Originally posted by Turion
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So here are the facts. The old clunker machine with iron core coils was able to put out between 1800-2000 watts. The input was 36 volts at 12 amps and with adjustment we could get it down to 7 amps, but it wouldn’t STAY adjusted. Too much play in critical areas. The mechanical issues were addressed, and my hope was that this NEW machine with twice as many magnets on the rotor would be more powerful. Perhaps TWICE as powerful.
And it may well be, but I am not using the same coils because they heat up too quickly and melt the coating off the wires after about 30 minutes of constant running.
So I have been busy doing the thing I like least in the world, which is winding coils while my partners in Sacramento cut, coated, and epoxied in the core materials. They also tested coil pair for output on the old clunker and shared the data with me which I posted here.
They would send me videos of coil tests and kept track of data so we could make a decision on what core material to use. One of those videos is what a few people here saw. There is a problem with the testing that was done. The numbers are open circuit voltage numbers, not voltage under load. This wasn’t clear until watching the videos a few times and I called to confirm. By the time I realized the issue, I had already picked up all the GOOD coils and brought them home. So the voltage under load test he did yesterday was with a pair of mismatched coils and ones that produced LESS output than the wiring configuration we are using on the GOOD coils. BUT, the test shows that these new coils don’t put out NEAR the voltage of the iron core coils. Only about 55-60%.
My hope is that the GOOD coils put out enough more than the mismatched coils that with a 24 magnet rotor I will be right back up to the original 1800-2000 output of the original generator. But I am very aware it could be less.
But I want to be clear about a few things. The measurements I took on the original coils were ALWAYS under load, so those numbers are accurate. I first time I fired up a coil pair the bulb didn’t light up and it took me a bit to figure out I had blown it. And a coil pair blew two 100 watt bulbs in series. It lit 3 to brighter than when connected to wall voltage and increasing the RPM would blow the bulb, so I am very aware of the voltage and amps I was getting because I used an oscilloscope as well as several different meters.
But as to total output of this machine with this new core material, it’s an unknown until I see it run on the bench. And if I want to win the bet with bistander I might have to put all the old coils back in it. I could. But I am curious to see what this machine will output with these new coils and will go from there. This motor could turn a second or even a third rotor. That would be a much bigger machine, so I will probably leave that to someone else.
oh, the mismatched coils under load were outputting 77 volts at 1.3 amps. Not even close to the 120-130 volts at 1.5 amps the iron core pair put out. But that’s with a 12 magnet rotor. I don’t know what MATCHED coils will do on a 24 magnet rotor yet. So it may be back to testing core material. We still have a couple we didn’t test, but I wound the extra coils already.Leave a comment:
better than everybody else who has nothing
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