超级奶爸奶茶菜单:制作10英尺的风力发电机组（4）

About 10" from the end of the wire bend it sharply 90 deg with the needle nosed pliers.

Drop the wire in the slot of the coil winder and bend the end around the nut. (A wing nut helps here too..) This will hold the wire from slipping when you wind the coil.

Hold the wire tightly in one hand (keep tension on it) while turning the crank with the other hand. Be careful to keep c**tant tension on the wire and try to turn the coil winder at a c**tant speed. I notice lots of folks tend to turn it faster on the down stroke and slower on the upstroke - this will usually result in a lop-sided coil (one side of the coil wider than the other). It's important to keep c**tant speed and c**istant tension. Try to wind the wire in neatly but don't obsess over perfection. I've seen some folks take over an hour to wind a coil trying to pile the wire in perfectly. It should take no more than a minute or two to wind a coil.

Once you've got the correct number of turns, pull the lead out of the slot and twist the two ends together (1/2 twist - just enough to hold them together). Don't twist more than you need because later you'll undo this and it's nice not to bend up the wire more than necessary. Grab the wire between the spool and the coil with one hand, and clip it so that there's about 10" of wire out of the coil. (both leads coming from the coil should be about 10" long) Take the loose end that's coming from the spool, put it on the workbench and set something on it (the side cutters are handy since they're probably still in your hand) so that the wire on the spool doesn't unravel.

Remove the duct tape, it should pull off easily.

Now you can carefully pick up the uncast stator and remove it from the mold. Put it somewhere safe untill you're ready to cast the stator in resin.
Casting the stator

The stator will be cast in the same polyester resin you used for the magnet rotors. You'll need fiberglass cloth on both sides of the coils. It might be useful to reveiw the section on casting magnet rotors before doing this as the proceedure is very similar and safety precauti** are the same.

If you fold the fabric correctly, you can lay out just 1/4 of the ring and cut out two in one shot. You need two rings of fiberglass 15" outer diameter and 6" inner diameter.
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hog

论坛元老

38#
 发表于 2010-8-30 13:10 | 只看该作者

In the picture you can see the two rings of fiberglass. Set them, and the coils aside for now. Grease the stator mold inside, on top - and around the edge. Same with the lid - everything should be carefully covered with grease, or wax. Automotive or wood wax works really well.

It takes about exactly 1/2 gallon of resin to cast the stator. Find a level place to put the mold. It's important to either keep the edges of the mold off the workbench - or find a work bench (like the one in the picture) that allows access for C clamps around the edges of the mold. When your done you'll need to clamp the lid down with C clamps so think ahead! Pour about a pint of resin into the mold and roll the mold around so that the whole bottom and the sides become covered 'wet' with resin.

Put one of the fiberglass rings into the resin and work it with a stick untill it becomes saturated. When saturated - the fabric will become almost invisible. (you won't see any white)

Then pour about another pint of resin in the mold, work it into the fabric more - try to work out any airbubbles.
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hog

论坛元老

39#
 发表于 2010-8-30 13:10 | 只看该作者

Put the coils in carefully, poke at them so resin runs all around the coils and airbubbles come up.

Then fill the mold with resin and be sure all surfaces of the coils have resin on them.

Put the remaining fiberglass ring over the top of the coils and work resin into it - again, it should almost disappear.

Pour the remaining resin over the top of the fabric. Work it in and try to work out air bubbles. It might not hurt at this time to beat on the mold a bit or vibrate it with a sander (or something) for a couple minutes to help air bubbles rise to the top.
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hog

论坛元老

40#
 发表于 2010-8-30 13:11 | 只看该作者

Carefully put the lid of the mold down over the casting.

Put a 1/2" washer over the threaded rod, and run the 1/2" nut down over it. Tighten the nut - this does a good job of clamping the lid tightly on the mold and assuring that the finished casting will be 1/2" thick.

Put a C clamp on each side of the mold (use 4 C clamps) and tighten them evenly. You'll have some idea when the resin is hard by all the stuff that spilled out the side! Let the stator sit in the mold untill the resin is hard.

A chisel works well to scrape/peel the resin off around the outside of the mold. A good time to do this is while it's still a bit flexible (before it gets really hard).