Muller Dynamo

[Scorch]

Completed the timing disk and reed switch.
Some of the cap screws, which are supposed to be stainless steel, turned out to be regular steel.
Suspect they got mixed up in the bin, or box, before parts kit was assembled at the manufacturer.

Fabricated a mount for an ammeter.
First test of pulse motor section - Running at around 400 RPM at 300 ma. and 24.9 vdc.

Still need to build other stuff but first test run looking really good and seeing around 27.5 vdc at the BEMF output with no load and meter measurement only.

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[marcx41]

Hi Scorth,
Do you can say where you find thr toroid core, please.
I think finish the mecanical support for my replication of the Q serie the next week, like you can see on the pictures I have somme work before the first test.
Thank again to share and put somme life in this topic, Marc

[Scorch]

http://www.micrometals.com/pcparts/torcore7.html
See part number: T650-52

They make larger cores but they do get pretty expensive.

}:>

Hi Scorth,
Do you can say where you find thr toroid core, please.
I think finish the mecanical support for my replication of the Q serie the next week, like you can see on the pictures I have somme work before the first test.
Thank again to share and put somme life in this topic, Marc

[marcx41]

thank you for your quick answer

[Scorch]

Ran into another fit issue today which has brought assembly progress to halt.

The kit did not include a critical part needed for sine wave peak switching.
The commutator required to accomplish this is to be fabricated, from local materials, including the insulator and copper contacts.
This part is based on an aluminum hub (included) to be used as the base, and mount, for a commutator which is supposed to be built from a spray can lid and copper strip contacts.
I did order some copper tape from amazon.com and, hopefully, that will work ok.

But what has become a big fit issue is the insulator which should have a smooth surface, fit the hub tightly and evenly, and be able to fasten the copper contacts to it.
The instructions read: "A common spray paint cap (smooth) works well as an insulator for the 2.48" diameter hub. . ."
But this is where the problem is. I have LOTS of cans but none of the caps actually fit including paint caps.
Most are too small; others are to big and none 'work well' . . .

Have already destroyed several caps tying to make them fit.
Have tried heating them so they might stretch a little but this merely caused deformations instead of a uniform 'stretch'.

At this point I am stuck until I can find something that actually fits and, hopefully, has a half way decent, smooth, surface for the copper tape and brushes.
I will go ahead and send a request, to quanta magnetics, for a solution and, hopefully, they will have some suggestions, or materials, I can use to move forward.

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