Axial Flux Generator

thingiverse

This is a rough draft of the framework necessary for an axial flux generator, a type of non-commutated turbine ideal for home construction. Great for wind turbines! Instructions I don't recommend you try to make this thing yet! I'm still saving up for a RepRap, so I don't know how well it works, if at all. I'll post more instructions as I progress with the project, but the basic idea is: 1) rotor (you'll need two copies) a) print the main component (rotor.scad or rotor.stl) b) print rotor_cap c) rotor_magnet_cap needs to be made of steel to correctly shape the flux; there are companies that do 3D printing of metal, or you can find an appropriately sized hubcap. I'm planning to order copies made of steel after trimming it down a bit. b) place magnets in the rotor such that they have the same polarity relative to the center axis (i.e. each magnet should repel the magnets next to it). BE EXTREMELY CAREFUL IF YOU ARE USING RARE EARTH MAGNETS; you can easily lose a finger or worse if one magnet attracts another. c) screw on the rotor_cap and rotor_magnet_cap as demonstrated in turbine.scad 2) stator a) print the stator b) place wire coils (I still need to design a winder for these) in the holes and secure with epoxy or similar; make certain you've configured them correctly before securing them permanently (I plan to use a 3-phase configuration, details to come). 3) place the stator on top of the bottom rotor 4) place a lazy susan bearing on top of the stator 5) secure the top rotor on the assembly — USE EXTREME CAUTION! If you are using rare earth magnets, the attractive force will be measurable in tons! 6) you're done with the generator! Now you need to attach it to a resistor, and something that turns...