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150 Watt Generator

This 12 volt, 3-phase generator is one of my latest projects.

The client needed to power high-intensity LED spotlights and
other airborne equipment in model airplane drones that are
being used for air reconnaissance in wildlife conservation.
Typical mission duration can be up to 6 hours long, thus in- ight
charging is a necessity.
The generator had to be mounted in close proximity to the
engine, therefore temperature was an important design concern.
Potential heat-related problems were averted by using a
Scorpion motor, because it employs magnets with a temperature
rating of 200°C.

The shaft of the generator is turned via a timing belt by the same The 150 Watt, 12 volt generator is based on a Scorpion S-3020
60cc petrol engine that powers the aircraft. brushless motor kit. The stator was wound so that charging
voltage is obtained at just above idle speed.

Scorpion S-3020 brushless motor Scorpion S-3020 3-phase Three of the drones used in
wound as 12 volt generator generator next to DLE-60cc petrol wildlife conservation
engine

Wind Generators
Over the course of the last 15 years, I've been fortunate to have With the generous help of the very knowledgeable members of
been involved in the design and contstruction of a few wind the LRK Torquemax forum, many stumbling blocks were
generators, ranging in size from 500 Watt to 4 KiloWatt. overcome or prevented.

With my rst generator project, I was thrown in the deep end to
do the stator and winding design of a 4 KiloWatt "monster",
relatively speaking. It was a joint e ort with my ying buddy who
was an armature winder. Up until then, my motor building
experience was limited to rewinding some CD-ROM motors and
building a couple of small outrunner motors for model
aeroplanes.
To be able to start turning in light wind conditions, low cogging is
an important requirement for a successful wind generator.
Because this was a permanent magnet generator of the
"outrunner" type, the main challenge was undoubtedly to
minimize cogging, which we succeeded to do very well. There
was hardly any cogging noticable.

Roughly machined flux ring and Flux ring with 50x22x8mm curved The parts before winding the The stator wound and terminated
some stator plates stacked Neo magnets stator and final assembly

500 Watt Wind Generator

This 500 Watt wind generator is also a recent project. With the
experienced gained in previous generator projects, designing
this unit was rather straight-forward. Because the generator was
intended for vertical-axis installion, the exterior design was
styled to be weather resistant and therefore doesn't require an
enclosure.
The very low cogging torque that was achieved with this design,
is a direct result of an optimum slot/pole combination and good
stator design. Observant viewers will notice that the aluminium
parts are not anodized. We tried to keeps costs to a minimum,
because this is a prototype unit.

Trial fitting of the parts of the All the parts prior to winding the The stacked stator and magnets
generator stator

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