – we'll break it down throughout this lesson.

Every magnet has at least one the North Pole and one South Pole. By convention, we say that the magnetic field lines leave the north end of a magnet and enter the south end of a magnet. This is an example of a magnetic dipole ("di" means two, thus two poles). If you take a bar magnet and break it into two pieces, each piece will again have a north pole and a south pole. If you take one of those pieces and break it into two, each of the smaller pieces will have a north pole and a south pole. No matter how small the pieces of the magnet become, each piece will have a north pole and a south pole. It has not been shown to be possible to end up with a single north pole or a single south pole which is a monopole ("mono" means one or single, thus one pole).

All magnets are made of a group of metals called the ferromagnetic metals. These are metals such as nickel and iron. Each of these metals has the exclusive property of being able to be magnetized uniformly. When we ask how a magnet works, we are merely asking how the object we call a magnet exerts its magnetic field. The answer is quite impressive.

In every material, there are several small magnetic fields called domains. Most of the times these domains are independent of each other and face different directions. However, a strong magnetic field can arrange the domains of any ferromagnetic metal so that they align to make a more extensive and stronger magnetic field. This is how most magnets are made.

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The significant difference between magnets is whether they are permanent or temporary. Temporary magnets lose their larger magnetic field over time as the domains return to their original positions. The most common way that magnets are produced is by heating them to their Curie temperature or beyond. The Curie temperature is the temperature at which a ferromagnetic metal gains magnetic properties. Heating a ferromagnetic material to its given temperature will make it magnetic for a while. While heating it beyond this point can make the magnetism permanent. Ferromagnetic materials can also be categorized into soft and hard metals. Soft metals lose their magnetic field over time after being magnetized while hard metals are likely candidates for becoming permanent magnets.

Not all magnets are human-made. Some magnets occur naturally in nature such as lodestone. This mineral was used in ancient times to make the first compasses. However, magnets have other uses. With the discovery of the relationship between magnetism and electricity, magnets are now a significant part of every electric motor and turbine in existence. Magnets have also been used in storing computer data. There is now a type of drive called a solid state drive that allows data to be still saved more efficiently on computers.

Not only do the shape and material of magnets vary, so make their applications. At many companies, magnets are used for lifting, holding, separating, retrieving, sensing, and material handling. You can find magnets in a car and around your house. Magnets are used in the home to organize tools or kitchen utensils and can be found in doorbells, loudspeakers, microwaves, and televisions. Business offices and schools use magnetic planning boards to display schedules and charts.

Magnets are also used in a compass to guide people if they are lost. The compass was probably the first crucial magnetic device discovered. Around the 12th century, someone noticed that when allowed free movement, a magnet always points in the same north/south direction. This discovery helped mariners who often had trouble navigating when the clouds covered the sun or stars.

But the use of the magnets for this device will revolutionize the entire energy industry.

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What is an electromagnet?

An electromagnet is a magnet that runs on electricity. Unlike a permanent magnet, the strength of an electromagnet can easily be changed by changing the amount of electric current that flows through it. The poles of an electromagnet can even be reversed by reversing the flow of electricity.

An electromagnet works because

an electric current produces a magnetic field. The magnetic field generated by an electrical current forms circles around the electric current, as shown in the diagram below:

Mechanically, an electromagnet is simple. It consists of a length of conductive wire, usually copper, wrapped around a piece of metal. A current is introduced, either from a battery or another source of electricity and flows through the wire. This creates a magnetic field around the coiled wire, magnetizing the metal as if it were a permanent magnet. Electromagnets are useful because you can turn the magnet on and off by completing or interrupting the circuit, respectively.

Before we go too much farther, we should discuss how electromagnets differ from your run-of-the-mill "permanent" magnets. As you know, magnets have two poles, "north" and "south," and attract things made of steel, iron or some combination thereof. Like poles repel and opposites. For example, if you have two bar magnets with their ends marked "north" and "south," the north end of one magnet will attract the south end of the other. On the other hand, the north end of one magnet will repel the north end of the other (and similarly, the south will repel south). An electromagnet is the same way, except it is "temporary" - the magnetic field only exists when an electric current is flowing.

The doorbell is a good example of how electromagnets can be used in applications where permanent magnets wouldn't make any sense. When a guest pushes the button on your front door, the electronic circuitry inside the doorbell closes an electrical loop, meaning the circuit is completed and "turned on." The closed circuit allows electricity to flow, creating a magnetic field and causing the clapper to become magnetized. The hardware of most doorbells consists of a metal bell and metal clapper that, when the magnetic charges cause them to clang together, you hear the chime inside and you can

answer the door. The bell rings, the guest releases the button, the circuit opens, and the doorbell stops its infernal ringing. This on-demand magnetism is what makes the electromagnet so useful.

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Permanent Magnets and Electromagnets: What are the Differences?

A permanent magnet is an object made from a material that is magnetized and creates its persistent magnetic field. As the name suggests, a permanent magnet is 'permanent.' This means that it always has a magnetic field and will display a magnetic behavior at all times.

An electromagnet is made from a coil of wire which acts as a magnet when an electric current passes through it. Often an electromagnet is wrapped around a core of ferromagnetic material like steel, which enhances the magnetic field produced by the coil.

Permanent Magnet v. Electromagnet: Magnetic Properties

A permanent magnet‟s magnetic properties exist when the magnet is (magnetized). An electromagnetic magnet only displays magnetic properties when an electric current is applied to it. That is how you can differentiate between the two. The magnets that you have affixed to your refrigerator are permanent magnets, while electromagnets are the principle behind AC motors.

Permanent Magnet v. Electromagnet: Magnetic Strength

Permanent magnet strength depends upon the material used in its creation. The strength of an electromagnet can be adjusted by the amount of electric current allowed to flow into it. As a result, the same electromagnet can be adapted for different strength levels.

Permanent Magnet v. Electromagnet: Loss of Magnetic Properties

If a permanent magnet loses its magnetic properties, as it does by heating to a (maximum) temperature, it will be rendered useless, and its magnetic properties can be only recovered by re-magnetizing. Contrarily, an electromagnet loses its magnetic power every time an electric current is removed and becomes magnetic once again when the electric field is introduced.

Permanent Magnet v. Electromagnet: Advantages

The main advantage of a permanent magnet over an electromagnet is that a permanent magnet does not require a continuous supply of electrical energy to maintain its magnetic field. However, an electromagnet‟s magnetic field can be rapidly manipulated over a wide range by controlling the amount of electric current supplied to the electromagnet.

The Power Efficiency Guide uses this principle and multiplies the energy the magnets supply, eventually offering enough energy to power household appliances.

The most recent and life-changing discovery is the Neodymium Magnet

A neodymium magnet (also known as NdFeB, NIB or Neo magnet), the most widely used type of rare-earth magnet, is a permanent magnet made from an alloy of neodymium, iron, and boron to form the Nd2Fe14B tetragonal crystalline structure. Developed in 1982 by General Motors and Sumitomo Special Metals, neodymium magnets are the strongest type of permanent magnet commercially available. They have replaced other types of magnets in the many applications in modern products that require strong permanent magnets, such as motors in cordless tools, hard disk drives, and magnetic fasteners.

Description

Neodymium is a metal which is ferromagnetic (more specifically it shows antiferromagnetic properties), meaning that like iron it can be magnetized to become a magnet, but its Curie temperature (the temperature above which its ferromagnetism disappears) is 19 K (−254 °C), so in pure form its magnetism only appears at extremely low temperatures.However, compounds of neodymium with transition metals such as iron can have Curie temperatures well above room temperature, and these are used to make neodymium magnets.

The strength of neodymium magnets is due to several factors. The tetragonal Nd2Fe14B crystal structure has exceptionally high uniaxial magnetocrystalline anisotropy (HA ~7 T – magnetic field strength H in units of A/m versus magnetic moment in A·m2). This means a crystal of the material preferentially magnetizes along a specific crystal axis but is very difficult to attract in other directions. Like other magnets, the neodymium magnet alloy is composed of microcrystalline grains which are aligned in a powerful magnetic field during manufacture so their magnetic axes all point in the same direction. The resistance of the crystal lattice to turning its direction of magnetization gives the compound a very high coercivity or resistance to being demagnetized.

The neodymium atom also can have a large magnetic dipole moment because it has

seven unpaired electrons in its electron structure as opposed to (on average) 3 in iron. In

a magnet, it is the unpaired electrons, aligned, so they spin in the same direction, which

generates the magnetic field. This gives the Nd2Fe14B compound a high saturation

magnetization (Js ~1.6 T or 16 kG) and typically 1.3 teslas. Therefore, as the maximum 2

energy density is proportional to Js , this magnetic phase has the potential for storing large amounts of magnetic energy (BHmax ~ 512 kJ/m3 or 64 MG·Oe). This magnetic energy value is about 18 times greater than "ordinary" magnets by volume. This property is higher in NdFeB alloys than in samarium cobalt (SmCo) magnets, which were the first type of rare-earth magnet to be commercialized. In practice, the magnetic properties of neodymium magnets depend on the alloy composition, microstructure, and manufacturing technique employed.

History

In 1982, General Motors (GM) and Sumitomo Special Metals discovered the Nd2Fe14B compound. The research was initially driven by the high raw materials cost of SmCo permanent magnets, which had been developed earlier. GM focused on the development of melt-spun nanocrystalline Nd2Fe14B magnets, while Sumitomo developed full-density sintered Nd2Fe14B magnets.

GM commercialized its inventions of isotropic Neo powder, bonded Neo magnets, and the related production processes by founding Magnequench in 1986 (Magnequench has since become part of Neo Materials Technology, Inc., which later merged into Molycorp). The company supplied melt-spun Nd2Fe14B powder to bonded magnet manufacturers.

The Sumitomo facility became part of theHitachi Corporation, and currently manufactures and licenses other companies to produce sintered Nd2Fe14B magnets. Hitachi holds more than 600 patents covering neodymium magnets.

Chinese manufacturers have become a dominant force in neodymium magnet

production, based on their control of much of the world's sources of rare earth mines.

The United States Department of Energy has identified a need to find substitutes for rare earth metals in permanent magnet technology and has begun funding such research. The Advanced Research Projects Agency-Energy has sponsored a Rare Earth Alternatives in Critical Technologies (REACT) program, to develop alternative materials. In 2011, ARPA-E awarded 31.6 million dollars to fund Rare-Earth Substitute projects.

Production

There are two principal neodymium magnet manufacturing methods:

 Classical powder metallurgy or sintered magnet process

 Rapid solidification or bonded magnet process

Sintered Nd-magnets are prepared by the raw materials being melted in a furnace, cast into a mold and cooled to form ingots. The ingots are pulverized and milled; the powder is then sintered into solid blocks. The blocks are then heat-treated, cut to shape, surface treated and magnetized.

In 2015, Nitto Denko Corporation of Japan announced their development of a new method of sintering neodymium magnet material. The method exploits an "organic/inorganic hybrid technology" to form a clay-like mixture that can be fashioned into various shapes for sintering. Most importantly, it is said to be possible to control a non-uniform orientation of the magnetic field in the sintered material to concentrate the field to locally, e.g., improve the performance of electric motors. Mass production is planned for 2017.

As of 2012, 50,000 tons of neodymium magnets are produced officially each year in China, and 80,000 tons in a "company-by-company" build-up done in 2013. China produces more than 95% of rare earth elements and produces about 76% of the world's total rare-earth magnets.

Bonded Nd-magnets are prepared by melt spinning a thin ribbon of the NdFeB alloy. The ribbon contains randomly oriented Nd2Fe14B nano-scale grains. This ribbon is then pulverized into particles, mixed with a polymer, and either compression- or injection- molded into bonded magnets. Bonded magnets offer less flux intensity than sintered magnets, but can be net-shape-formed into intricately shaped parts, as is typical with Halbach arrays or arcs, trapezoids and other shapes and assemblies (e.g., Pot Magnets, Separator Grids, etc.). There are approximately 5,500 tons of Neo bonded magnets produced each year. Also, it is possible to hot-press the melt spun nanocrystalline particles into fully dense isotropic magnets, and then upset-forge or back-extrude these into high-energy anisotropic magnets.

Properties

Neodymium magnets are graded according to their maximum energy product, which relates to the magnetic flux output per unit volume. Higher values indicate stronger magnets and range from N35 up to N52. Letters following the grade indicate maximum operating temperatures (often the Curie temperature), which range from M (up to 100 °C) to EH (200 °C).

Hazards

The greater forces exerted by rare-earth magnets create hazards that may not occur with other types of magnet. Neodymium magnets larger than a few cubic centimeters are strong enough to cause injuries to body parts pinched between two magnets, or a magnet and a ferrous metal surface, even creating broken bones.

Magnets that get too near each other can strike each other with enough force to chip and shatter the brittle material, and the flying chips can cause various injuries, especially eye injuries. There have even been cases where young children who have swallowed several magnets have had sections of the digestive tract pinched between two magnets, causing injury or death. The stronger magnetic fields can be hazardous to mechanical and electronic devices, as they can erase magnetic media such as floppy disks and credit cards, and magnetize watches and the shadow masks of CRT type monitors at a greater distance than other types of magnet.

That is why we recommend extra precaution when building the generator.

Working principle

Using the technology electric cars use nowadays, the Power Efficiency Guide was developed to be easier to build than any other generator plans.

Some of the steel parts can be made from wood instead of metal. But for a long lasting and a more reliable, it is best to use steel or durable materials. Please be careful!

The generator starts with a DC motor, which in the case of his prototype is a General Electric permanent magnet, one-twelfth horsepower (62 watts) 12-volt motor which runs at 1100 rpm. That motor is coupled to a gear that transfers the spins, multiplying them to another gear that is attached to a flywheel's driveshaft.

Once the driveshaft reaches the optimum RPMs, around 2000, the rotor attached to the other end of the flywheel will spin with the flywheel with the same RPMs.

One of the other rotors will start to spin along with the main rotor because of the neodymium magnets and will begin to power the DC motor.

This is the moment the battery is removed because the system will self-sustain itself. The constant RPSs of the second rotor will provide enough energy to supply the DC motor that supplies the flywheel.

The energy will not be lost due to the strength of the magnets and because there is no contact and no friction to diminish the energy.

List of components

Dc Motor 12-volt

You can find DC motor in many portable home appliances, automobiles, and types of industrial equipment. Small DC motors are used in tools, toys, and devices.

A DC motor is any of a class of rotary electrical machines that converts direct current electrical power into mechanical power. The most common types rely on the forces produced by magnetic fields. Nearly all types of DC motors have some internal mechanism, either electromechanical or electronic, to periodically change the direction of current flow in part of the motor.

DC motors were the first type widely used since they could be powered from existing direct-current lighting power distribution systems. A DC motor's speed can be controlled over a wide range, using either a variable supply voltage or by changing the strength of the current in its field windings. The universal motor can operate on direct current but is a lightweight motor used for portable power tools and appliances.

Larger DC motors are used in the propulsion of electric vehicles, elevator, and hoists, or in drives for steel rolling mills. The advent of power electronics has made replacement of DC motors with AC motors possible in many applications.

The direction of rotation of this motor is given by Fleming's left-hand rule, which states that if the index finger, middle finger, and thumb of your left hand are extended mutually perpendicular to each other and if the index finger represents the direction of magnetic field, middle finger indicates the direction of current, then the thumb represents the direction in which the shaft of the DC motor experiences force.

Structurally and construction wise a direct current motor is precisely similar to a DC generator, but electrically it is just the opposite. Here, unlike a generator, we supply electrical energy to the input port and derive mechanical strength from the output port. We can represent it by the block diagram shown below.

Here in a DC motor, the supply voltage E and current I is given to the electrical port or the input port, and we derive the mechanical output, i.e., torque T and speed ω from the mechanical port or output port.

The input and output port variables of the direct current motor are related by the parameter K.

~~T = KI and E = Kw~~

So from the picture above, we can well understand that motor is just the opposite phenomena of a DC generator, and we can derive both motoring and generating operation from the same machine by merely reversing the ports.

To understand the DC motor in details let‟s consider the diagram below:

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The direct current motor is represented by the circle in the center, on which is mounted the brushes, where we connect the external terminals, from where the supply voltage is given. On the mechanical terminal, we have a shaft coming out of the Motor, and connected to the armature, and the armature-shaft is coupled to the mechanical load. On the supply terminals, we represent the armature resistance Ra in series.

Now, let the input voltage E, is applied across the brushes. The electric current which flows through the rotor armature via brushes, in the presence of the magnetic field, produces a torque Tg. Due to this torque Tg, the dc motor armature rotates. As the armature conductors are carrying currents and the armature rotates inside the stator magnetic field, it also produces an emf Eb in the manner very similar to that of a generator. The generated Emf Eb is directed opposite to the supplied voltage and is known as the back Emf, as it counters the forward voltage.

The back Emf like in case of a generator is represented by

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Where P = no of poles

φ = flux per pole

Z= No. of conductors

A = No. of parallel paths

and N is the speed of the DC Motor.

So, from the above equation, we can see Eb is proportional to speed „N.' That is whenever a direct current motor rotates; it results in the generation of back Emf. Now let's represent the rotor speed by ω in rad/sec. So Eb is proportional to ω.

So, when the speed of the motor is reduced by the application of load, Eb decreases. Thus the voltage difference between supply voltage and back emf increases that means E − Eb increases. Due to this increased voltage difference, armature current will increase and therefore torque and hence speed increases. Thus a DC Motor is capable of maintaining the same speed under variable load.

Now armature current Ia is represented by

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Now at starting,speed ω = 0 so at starting Eb = 0.

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Now since the armature winding electrical resistance Ra is small, this motor has a very high starting current in the absence of back Emf. As a result, we need to use a starter for starting a DC Motor.

Now as the motor continues to rotate, the back Emf starts being generated and gradually the current decreases as the motor picks up speed.

On our project, we used a one-twelfth horsepower (380 watts) 40A, 12-volt motor which runs at 1600 rpm.

You can also use other types of DC Motor, provided that they have these characteristics: - 12V

60-80 Amps
Minimum 650 RPM

The main criteria by which you need to choose the DC Motor is that it needs to be able to input to the flywheel minimum 2500 RPMs.

It's one of the most important parts because the math must be precise to reach the optimum RPMs for the device.

Gears with Sprocket Chains (you can also use rollers belts)

For our initial tests, as seen in the presentation, we used belts, but after a thorough investigation, we concluded that using Gears with Sprocket Chains is safer and a lot more efficient.

The means of transmitting the spin is essential. This transmission is crucial for the functionality of the generator. The connection between the DC motor's shaft and the flywheel's shaft is more efficient using Gears with Sprocket Chains because you can easily adjust it to reach the 2000 RPMs.

For the DC motor's Gear, you can use an old (or new) bicycle gear with 32 spikes or 42. You can find them with standard dimensions.

The gear that will be attached to the flywheel must be two or three times smaller than the gear used on the DC motor.

The difference between the two gears cannot be too big because the power of the DC motor would not be enough to spin the flywheel.

If the size of the gears is somehow not enough to start the spin, you may carefully help the flywheel by imprinting an initial spin (No more than two touches!). Please pay extra attention not to make contact with the flywheel more than two times because the flywheel will speed up and accidents may occur. We also advise using gloves and avoiding as much as possible this method of speeding up the flywheel.

If the first gear has 32 spikes, the small one must have 11 spikes, and if you choose to use the 42 spike gear, for the second gear, you must use a 15 spike one.

You can also use other gears, provided that the ratio between the two gears supplies the 2000 RPMs needed.

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The chain (or, as used in the first devices, the belt) must not be tight and tensioned. As presented in the picture above, the chain needs to oscillate at a maximum of 1.6 inches and a minimum of 0.8 inches.

For proper functioning, the chain needs to be periodically greased

Both gears and the chain need to be firmly placed and protected with a casing (that ensures its functionality) to avoid any risks.

< Flywheel

The principle of the flywheel is found in the Neolithic spindle and the potter's wheel.

A flywheel is a rotating mechanical device that is used to store rotational energy. Flywheels have inertia called the moment of inertia and thus resist changes in rotational speed. The amount of energy stored in a flywheel is proportional to the square of its rotational speed. Energy is transferred to a flywheel by the application of a torque to it, thereby increasing its rotational speed, and hence its stored energy. Conversely, a flywheel releases stored energy by applying torque to a mechanical load, thereby decreasing the flywheel's rotational speed.

The efficiency of a flywheel is determined by the amount of energy it can store per unit weight. As the flywheel‟s rotational speed or angular velocity is increased, the stored energy increases; however, the centrifugal stresses also increase. If the centrifugal stresses surpass the tensile strength of the material, the flywheel will break apart. Thus, the tensile strength determines an upper limit to the amount of energy that a flywheel can store.

The inclusion of the flywheel is said to be to keep the motor running well when it is being pulsed rather than having a continuous feed of electricity from the battery.

The flywheel draws energy in from the local gravitational field.

Every particle making up the rim of the flywheel is accelerating inwards towards its axle, and that happens continuously when it rotates.

Rotors

The diameter of the rotor we used for this project is 6 inch.

You can make it bigger; it is expected to produce more power when the rotor is bigger in diameter.

This is the front view about how the magnetic rotors would rotate. In series, each rotor rotates in the opposite direction of the one after or before.

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All the magnets are mounted in ATTRACTION with all south or north outwards from one rotor to the other.

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It is imperative to use neodymium magnets because of their properties.

It is also advised to put a case or box around the rotors for safety reasons.

To generate even more electricity, you can make some adaptations:

• Increase the number of magnets

• Increase the number of disks

• Increase the power of the magnets • Increase the number of rotors

• Increase the diameter of the rotors

< 1st pic

This is a schematic that shows how the rotor is fixed on the shaft of the generator and one of the alternators.

< 2nd pic

For higher RPMs which leads to more power, the rotors on the sides of the main rotor will need to have a smaller diameter.

< 3rd pic

Alternator

The alternator is the main component of a generator that provides electricity.

The alternator is an electric device three-phased that is driven by the combustion engine via the accessory belt.

Depending on the electronic equipment on a vehicle, electricity consumption can reach maximum values of 1.7 - 2 kW. The alternator must be able to produce this extra energy to charge the battery.

An alternator must have the following characteristics:

It needs to produce enough energy to power all electric consumers
It needs to produce enough energy to charge the battery, regardless of the consumption of the electrical systems that are connected to it.
It needs to produce enough energy regardless of the RPMs required for functionality.
It needs to have the power/mass ratio as small as possible.
It needs to be reliable, to run as silent as possible
No maintenance

The stator is made of metal plates wound with copper conductors which represent the three phases of the alternator (A, B and C). The stator windings of the three phases are connected in star, each phase having a wire connection with the bridge rectifier.

To produce more power the stator windings need a rotating magnetic field. The rotor produces the magnetic field. Positioned on the shaft, the rotor comprises a wound rotor and a pair of claw-shaped poles. Each pair of successive claws forms the two apparent magnets (N, S) which generate a magnetic field in order to have a higher efficiency of the rotor contains 12 to 16 poles.

The operating principle is relatively simple. The magnetic field generated by the rotor produces on each phase of the stator a sinusoidal electric current. All electrical components of the device are DC. Switching from AC to DC is done using a diode bridge rectifier.

The bridge rectifier contains six diodes that are integrated into an aluminum radiator. For each phase of the alternator two diodes are used to convert the alternating current into electric current.

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The frequency of the electric current depends on the rotor speed and the number of magnetic poles.

To prevent overloading the battery, the voltage from the alternator must remain constant all the time, regardless of the operating conditions of the device and the electricity consumption.

The voltage regulator is designed to control the power supply of the rotor. It controls the rotor‟s magnetic field, implicitly the voltage induced in the stator. The voltage generated by the alternator must be maintained around 14.2 V. The voltage regulator is integrated into the alternator casing.

< 2nd pic

The end caps are aluminum plates. You will need two such plates, and you will position them at each end of the generator. The flange bearings are fixed to the end caps as well as to the protective case with stator mounting bolts. The flange bearings are attached at the four bolts that are visible in the picture. You will be presented with a radius, but it can be changed, depending on the flange bearing you will use. The six outer bolts are shown in the picture if for the six bolts that will support the stator. You can build these plates from aluminum by drawing the dimension on a square sheet of aluminum. You can use a handsaw or jig saw. The overall shape of the end caps is not crucial because none of the two will rotate. However, a significant difference between them the outer casing will not fit:

< 2nd pic

Rotors

Each of the two rotors will be a thin steel plate (1/8 inch thick and 12 inches in diameter). As shown in the picture, a radial pattern on magnets will be placed on each rotor. The rotor is then placed into a mold, and Devcon Flexane-80 liquid will be poured on top of the rotor until the magnets will barely be seen. The Flexane-80 liquid urethane resin must be of medium consistency. This will allow the plates to expand or contract, depending on the weather condition:

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The above picture shows the rotor before the Flexane-80 liquid is added. The four bolts circling the center of the rotor plate are used to fix the plates to the flange (which will be attached to the driveshaft).

You can use the same dimension for the steel plate (1/8 inch thick).

You can use any type of magnet (the stronger, the better). We recommend using 45 neodymium-boron rare earth magnets. You will need 12 for each rotor resulting in a total of 24. You must arrange the magnets at 3.5 inches from the center of the plate. The dimensions of the magnets are 2” x 1” x 1/2” (L x W x T). Their thickness will provide the magnetic force.

As you position, the magnets to make sure you alternate the poles. This means that they must alternate N, S, N, etc. as they go around. To properly arrange the magnets, a wooden jig will be used (it will later be presented). The jig will be placed using four pins that will go through the four bolt holes presented in the picture. Then simply arrange the magnets and remove the jig.

Here is a picture of the pattern of the magnets, as they should be placed:

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The jig will simplify the placing process, and it can be used for both rotor plates. You need to create the rotor plates opposite of one another and take special care in arranging the magnets. First, select a starting point on the wooden jig for the first magnet and continue with the second one, placing it with the opposite pole. Continue by alternating the poles of the magnets until the circle is complete. The second rotor plate must be built in the same manner, except the fact that the first magnet must be placed on the opposite pole as to the first magnet on the first plate. This will result in a complete opposite placement of the magnets (from the first rotor plate) - opposite poles all face one another, enhancing the magnetic flux.

Safety advice: Because the magnets are powerful, take care when handling them around the garage. Also, take care when placing the magnets of the rotor plates because they can crack/shatter and decay their magnetic potential over time.

Next, we will present the parts needed for casting the rotors.

Magnet jig and mold hardware

The wooden jig is a round piece of wood with slots cut into to facilitate the placement of the magnets. The inner four bold circle has a 1.375'' radius - the same as the rotor plates. Because 12 magnets are used, you need to cut 12 slots into the jig at a 30-degree angle around the circumference. This way you can fix the jig with the bolts to the rotor plate and fit the magnets into the slots. Gently remove the jig after fitting all magnets.

The overall diameter of the jig is not relevant, but the distance from the center of the jig to the inner edge of the slots is crucial because the magnets must be placed equally from the center of the plate:

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The next picture presents a second suggestion for the jig. This second idea provides an easier removal of the jig after the magnets are placed:

< 2nd pic

The bolt circle

…around the outside of the rotor mold base is used to bolt the entire mold together. The inner bolt circle will hold pins that will act as "dummy bolts" for the casting process and keep bushings in perfect alignment. A plug goes in the center hole which will allow the cast to mount to the flange. This part has a stepped thickness that corresponds with the top half that allows the two parts to lock together. This will prevent flexing from leaking out of the mold and keep the metal plate centered. This part is cut from MDF and stepped using a rotary table but can be left flat if the right equipment isn't present:

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The top part of the mold can be cut from MDF. It has the same bolt circles, at the same distance as the one on the bottom. This second piece is a little thicker to lock to the one on the bottom. It is not necessary for it to be thicker. If not possible, you can make this part flat. It is important to have the same dimensions as the one on the bottom:

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The material for these pins is not relevant. They must fit the bushings, and they need to be placed and removed easily from them

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The bushings you need must slide over the pins during the casting process and have knurls to be adequately bonded with the Flexane-80. You must use steel bushing to avoid corrosion:

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Mold assembly

We will present in the next section the steps to build the rotor mold. The surface of the rotor plates must be roughened using sand paper.

A. First, place the steel rotor plate on the base of the mold and insert all four pins and the center plug through the holes until you have a plane surface on the bottom.

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B. Next, place the wooden jig onto the rotor plate and fix it using the pins.

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C. Start placing the magnets by alternating the poles. Before placing the magnets make sure to set the first magnet as the top one and remember its pole because you will need the second rotor plate to start with the opposite pole.

Place the magnets into the jig's slots by alternating the poles. You can check the polarity by hovering another magnet around the plate and checking the attraction and repulsion.

BE CAREFUL NOT TO LET THE MAGNET SLIP FROM YOUR HAND! This could damage the magnets in the jig and ruin the rotor.

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D. Next, remove the wooden jig and place the knurled bushing onto the pins. Place the top of the mold and fix it using screws. You are now ready to pour the Flexane-80 liquid.

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Casting - preparation of the mold:

MATERIALS:

Two brushes with wood handles
2 Plastic mixing buckets
Johnson paste wax (or similar) and rags - Liquid silicon mold release
Hot air gun
Flexane 80 Liquid Resin
Devcon FL-10 Primer
Finished metal plates
Magnet Jig
Metal Bushings - Metal Pins

Preparing the mold and the surfaces

A. After preparing the MDF mold, apply Johnson paste wax on any area that the Flexane will come in contact with. Repeat this process after 10 minutes.

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B. Put the mold together and rub more of the Johnson paste wax all around the mold, especially at the jointure of the two pieces of MDF. This will prevent the Flexane from leaking. Leave it for 10 minutes to dry.

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C. Spread the liquid silicon onto the mold (once only).

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Prime surfaces

Make sure again that no loose metal objects are near the magnets. 1. Place the rotor into the mold.

In a separate cup pour some Devcon FL-10 primer
Apply with a fresh brush some Devcon Fl-10 on the steel rotor plate and the bushings.

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Let it dry. After 15 minutes, apply a second layer.
Prop up the mold on one side, so there is a slight tilt before pouring the.
Put the mold together. Place the bolt ring around the wooden base of the rotor. Next place the four pins into the four holes of the wooden base of the rotor. Beforehand coat them with a layer of mold release. Place the plug into the middle hole and apply a layer of mold release.

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Place the second wooden ring on the first wooden ring and fix them using the nuts.

Cover the top of each magnet not to stain the magnets when pouring the material around them.

Mixing and pouring
In a different plate mix two bottles of Flexane and catalyst (as mentioned on the packages) for 2 minutes. You need two bottles for each rotor mold.
Take the mixed material to the wooden mold (that is already assembled). You will also need other brushes.
Apply a thin layer of Flexane on the mold - the metal and wooden part.
Pour the Flexane into the mold, and take extra care not to cover the magnets and leaving the top of the magnets slightly higher than the surface of the Flexane.

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Level the Flexane.
You need a hot air gun to bring air bubbles out of the Flexane. Apply the hot air for 5 to 10 minutes.
Let it dry.

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STATOR

The stator is an epoxy resin casting with nine coils arranged inside. You can use as many coils as you want, provided that you use a multiple of three (because the three- phase power is produced). The casting will have six bolts towards the outside area, similar to the end caps - same diameter, same holes. You may want to add six bushings to strengthen the casting on the whole device.

You also need to place small metal pieces in the center of each coil to help concentrate the flux through the center of each coil, which will improve the performance of the generator.

Anonymous ID: dd8deb Oct. 15, 2021, 8:28 p.m. No.14794611 🗄️.is 🔗kun >>4643

The molds for the epoxy resin casting

A. The mold base is made from the same material as the other mold - MDF. The outer bolt circle presented in the picture is needed to join the whole mold together and to fasten it together. The inner bolt circle (smaller holes) will hold the pins that will align the bushings. They will be removed after making the casting. The middle hole if for the center plug and it will serve for the flange.

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B. This wooden circle needs to be placed in 2 layers (as presented later). It needs to go over the outer bolt holes on the base so they can be fastened together. You will need two such wooden circles.

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C. The central plug can be made out of any materials lying around. Take care at its dimensions because its diameter will increase after applying for the mold release.

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D. The outer pins can be made of any materials because they will be removed. However, the bushing must be made of steel because they will be part of the casting. You can also knurl these bushings for higher resistance into the casting.

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