Instructions | Portal Point Generator

1

Generator V1: Coil Jig Preparation

Jig Preparation:

The winding jig is used to wind the coil. The Jig and the Jig holder are fastened together using M3 fasteners.

Attach the 3DP Jig Holder on one of the faces. I recommend marking this face, and you should use the same convention when winding all the coils., and the winding direction should match.

There is a small hole in the jig through which you can slot the wire, to keep it in place while winding. Put the 30 AWG wire into this from the inside of the jig, coming out.

Attach kapton tape in the 3 slots . Once the coiling is done, the kapton will be folded onto the finished coil to hold its shape.
2

Generator V1: Coil Preparation

Coil Preparation:

The jig is mounted on a power screw driver/drilling machine using a HEX bit. There is a notch on the jig to indicate when the maximum number of coils are reached.

Try and maintain a constant level of tension on the coils to get a roughly same number of coils. 6 coils will need to me made like this.

Use kapton tape to keep the cool from unwinding. Keep the kapton in place on the inside of the coil, and wind on top of it.

There is a hole on the jig where the start of the coil is placed. As long as you use the same convention for winding, and placing into the coil holder, you should be alright, only the polarity of the DC would change.
3

Generator V1: Removing coil from Jig

Fold the Kapton tape over the coil to hold it in place. Now work backwards to remove the coil.
4

Generator V1: Stator Assembly

Gluegun the hell out of the stator.
5

Generator V1: Wiring Generator

Mark the "Ins" and "outs" of the coil so as to not mix up the wireing.
6

Generator V1: Generator Testing & Construction
7

Generator V1: Generator Assembly

Discussions

Vijay wrote 04/21/2019 at 14:48

I would recommend to go for lower AWG, 18-20, that would reduce the resistive and heating losses as well as reduces the breaking effect when connected to a load. this should allow the turbine to pick up speed, and give you a decent current output, without the need to step down the voltage

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MaKoTo wrote 01/19/2019 at 18:23

Hi Vijay !
And thank you for sharing and documenting your project ^^

Because the V2 is not finished yet, i plan to realize your generator V1 to test it on my Savonius https://burogu.makotoworkshop.org/index.php?post/2019/01/01/eolienne-axe-vertical-12
I can got easily all the components, but for realisation, but I've two questions :
• To do very precise job on coils, how many turn of the 30 AWG wire have to be done ?
• The enamel copper wire is sell by weight, so, how many weight is necessary to make the 6 coils ?

And bonus question, with time passed and experience acquired, for optimizing the V1, would you still use 30 AWG wire ? In case of not, what AWG of wire and number of turn do you recommend ?

Good luck for V2 ^^

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