Electrical generation via cored coils and axial flux

[capthook]

Thought I’d share some of my electrical generation via cored coils and also an axial flux design for pulse motors/adams motors etc.

First, an ‘iron’ cored coil.

1st pic: coil materials
5/16 threaded rod core
#30 AWG magnet wire

2nd pic: custom bobbin ends
Homemade plastic washers cut out of a broken/cracked old trash can with a hole saw attachment.
Couldn’t find any the right size â€" and the ones that were close are $.25 a piece.
I needed 84 â€" so I saved $25 bucks AND I have washers that are the PERFECT size!

3rd pic: coil winding
Clamped a drill to the table and mounted the wire on a supported wooden dowl.

4th pic: coil testing
Using the drill again to spin a disk with magnets at steady rpm and same airgap to test the output of various coil windings.

5th pic: finished coil
#30 AWG magnet wire 1”x1” coil dimensions
5/16” x 3” threaded rod core dimensions
Custom nylon bobbins 1 1/8” x 1/8” with 17/64” hole
Masking tape wrap after each winding layer
2 layers electrical tape over finished coil

More to come….

[capthook]

Continued….
Pic 1: trying hoptoads sheath idea.  Cogging was less due to the hollow shaft, but power output was also reduced.  Net was an overall reduction in efficiency vs. the solid core in my tests.

Pic 2: mounting multiple coils below magnet wheel.  Magnets are 3/4 “ x ¾” N42.  Airgap of ¼”

Pic 3: wiring of coils for 3-phase star connection.

Pic 4: wiring diagram for 3-phase star connection.

Pic 5: Schottky diode full-wave rectifier on bread board.
These diodes cut the voltage drop loss by 50% over a standard rectifier.

Next: axial flux

[tropes]

I have a question regarding the direction of electrical flow.
When a magnet is travelling towards a coil does the current induced in that coil produce an electromagnet that repels or attracts the magnet?
Tropes

[gyulasun]

Hi Tropes,

Normally, due to Lenz law, an approaching magnet in a coil produces a repel situation (assuming the coil has a heavy electrical load connected to it).

My further notice here is that in case of the coil has a soft iron core, the repel effect is somewhat gets reduced due to the natural attraction between the core and the approaching magnet. But Lenz still affects the operation.

rgds, Gyula

[tropes]

Hi Gyula
This means that the current induced in the coil is moving in the same direction as the current used in a pulse motor to repel the rotor magnets.
Therefor, the approaching magnets would amplify the strength of the coil.
This would explain why it takes so much less current to repel the rotor when the rotor is in motion.
Tropes